Volvo ECR235E User manual

Ref. No. 20042893-E 2019.08 English
OPERATOR'S MANUAL
ECR235E English
OPERATOR'S MANUAL
ECR235E

ADVERTENCIA: Respirar los gases del escape de
motores a diésel le expone a químicos conocidos por el
Estado de California como causantes de cáncer y defectos
de nacimiento u otros daños reproductivos.
• Siempre encienda y opere el motor en un área bien
ventilada.
• Si es en un área cerrada, ventile el orificio del escape
hacia el exterior.
• No modifique ni altere el sistema de escape.
• No encienda el motor, excepto cuando sea necesario.
Para mayor información visite
www.P65warnings.ca.gov/diesel.
WARNING: Breathing diesel engine exhaust exposes you
to chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated
area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING: Operating, servicing and maintaining a
passenger vehicle or offroad vehicle can expose you to
chemicals including engine exhaust, carbon monoxide,
phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary,
service your vehicle in a well-ventilated area and wear
gloves or wash your hands frequently when servicing your
vehicle. For more information go to
www.P65Warnings.ca.gov/passenger-vehicle.
ADVERTENCIA: Operar, dar servicio y mantenimiento a
un vehículo de pasajeros o vehículo todo terreno puede
exponerle a químicos incluyendo gases del escape,
monóxido de carbono, ftalatos y plomo, los cuales son
conocidos por el Estado de California como causantes de
cáncer y defectos de nacimiento u otros daños reproductivos.
Para minimizar la exposición, evite respirar los gases del
escape, no encienda el motor excepto si es necesario, dé
servicio a su vehículo en un área bien ventilada y utilice
guantes o lave sus manos frecuentemente cuando dé
servicio a su vehículo. Para mayor información visite
www.P65Warnings.ca.gov/passenger-vehicle.

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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.
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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. T
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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
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ECR235E L
Ref. No. 20042893-E
The original language is English. Original instructions.
2019.08
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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.
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The safety symbol combined with this signal word indicates a
hazardous situation which, if not avoided,
will result in death
or serious injury.
Danger is limited to the most extreme
situations.
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The safety symbol combined with this signal word indicates a
hazardous situation which, if not avoided, could result in
death
or serious injury
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The safety symbol combined with this signal word indicates a
hazardous situation which, if not avoided, could result in
moderate or minor injury
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NOTICE
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Used in order to refer to installation, operating, or maintenance
information which is important but not danger-related.
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Make a note below of the identification numbers of the machine and its components.
Always use this information when contacting the manufacturer and when ordering spare
parts.
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:
:
Volvo Group Korea Co., Ltd.
Seongsan-gu, Changwon-si, Gyeongsangnam-do,
Korea 51710
Machine PIN (Serial number)
Engine
Main pump
Swing motor
Track motor
Main control valve
Please send any comments about the Operator's Manual to [email protected].
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Identification numbers ..................................... 3
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Machine view ................................................ 19
CE-marking, EMC-directive .......................... 20
Communication equipment, installation ........ 23
Safety components ....................................... 24
Product plates ............................................... 25
Information and warning decals .................... 27
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Instrument panel, left .................................... 36
Instrument panel, front .................................. 38
Display unit ................................................... 44
Instrument panel, right .................................. 80
Instrument panel, rear ................................... 94
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Controls ........................................................ 96
Cab ............................................................. 107
Control lockout system ............................... 111
Operator comfort ......................................... 112
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Safety rules when operating ....................... 166
Measures before operating ......................... 171
Starting engine ............................................ 172
Hydraulic system, warming up .................... 177
Operating .................................................... 179
Exhaust aftertreatment system ................... 180
Stopping ...................................................... 192
Parking ........................................................ 193
Retrieving and towing ................................. 195
Transporting machine ................................. 197
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Whole-body vibrations ................................ 203
Rules for digging ......................................... 205
Working within dangerous areas ................ 208
Attachments ................................................ 219
Attachments, connecting and
disconnecting .............................................. 221
Buckets ....................................................... 237
Hammer ...................................................... 239
Working with long range attachments ......... 245
Hose rupture valves .................................... 246
Selecting track shoes .................................. 248
Lifting objects .............................................. 250
Signalling diagram ...................................... 256
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Service position .......................................... 260
Before service, read .................................... 261
Entering, leaving and climbing the machine 267
Fire prevention ............................................ 268
Handling hazardous materials .................... 271
Handling line, tubes and hoses ................... 276
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Lubrication and service chart ...................... 279
Maintenance service, every 10 hours ......... 287
Maintenance service, every 50 hours ......... 289
Maintenance service, every 250 hours ....... 296
Maintenance service, every 500 hours ....... 300
Maintenance service, every 1000 hours ..... 303
Maintenance service, every 2000 hours ..... 306
Maintenance service, every 4000 hours ..... 309
Maintenance service, when required .......... 310
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Recommended lubricants ........................... 338
Fuel system ................................................ 345
Service capacities and change intervals ..... 353
Engine ......................................................... 356
Electrical system ......................................... 357
Cab ............................................................. 360
Hydraulic system ........................................ 362
Machine weights ......................................... 364
Ground pressure ......................................... 366
Dimensions ................................................. 370
Working ranges ........................................... 374
Recommended bucket sizes ....................... 376
Digging forces ............................................. 378
Lifting capacities ......................................... 380
Service history ............................................ 394
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7
7

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V1151239
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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.
E
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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.
E
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The machine is equipped with a straight six-
cylinder, four-stroke, turbocharged diesel engine
with direct injection and charge-air cooler.
The engines are equipped to meet the legal
requirements for exhaust emissions according to
US Tier 4 final, California Tier 4 final, or EU Stage
V.
N
N
O
O
T
T
E
E
!
!
Machines with engines for the US market may not
be sold or used within the EU, and machines with
engines for the EU market may not be sold or used
within the USA, unless the engine is replaced with
an engine valid for the applicable market. The
market for which the engine is intended is indicated
on the emission plate and by the engine's serial
number (see page
25 ).
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9
9

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.
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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.
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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.
Regeneration is also required to release trapped
sulphur (SO
2
) and other substances that are
trapped in the SCR and reduce the SCR's efficiency
if they are not removed.
In order to ensure reduction of NOx-emissions, the
EATS is monitored by the aftertreatment control
module (ACM).
For more information, see page
180 .
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The electrical system consists of engine starting
system, charging system, machine monitoring
system, engine / pump control system and air
conditioning system.
The machine is equipped with a high capacity
electrical system well protected. Waterproof
double-lock harness plugs are used to secure
corrosion-free connections. The main relays and
solenoid valves are shielded to prevent damage.
The master switch is standard.
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Automatic idling system reduces engine speed to
idle when the levers and pedals are not activated
for a certain period of time, resulting in less fuel
consumption and low cab noise level.
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Automatic engine shut-down system is to stop the
engine automatically when the machine is not
operated for a certain period of time. Default time is
set at 5 minutes and can be changed with Volvo's
service tool only. Contact a workshop authorized by
Volvo.
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- Control lockout lever is down.
- Engine speed control switch is not changed.
- DPF regeneration is not on progress.
1 minute before engine shut-down, info screen will
be displayed on IC (Instrument Cluster) so that the
operator can cancel engine shut-down by pushing
the keypad ESC button or moving the control
lockout lever up or changing engine speed control
switch (at the control lockout lever down position).
1
1
2
2
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The operator's cab has easy access via a wide door
opening. The cab is supported on hydraulic
dampening mounts to reduce shock and vibration
level. These along with sound absorbing lining
provide low noise levels. The cab has excellent all-
round visibility. The front windshield can easily slide
up into the ceiling, and the lower front glass can be
removed and stored in the right side of the cab.
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The pressurized and filtered cab air is supplied by
an automatically-controlled fan. The air is
distributed throughout the cab from 8 vents.
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The adjustable seat and joystick console move
independently to accommodate the operator. The
seat has 12 different adjustments plus a seat belt
for the operator's comfort and safety.
P
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F
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The cab is designed to meet the requirements for
falling objects, the weight of which agrees with
testing methods according to FOPS and FOG.
The cab is approved as a part of protective structure
according to FOPS and FOG standards. (FOPS:
ISO10262 (Level II), FOG: ISO10262:1998 (Level
II) and SAE J1356)
FOPS is an abbreviation of Falling Object
Protective Structure (top guard) and FOG is an
abbreviation of Falling Object Guard (top guard and
front guard).
R
R
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P
P
S
S
The cab is approved as a part of protective structure
according to ROPS standard (ISO12117-2).
1
1
4
4
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H
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The hydraulics system, combined with the fully
electronic control system and advanced ECO
mode, has been optimized to work in harmony with
engine to match the engine power, reduce power
loss and improve controllability and response time.
1 Summation system: Combines the flow of both
hydraulic pumps to ensure quick cycle times and
high productivity.
2 Boom priority: Gives priority to the boom up
function for faster cycle times during loading and
deep excavations.
3 Arm priority: Gives priority to the arm operating
function for faster cycle times during digging and
dumping.
4 Swing priority: Gives priority to the swing
function during trenching application to improve
productivity.
5 Regeneration system: Prevents cavitation and
provides flow to other functions during
simultaneous operations for maximum
productivity.
6 Power boost: All digging and lifting forces are
increased.
7 Holding valves: Boom and dipper arm holding
valves are provided to minimize cylinder drifting
while holding loads.
P
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1
1
5
5

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b
b
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x
x
Each track is powered by an automatic two-speed
shift travel motor. The track brakes are multi-disc,
spring-applied and hydraulic released. The travel
motor, brake and planetary gears are well protected
within the track frame.
S
S
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s
s
y
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s
s
t
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m
m
The swing system uses an axial piston motors,
driving a planetary gearbox for maximum torque. An
automatic holding brake and anti rebound valve are
standard
1
1
6
6
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The machine can be equipped with different types
of optional equipment, depending on the
requirements of different markets. Examples of
such equipment are automatic engine shutdown,
and automatic lubricating system (standard on
certain markets).
M
M
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s
s
Modifications of this machine and its components
such as engine and auxiliary system, including the
use of unauthorized attachments, accessories,
units, or parts, may affect the machine's integrity
(condition), the machine's ability to function in the
way for which it is designed and voids the EU type-
approval of the machine and engine- and auxiliary
system. Persons or organizations performing
unauthorized modifications assume all
responsibility for consequences that arise due to
modifications or can be attributed to modifications,
including damages to the machine.
No modifications of any kind may be performed on
this product unless each specific modification first
has been approved in writing by Volvo Construction
Equipment. Volvo Construction Equipment
reserves the right to reject all warranty claims that
have arisen due to or can be traced to unauthorized
modifications.
Modifications may be considered to be officially
approved, if at least one of the following conditions
has been met:
1 The attachment, the accessory, the unit, or the
part has been manufactured or distributed by
Volvo Construction Equipment and has been
installed according to the factory-approved
method described in a publication available from
Volvo Construction Equipment; or
2 The modification has been approved in writing
by the Engineering Department for the relevant
product line at Volvo Construction Equipment.
P
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1
1
7
7

A
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An installed anti-theft device makes it more difficult
to steal the machine. Volvo Construction
Equipment can supply an anti-theft device as
optional equipment. If your machine is not equipped
with such a device, look into the possibility of having
one installed by a qualified service technician.
L
L
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The machine is equipped with a software system,
which records various information about the
machine and this information is transferred from the
machine to Volvo and used by Volvo and its
authorized workshops in the product development
process and for possible malfunction detection.
Questions regarding this information can be
directed to your dealer.
C
C
a
a
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T
T
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k
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The machine may be equipped with CareTrack, a
telematics system developed by Volvo
Construction Equipment. The system stores
machine data, e.g., machine position, operating
hours, fuel consumption, fuel level, that can be sent
by wireless transmission to a computer. CareTrack
is available in different versions, depending on the
required information level.
CareTrack makes it easier to plan for service and
reduces costly downtime. Productivity is improved
by knowing if machines are being operated
correctly and how much fuel is being consumed.
CareTrack also allows the customer to restrict the
operating area of the machine, by using virtual
fences. This helps to eliminate unauthorized
machine use and theft. For further information,
contact a Volvo Construction Equipment dealer.
The CareTrack system transmits data, in the same
way a mobile phone does, with a maximum output
rate of 10 W. The transmitter is always on and the
operator cannot switch it off.
Local precautions and restrictions applicable to
mobile phones, for example safety distance, also
apply to the CareTrack system.
1
1
8
8
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