Volvo EWR150E User manual

EWR150E
EWR150E
operator's manual
Ref. no. PUB20045551-B
2015.10
Volvo, Konz
English
English

California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts, terminals and other related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and other
reproductive harm.
Wash hands after handling.

Foreword
Foreword
This operator's manual is intended as a guide for the correct use and
maintenance of the machine. Read this manual carefully before you start
and move the machine or before you carry out any preventive
maintenance.
Keep this manual in the lockable storage compartment so that it is always
available for easy reference. Replace it immediately if it is lost.
The operator's manual describes the applications for which the machine
was primarily designed. It has been written to be valid on all markets.
Therefore, please ignore any sections which do not relate to your machine
or to the work that you do with your machine.
NOTE!
NOTE!
If the manual covers more than one machine, the information relates to all
machines unless otherwise specified.
When designing this machine, much time has been invested in achieving
the best possible efficiency and safety. But accidents do happen, and most
of them can be attributed to human error. A safety-conscious person and
a well-maintained machine make up a reliable, powerful, and profitable
combination. Therefore, read the safety instructions and follow them.
Therefore, read the safety instructions and follow them.
We constantly strive to develop and improve the efficiency of our products
by making changes to their design. We reserve the right to make design
modifications to the products even after they have been delivered. Also,
we reserve the right to change data and equipment, as well as the service
and maintenance instructions, without prior notice.
OPERATOR'S MANUAL
Table of contents
Table of contents
Presentation
Presentation
Instrument panels
Instrument panels
Other controls
Other controls
Operating instructions
Operating instructions
Operating techniques
Operating techniques
Safety when servicing
Safety when servicing
Maintenance
Maintenance
Specifications
Specifications
Alphabetical index
Alphabetical index
EWR150E
Ref. No. 20045551-B
The original language is English. Original instructions.
2015.10
Copyright © 2015, Volvo Construction Equipment. All rights reserved.
Copyright © 2015, Volvo Construction Equipment. All rights reserved.

Safety regulations
Safety regulations
The machine operator is responsible for being aware of and complying
with the relevant, legally prescribed, national and regional safety
instructions. The safety instructions in this operator's manual are
applicable only in cases where no legislated safety instructions are in
force.
DANGER
DANGER
The safety symbol combined with this signal word indicates a hazardous
situation which, if not avoided, will
will
result in
result in
death or
death or
serious
serious
injury.
injury.
Danger
is limited to the most extreme situations.
WARNING
WARNING
The safety symbol combined with this signal word indicates a hazardous
situation which, if not avoided, could result in death or serious injury
death or serious injury
.
CAUTION
CAUTION
The safety symbol combined with this signal word indicates a hazardous
situation which, if not avoided, could result in moderate or minor injury
moderate or minor injury
.
NOTICE
NOTICE
Indicates a potentially hazardous situation which may result in machine
Indicates a potentially hazardous situation which may result in machine
damage.
damage.
NOTE!
NOTE!
Used in order to refer to installation, operating, or maintenance information
which is important but not danger-related.
Get to know the capacity and limits of your machine!
Get to know the capacity and limits of your machine!
2
Foreword
Foreword

Table of contents
Table of contents
Foreword
Foreword
................................................................. 1
.................................................................1
Identification numbers ......................................................... 6
Presentation
Presentation
............................................................ 7
............................................................ 7
Machine view ..................................................................... 12
CE-marking, EMC-directive ............................................... 13
Communication equipment, installation ............................. 16
Safety components ............................................................ 17
Product plates ................................................................... 18
Information and warning decals ........................................ 19
Instrument panels
Instrument panels
.................................................. 27
.................................................. 27
Instrument panel, left ......................................................... 28
Instrument panel, front ...................................................... 32
Display unit ........................................................................ 39
Instrument panel, right ....................................................... 67
Instrument panel, rear ....................................................... 75
Other controls ........................................................ 76
Other controls ........................................................ 76
Controls ............................................................................. 76
Cab .................................................................................... 83
Control lockout system ...................................................... 87
Operator comfort ............................................................... 88
Operating instructions
Operating instructions
..........................................
..........................................
117
117
Safety rules when operating ............................................ 119
Measures before operating ............................................. 126
Starting engine ................................................................ 127
Hydraulic system, warming up ........................................ 131
Operating ......................................................................... 132
Braking ............................................................................ 133
Exhaust aftertreatment system ........................................ 135
Stopping .......................................................................... 144
Parking ............................................................................ 145
Retrieving and towing ...................................................... 147
Attachments, alternative lowering ................................... 151
Transporting machine ...................................................... 154
Operating techniques
Operating techniques
..........................................
..........................................
159
159
Eco driving ....................................................................... 160
Whole-body vibrations ..................................................... 161
Rules for digging ............................................................. 163
Boom Suspension System (BSS) .................................... 165
Working within dangerous areas ..................................... 167
Attachments .................................................................... 173
Attachments, connecting and disconnecting ................... 181
Pressure release ............................................................. 191
Buckets ............................................................................ 192
Offset boom ..................................................................... 197
Hammer ........................................................................... 198
Lifting objects .................................................................. 200
Equipment towing ............................................................ 204
Signalling diagram ........................................................... 211
Table of contents
Table of contents
3

Safety when servicing ..........................................
Safety when servicing ..........................................
214
214
Service position ............................................................... 215
Before service, read ........................................................ 218
Entering, leaving and climbing the machine .................... 221
Fire prevention ................................................................ 223
Handling hazardous materials ......................................... 225
Handling line, tubes and hoses ....................................... 228
Maintenance ........................................................
Maintenance ........................................................
229
229
Lubrication and service chart .......................................... 236
Maintenance service, every 10 hours .............................. 241
Maintenance service, every 50 hours .............................. 243
Maintenance service, every 100 hours ............................ 251
Maintenance service, every 250 hours ............................ 253
Maintenance service, every 500 hours ............................ 261
Maintenance service, every 1000 hours .......................... 266
Maintenance service, every 2000 hours .......................... 267
Maintenance service, when required ............................... 268
Specifications ......................................................
Specifications ......................................................
290
290
Recommended lubricants ................................................ 290
Fuel system ..................................................................... 295
Service capacities and change intervals ......................... 298
Engine ............................................................................. 299
Electrical system ............................................................. 300
Wheels ............................................................................ 304
Cab .................................................................................. 306
Noise and vibrations ........................................................ 307
Hydraulic system ............................................................. 308
Machine weights .............................................................. 309
Dimensions ...................................................................... 310
Working ranges ............................................................... 315
Recommended bucket sizes ........................................... 318
Digging forces ................................................................. 320
Lifting capacities .............................................................. 321
Service history ................................................................. 334
Alphabetical index
Alphabetical index
...............................................
...............................................
337
337
4
Table of contents
Table of contents

5
5

Identification numbers
Identification numbers
Make a note below of the identification numbers of the machine and its components. Always state the number
when contacting the manufacturer and when ordering spare parts.
Manufacturer:
Manufacturer:
Volvo Construction Equipment Germany GmbH
D-54329 Konz-Könen
Germany
Machine PIN
(Serial number)
Axles
Travel gearbox
6
Identification numbers
Identification numbers

Presentation
Presentation
V1160200
Intended use
Intended use
The machine is intended to be used under normal conditions for
the applications described in this manual. If it is used for other
purposes or in potentially dangerous environments, for example
explosive atmosphere, flammable environment or areas with dust
containing asbestos and so on, special safety regulations must
be followed and the machine be equipped for such use. Contact
the manufacturer / dealer for further information.
Environmental requirements
Environmental requirements
Be aware of the environment when operating and during service
and maintenance of the machine. Always follow local and national
environmental legislation applicable to all handling of the
machine.
Engine
Engine
D4J is a four stroke, straight, four-cylinder, turbocharged, direct
injected diesel engine with charge air cooling.
In order to reduce nitrogen oxides, particles, hydrocarbons and
carbon monoxide, the engine includes external, cooled exhaust
gas recirculation (EGR) and an exhaust aftertreatment system
(EATS) with AdBlue®/DEF injection.
The exhaust aftertreatment system is a certified spark arrestor in
accordance with Directive 97/68/EC and EN 1834.
AdBlue®/DEF information
AdBlue®/DEF information
AdBlue®/DEF is needed for the reduction of nitrogen oxides
(NOx). AdBlue®/DEF is filled in a separate tank on the machine
that is completely separate from the fuel tank. AdBlue®/DEF must
not be mixed into the diesel tank and diesel must not be mixed
into the AdBlue®/DEF.
For distribution of AdBlue®/DEF (only valid for US market):
For distribution of AdBlue®/DEF (only valid for US market):
- Volvo CE Customer Support: 1-877-823-1111 (business
Volvo CE Customer Support: 1-877-823-1111 (business
hours)
hours)
- www.volvoce.com (outside of business hours)
www.volvoce.com (outside of business hours)
Presentation
Presentation
7

For distribution of AdBlue®/DEF (all other markets), please
For distribution of AdBlue®/DEF (all other markets), please
contact your local Volvo dealer for more information.
contact your local Volvo dealer for more information.
See page
See page
268
268
for information about filling AdBlue®/DEF.
for information about filling AdBlue®/DEF.
Exhaust aftertreatment system
Exhaust aftertreatment system
The engine features an exhaust aftertreatment system (EATS) in
the form of two mufflers. The first one contains a diesel oxidation
catalyst (DOC) and a diesel particulate filter (DPF) to reduce
emissions of particulate matter (PM). The second one contains a
selective catalytic reduction catalyst (SCR) to reduce nitrogen
oxide (NOx) emissions. AdBlue®/DEF is injected into the
exhausts in order to reduce NOx.
The DPF traps particles from the engine exhausts and, since it is
continuously loaded with these particles from the exhausts, it
needs to be regenerated in order to burn off the particles.
A passive regeneration process is constantly oxidizing the soot
particles stored in the DPF.
To achieve the defined emission values the EATS is electronically
controlled and monitored by the aftertreatment control module
(ACM).
For more information, see page 135 .
Electrical system
Electrical system
The machine has different electronic control units for the vehicle,
the IC (Instrument Cluster) and keypads, the climate control, the
engine and the aftertreatment system.
Additionally a caretrack unit is installed if the machine is equipped
with the optional Caretrack-System.
The relays and fuses are grouped in the electrical distribution box
in the cab behind the driver seat under the cover.
Brake system
Brake system
The brake system and the steering system have a common gear
pump, which supplies oil to both circuits. The brake circuit has
priority over the steering circuit.
The brake system is a dual-circuit system with two accumulators,
operated via the servo hydraulics. The system meets the
requirements according to ISO 3450.
In order to prevent immediate loss of brake action, should there
be a loss of servo pressure, there is a brake pressure
accumulator. Therefore it is possible to apply the brakes at least
eight times after the loss of servo pressure.
Service brakes
Service brakes
The service brakes are servo-hydraulically operated, self-
adjusting, wet, multi-disc brakes in two separate brake circuits.
Digging brake
Digging brake
The service brake pedal is also used as digging brake.
Parking brake
Parking brake
The parking brake is a negative action wet disc brake integrated
in the travel gearbox. It is spring applied and pressure released.
8
Presentation
Presentation