L120F

OPERATOR'S MANUAL

Ref.No. VOE21B1003320

English CST

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.

L110F/L120F OPERATOR'S MANUAL

Foreword This Operator's Manual is intended as a guide for the correct use and maintenance of the machine. Therefore, study it carefully before starting and operating the machine, or before carrying out any preventive maintenance. Keep the manual in the cab so that it always is at hand. Replace it immediate if it is lost. The manual describes the applications for which the machine primarily is intended and is written to apply for all markets. We therefore ask you to disregard the sections which are not applicable to your machine or to the work for which you use your machine.

Table of contents

Presentation

NOTE! The information in the manual applies to machine models L110F and L120F, unless otherwise stated. Many hours are spent on design and production to make a machine that is as efficient and safe as possible. The accidents which occur in spite of this, are mostly caused by the human factor. A safety conscious person and a well maintained machine make a safe, efficient and profitable combination. Therefore, read the safety instructions and follow them. We continually strive to improve our products and to make them more efficient through changes to their design. We retain the right to do this without committing ourselves to introduce these improvements on products, which have already been delivered. We also retain the right to change data and equipment, as well as instructions for service and other maintenance measures without prior notice.

Instrument panels

Other controls

Operating instructions

Operating techniques

Safety regulations It is the operator's obligation to know and follow the applicable national and local safety regulations. The safety instructions in this manual only apply to cases when there are no national or local regulations.

Safety when servicing

Service and maintenance

WARNING! The symbol above appears at various points in the manual together with a warning text. It means: Warning, be alert! Your safety is involved! It is the obligation of the operator to make sure that all warning decals are in place on the machine and that they are readable. Accidents may otherwise occur.

Get to know the capacity and limits of your machine!

Specifications

Alphabetical index

Ref.nr VOE21B1003320 2009.12 The original languages are Swedish and English. Original instructions. Copyright © 2009, Volvo Construction Equipment Customer Support. With sole rights.

Foreword

Identification numbers

2

Identification numbers State the identification number of the machine and the components below. The number should be stated when contacting the manufacturer and when ordering spare parts. The position of the plates is shown on page 15.

Manufacturer

Volvo Construction Equipment AB SE-631 85 Eskilstuna Sweden

Machine product identification number (PIN)

Engine

Transmission

Front axle

Rear axle

Lifting frame

Cab

Please send any comments regarding the Operator´s Manual to [email protected]

Table of contents

3

Table of contents Foreword....................................................................1 Identification numbers ............................................................ 2

Presentation ..............................................................5 CE-marking, EMC-directive .................................................. 11 Communication equipment, installation................................ 14 Product plates....................................................................... 15 Information and warning plates / decals ............................... 16 The USA Federal Clean Air Act............................................ 20

Instrument panels ...................................................23 Instrument panel, front.......................................................... 24 Display.................................................................................. 29 Instrument panel, cab post ................................................... 56 Instrument panel, overhead.................................................. 65 Rear cab wall........................................................................ 66 Control panel (optional equipment) ...................................... 67

Other controls .........................................................69 Controls ................................................................................ 69 Operator comfort .................................................................. 83

Operating instructions ...........................................93 Visibility................................................................................. 94 Safety rules when operating ................................................. 96 Actions before operating..................................................... 100 Starting engine ................................................................... 101 Gear shifting ....................................................................... 103 Steering .............................................................................. 107 Braking ............................................................................... 109 Stopping machine............................................................... 111 Parking ............................................................................... 112 What to do if the machine gets stuck.................................. 113 Recovering/towing .............................................................. 114 Transporting machine......................................................... 117

Operating techniques ...........................................125 Economical operation ......................................................... 125 Whole-body vibrations ........................................................ 126 Working within dangerous areas ........................................ 128 Attachments........................................................................ 132 Attachment brackets........................................................... 133 Hydraulic function, 3rd and 4th........................................... 135 Buckets............................................................................... 136 Log grapples (optional equipment) ..................................... 142 High-Lift grapple (optional equipment) ............................... 145 Pallet forks (optional equipment) ........................................ 146 Material handling arm (optional equipment) ....................... 150 Rotating attachments.......................................................... 153 Lifting objects...................................................................... 154 Signalling diagram .............................................................. 156

Safety when servicing ..........................................159 Service position .................................................................. 159 Before service read ............................................................ 160 Fire protection..................................................................... 162 Handling hazardous materials ............................................ 164

Table of contents

4 Service and maintenance.....................................169 Service points ..................................................................... 172 Engine ................................................................................ 173 Fuel system ........................................................................ 175 Engine air cleaner............................................................... 179 Oil-bath air cleaner (optional equipment) ........................... 180 Cooling system ................................................................... 181 Electrical system................................................................. 184 Transmission ...................................................................... 189 Axles................................................................................... 191 Brake system...................................................................... 193 Tyres................................................................................... 194 Cab ..................................................................................... 195 Air conditioning ................................................................... 197 Bucket teeth........................................................................ 199 Hydraulic system ................................................................ 200 Lubrication .......................................................................... 203 Automatic greasing system ................................................ 204 Lubrication and service chart.............................................. 209 Lubrication and service chart.............................................. 210

Specifications........................................................215 Recommended lubricants................................................... 215 Change volumes................................................................. 218 Interval between changes................................................... 219 Engine ................................................................................ 220 Electrical system................................................................. 222 Transmission ...................................................................... 227 Axles................................................................................... 228 Brake system...................................................................... 229 Steering system.................................................................. 230 Tyre sizes and air pressures .............................................. 231 Wheel nuts, tightening torques ........................................... 233 Cab ..................................................................................... 234 Hydraulic system ................................................................ 236 Dimensions......................................................................... 238 Machine, volumes............................................................... 240 Combination table, interchangeable equipment (attachments) machine model ......................................... 242 Pallet forks.......................................................................... 243 Log grapples....................................................................... 245 Material handling arm ......................................................... 247 Service journal.................................................................... 249

Alphabetical index ................................................253

Presentation

5

Presentation

1026967

Intended use The basic machine is intended to be used under normal conditions, that is, outdoors, above ground, at an elevation up to 1,500 metres (4920 ft) above sea level, off-road, for earthmoving operations, at an ambient temperature between -25 °C (-13 °F) and +45 °C (113 °F). Conditions that deviate from this are also described in the Operator's Manual. For use on public roads the machine must be adapted according to governing national legislation. If it is used for other purposes or in potentially dangerous environments, for example explosive atmosphere, flammable environment or areas with dust containing asbestos, etc., special safety regulations must be followed and the machine be equipped for such use. Contact the manufacturer/dealer for further information. The exhaust system is certified as spark-arrester acc. to ATEX Directive 94/9/EC, EN 1834-2. The machine is designed for a maximum machine weight (incl. equipment and attachments) of 23000 kg (50706 lb) for L110F and 24000 kg (52911 lb) for L120F. If the maximum weight is exceeded, safety will be jeopardized. In addition, no warranties on the part of the manufacturer will apply. However, always pay attention to national regulations for travelling on public roads.

Environmental requirements Bear the environment in mind 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 Volvo D7 is a 7 litre (427 in3) engine. The engine is turbocharged with intercooling of the air to air type. It has unit pumps (electronic unit pumps, EUP). The unit pumps are positioned at an angle above the pistons and are controlled via the camshaft and a control unit, E-ECU. The fuel system is of the common rail type. The cylinder head covers all cylinders. The engine has two valves per cylinder. The accelerator position is transferred electrically from accelerator pedal and hand throttle control (optional equipment) to the control unit (E-ECU).

Presentation

6 Electrical system The machine has the following four control units (ECUs): The I-ECU for the instrumentation is integrated with the display unit, warning lamps and instruments and provides the operator with information via these. ECC (ECU for climate control system) The V-ECU (for the machine) receives signals from sensors on the machine and these are sent on to the I-ECU. E-ECU (for engine control). In addition to these four control units it is possible to obtain a V2ECU (for electric servo lever control). This is optional equipment.

Power transmission The transmission is electro-hydraulically controlled, where all gears are in constant mesh. The gear ranges are selected by the application of different clutches. Between engine and transmission there is a hydraulic torque converter, which steplessly controls the output torque. Front and rear axles have planetary gears in the wheel hubs, which reduce the strain on the respective drive shafts. The axles are of the AWB type.

Brake system The machine is provided with a dual-circuit all-hydraulic brake system with one circuit for each axle. Each circuit meets the requirements for secondary brake capability. The brakes are cooled with oil that circulates in the axle.

Parking brake The parking brake is electro-hydraulically controlled with a switch on the instrument panel. The parking brake is a wet multi-disc brake built into the transmission. The brake is applied by spring force and is released hydraulically.

Steering system The machine is provided with a load-sensing, hydrostatic steering system and has a steering arc of 40°.

Cab The cab has a heating and ventilation system with defrosting for all windows. Air conditioning is available as an option.

Emergency exit The cab has two emergency exits, the door and the right side window.

Presentation

7 FOPS and ROPS The cab is approved as protective cab according to FOPS and ROPS standards, see page 234. FOPS is an abbreviation of Falling Object Protective Structure (overhead roof protection) and ROPS is an abbreviation of Roll Over Protective Structure (rollover protection). If any part of the cab's protective structure is affected by plastic deformation or failures, the cab shall be replaced immediately. Never carry out any unauthorised alterations to the cab, e.g. lowering the roof height, drilling, welding on brackets for fire extinguisher, radio aerial or other equipment, without first, via a dealer, having discussed the alteration with personnel at the Volvo CE Engineering Department. This department will decide whether the alteration may cause the approval to become void. It is important that all parties concerned are ware of these regulations.

Hydraulic system The hydraulic system is load-sensing, which means that the oil in the system is supplied in proportion to the position of the hydraulic control levers. If the hydraulic control levers are in neutral position, consequently no oil is supplied. The hydraulic system is equipped with pumps in common for the steering system and the working hydraulics. However, the steering system has priority from one of the pumps. Normally brake charging takes place when steering and working hydraulics are used, but when there is a greater demand, also the fan pump contributes.

Equipment The machine can be provided with different types of optional equipment, depending on the requirements of different markets. Examples of such equipment are lever steering (CDC), Boom Suspension System (BSS), secondary steering, separate attachment locking, automatic engine shutoff, electric servo lever control (V2ECU) and automatic greasing (standard on certain markets).

Modifications Modifications of the machine including using non-approved attachments, accessories, and spare parts may impact the machine's condition and the machine's ability to function as intended and designed. No modifications of any type may be performed without prior written approval from Volvo Construction Equipment. Volvo Construction Equipment reserves the right to decline all warranty claims which have arisen because of or can be traced to unauthorised modifications. Persons or organisation who carry out unauthorised modifications, assume all responsibility for consequences, which arise because of the modification or can be attributed to the modification, including damaging affect on the machine. Modifications may be considered to be officially approved, if at least one of the following conditions has been met: The attachment, the accessory, or the spare part has been made or distributed by Volvo Construction Equipment och and has been installed according to the approved method described in a publication available from Volvo Construction Equipment; or The modification has been approved in writing by the Engineering Department of the relevant product line at Volvo Construction Equipment.

Presentation

8 Anti-theft device (optional equipment) An installed anti-theft device makes it more difficult to steel the machine. Volvo CE 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 your dealer.

Logged machine data The machine is equipped with a software system that registers and stores different kinds of information. The information can be transferred to Volvo CE in order to be used for product development purposes and for trouble-shooting. The stored information contains among other items travelling speed, fuel consumption and various temperatures. Volvo CE and their authorised workshops will be making use of this information.

CareTrack (optional equipment) The machine can 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 eliminate unauthorised machine usage and theft. For further information, contact a Volvo Construction Equipment dealer.

Fire suppression system (optional equipment) The fire suppression system is a sprinkler system for the engine compartment and features 13 sprinkler nozzles. The system meets the standards according to SBF 127 (Swedish rules for permanently installed sprinkler system and other fire protection equipment on forestry and construction machines).

C

A B A B C

Sprinkler circuit Detector circuit (parallel with A) Container with fire extinguishing agent

1044754

Presentation

9 Automatic mode. In automatic mode only the green light-emitting diode is activated (''On'') on the control panel, see page 67. The sprinkler system is activated automatically in two modes: when the machine is not operated (e.g., when parked) with the engine off and also when the main electric power is off (battery disconnector off), or when the parking brake is applied with the engine running. In case of high temperatures, a detector circuit detects fire and the sprinkler system is activated automatically. After the system has been activated, there is enough extinguishing agent for approx. 20 seconds of operation. Then the extinguishing agent container is empty.

C B

Manual mode In manual mode both the green light-emitting diode (''On'') and yellow light-emitting diode (''Manual'') are activated, see page67.

A

The sprinkler system is in manual mode (the operator activates the system) when the machine is operated and the parking brake is released. 1044230

Cab's front left pillar A Control panel B Plastic cover C Emergency stop (stops the engine, cuts off electric power, and activates the sprinkler system if fire is indicated)

B

When the machine is operated and fire is detected, an alarm is generated via a red light on the control panel (A) and the siren/ strobe light are activated, see page 10. Then the system should be activated manually with the emergency stop (C), see page 82, via the control panel, see page 67, or by pressing in the manual activation button (located by cab steps), see below. For the control panel's functions, see page 67. NOTE! Plastic cover (B) shall only be raised when the control panel is used. The safety seal is restored during service and maintenance. For safety rules in case of fire, see page 99.

A

Manual release (activation) button The manual release (activation) button (located by cab steps) can be used in all modes to activate the sprinkler system, even when the machine is not operated and if the machine's electric power supply is turned off. 1 Pull out the yellow safety seal (A). 2 Press in the red button (B).

1044757

A B

Safety seal Button to activate the fire suppression system outside the cab (located by cab steps)

1043942

Manual activation of the sprinkler system with the manual release (activation) button

Presentation

10 Siren/strobe light Siren/strobe light are activated when fire is detected when the sprinkler system is activated using the control panel when the system is activated with manual release (activation) button 1043937

when the test button on the control panel is pressed in.

Decal for siren (located by siren/strobe light)

Siren/strobe light remain activated until the test button on the control panel is pressed in. If there is still an indication of fire the siren/ strobe light are activated again, contact a workshop authorized by Volvo CE.

Location for handheld fire extinguisher (optional equipment) There is space provided for two handheld fire extinguishers, one on each front fender. These are a supplement to the permanently installed sprinkler system and the main purpose is to protect the surroundings as well as use for any needed continued suppression of the fire. According to standard SBF127, two fire extinguishers of 6 kg (13.2 lb) each are required for work in fire-hazardous conditions and environments.

1043938

Decal for handheld fire extinguisher (located by each handheld fire extinguisher)

To use the handheld fire extinguishers: 1 Hold the fire extinguisher upright, pull out and remove the safety pin. 2 Point the nozzle at the base of the flames, from a distance of at least 1 meter (3ft 3.4 in). 3 Press the trigger.

Fire extinguishing agent The fire extinguishing agent is a water-based powder ("wet chem") that is easy to wash off after the system has been activated. At activation of the sprinkler system, there is enough fire extinguishing agent for approx. 20 seconds of operation. The fire extinguishing agent is protected against freezing down to -30 °C (-22 °F).

WARNING! The fire extinguishing agent contains glycol which may cause personal injury in case of contact. Avoid contact In case of eye contact, rinse with water. In case of skin contact, wash with soap and water. Always contact a doctor after contact with the fire extinguishing agent.

1052584

Decal for fire extinguishing agent (located on container for fire extinguishing agent)

After activation of the sprinkler system After activation of the sprinkler system, contact a workshop authorized by Volvo CE.

Presentation

CE-marking, EMC-directive

11

CE-marking, EMC-directive CE-Sign (Declaration of Conformity) (Applies only to machines marketed within the EU/EEA) This machine is CE marked. This means that, when delivered to the customer, the machine meets the applicable "Essential Health and Safety Requirements" according to EU's so-called Machine Safety Directive, 2006/42/EC. L64437A

Any person carrying out changes that affect the safety of the machine, is also responsible for the same. As proof of that the requirements are met, an EU Declaration of Conformity and a sound certificate regarding sound level in dB(A) are supplied with the machine. The sound certificate includes both measured external values and guaranteed sound level. These declarations are issued by Volvo CE for each individual machine. This EU declaration also covers attachments manufactured by Volvo CE. The documentation is a valuable document, which should be kept safe and retained for at least ten years. The document should always accompany the machine when it is sold. If the machine is used for other purposes or with other attachments than described in this manual, safety must at all times and in each separate case be maintained. A modification may in certain cases require new CE-marking and issuing of a new EU declaration of conformity. The person performing the modification is responsible for this.

EMC Regulations of the EC The electronic equipment of the machine may in some cases cause interference to other electronic equipment, or suffer from external electromagnetic interference, which may constitute safety risks. The EU EMC directive about "Electromagnetic compatibility", 2004/108/EC, provides a general description of what demands can be made on the machine out of a safety point of view, where permitted limits have been determined and given according to international standards. A machine or device must meet the standards in order to be CEmarked. Our machines have been tested particularly for electromagnetic interference. The CE marking of the machine and the declaration of conformity also cover the EMC directive. If other electronic equipment is fitted to this machine, the equipment must be CE marked and tested on the machine with regard to electromagnetic interference.

Declaration of Conformity The next page shows a copy of the declaration of conformity for machine and on page 13 shows a general copy of the declaration of conformity for attachments in the category interchangeable equipment (attachments that can be changed by operator). NOTE! Declaration of conformity only applies within the European Union.

Presentation

12

CE-marking, EMC-directive Valid for Volvo Wheel Loaders This document is only applicable within the EU EG DECLARATION OF CONFORMITY FOR MACHINES (IIA) Volvo Construction Equipment AB, SE-631 85 ESKILSTUNA, Sweden, states that the product: Manufacturer Volvo Construction Equipment AB Type Wheel loader LYYYY Product identification number (PIN): *VCELXXXXXXXXXXXXX* for which this declaration is intended, meets the relevant regulations for "Essential Health and Safety Requirements" according to: European Council's directive 2006/42/EC for machines, European Council's directive 2000/14/EC for noise emission to the environment from outdoor equipment European Council's directive 2004/108/EC for electromagnetic compatibility, as well as amendments of these for machines, and other applicable directives. Governing harmonised standards: EN 474-1:2006+A1:2009 Earthmoving machines Safety general requirements, EN 474-3:2006+A1:2009 Earthmoving machines Requirements for loaders. This declaration only covers the machine in the condition in which it was introduced on the market, and does not include components that have been retrofitted or work after this which has been done by the end user Authorised issuer's signature and person authorised to compile the technical file which has been established in the European Community: ................................................................................................. Signature / Clarification of signature (print)

................................................................................................. Occupation or title

................................................................................................. Address and date of issue

Signature of authorised representative in the European Community with authorisation to complete the manufacturing process and produce the manufacturer's declaration of conformity (if applicable) ................................................................................................. Signature / Clarification of signature (print)



This declaration covers attachments that have been developed, designed/ approved, marked, and marketed by the manufacturer mentioned above. The machine owner must save this declaration for at least ten years after delivery.

Presentation

CE-marking, EMC-directive

13

Valid for attachments in the category interchangeable equipment (attachments that can be changed by operator) for Volvo Wheel Loaders This document is only applicable within the EU EG DECLARATION OF CONFORMITY FOR MACHINES (IIA) Volvo Construction Equipment AB, SE-631 85 ESKILSTUNA, Sweden, states that the product: Manufacturer Model / Type number *): Serial number:

Volvo Construction Equipment AB YYYYY XXXXXXXXXX

for which this declaration is intended, meets the relevant regulations for "Essential Health and Safety Requirements" according to: European Council's directive 2006/42/EC for machines and och supplements for machines, and other applicable directives. Governing harmonised standards: EN 474-1:2006+A1:2009 Earthmoving machines Safety general requirements, EN 474-3:2006+A1:2009 Earthmoving machines Requirements for loaders. This declaration only covers the machine in the condition in which it was introduced on the market, and does not include components that have been retrofitted or work after this which has been done by the end user Authorised issuer's signature and person authorised to compile the technical file which has been established in the European Community: ................................................................................................. Signature / Clarification of signature (print)



Signature of authorised representative in the European Community with authorisation to complete the manufacturing process and produce the manufacturer's declaration of conformity (if applicable) ................................................................................................. Signature / Clarification of signature (print)



The machine owner must save this declaration for at least ten years after delivery.

*) On page 242 there is a combination table showing attachments in the category interchangeable equipment (attachments that can be changed by operator) and for which machines these attachments are approved.

Presentation

14

Communication equipment, installation

Communication equipment, installation IMPORTANT! Every installation of optional communication equipment must be performed by trained professionals according to instructions issued by Volvo CE.

Protection against electromagnetic interference This machine has been tested in accordance with EC directive 2004/108/EEC concerning electromagnetic interference. It is therefore very important that all non-approved electronic accessories, such as communication equipment, are tested before they are installed and used, as they can interfere with the electronic system of the machine.

Guidelines for installing aerial (antenna) The guide lines listed below must be followed during installation:

The position of the aerial should be chosen in such a way, that it is well adapted to the environment.

The down lead from the aerial should be of coaxial cable type. Make sure that the cable is undamaged, that the screen is not split up at the ends, but thoroughly encased in the connector and has good galvanic contact with the same.

The surface between the mounting bracket for the aerial and the point of attachment must be free from dirt and oxide. Apply corrosion protection to the surfaces after installation so that good galvanic contact is maintained.

Take care to separate cables that may cause interference from those which may suffer interference. Interfering cables are the power supply cable and the aerial cable to the communication equipment. Cables that may suffer from interference are connecting cables for the electronics of the machine. Install cable harnesses as close to grounded plate surfaces as possible, as these have a screening effect.

Presentation

Product plates

15

Product plates With the aid of the product plates listed below, it is possible to identify the machine and its components. State these numbers when ordering spare parts or when making enquiries.

3, 4,10

6

5

1

2

9 8 7

1031007

1 Lifting frame

6 Engine + exhaust decal

The manufacturer's name and address and the lifting frame CIN.

The engine's type designation and component number.

2 Primary marking

7 Front axle

The machine's PIN (stamped on the left side next to the product plate).

The manufacturer's name and address and front drive axle CIN.

3 Product plate

8 Transmission

The manufacturer's name and address, machine PIN. The manufacturer's name and address and the transmission's component number.

4 Additional plate for product plate

Machine weight 1), engine output, year of manufacture, year of delivery and position of CE mark (EU/ EEA countries only).

9 Rear axle The manufacturer's name and address and rear drive axle's component number.

5 Cab

10 Supplementary exhaust decal

Manufacturer's name and address, product number, machine's model designation, max. machine weight2) (for which the cab is approved acc. to the ROPS-test), cab serial number, ROPS/FOPS-number, and ROPS/ FOPS-certificate number.

The engine's type designation and component number (easier to access than ordinary exhaust decal, which may be hidden)

1) For current machine weight, see page 240. 2) For the machine's max. machine weight, see page 5.

Presentation

16

Information and warning plates / decals

Information and warning plates / decals The operator should know and pay attention to the information and warning plates / decals which are positioned on the machine. All plates/decals are not installed on all machines, as they are market and machine dependent. The decals/plates must be kept free from dirt, so that they can be read and understood. If they have disappeared or are no longer legible, they must be replaced immediately. The part number (order number) is shown on the respective decal /plate and in the parts catalogue. NOTE! "WARNING" is written on the warning decals for North America.

29

9 27 26 13 15

24

11

19

22

2

21

6

16 20 7 21 10 5

24

21 8

1026954

28

18 11

17, 23 14

1, 30 4, 9

12

2

24 21

8

6

25 7 21 10 24 8 21 5

1030669

3

Presentation

1

WARNING! First read the Operator's Manual (Spare part number in USA: 13935003)

2

1052898

15048368

WARNING! Rotating fan (Spare part number in USA: 13935001)

15048526

5

WARNING! Check that the attachment is locked (Spare part number in USA: 11111506)

15048335

WARNING! Risk of crushing at frame joint if machine is steered (Spare part number in USA: 13935000)

15048515

7

4

1052897

WARNING! Reversing machine (Spare part number in USA: 11400920)

6

1052901

3

WARNING! Do not step on this surface (Spare part number in USA: 11026072)

WARNING! Do not walk under raised attachment (Spare part number in USA: 11027566)

4948092

8

L67533A

15048239

1052896

15048422

1052892

10548264

1040932


Pressurised system

17

Presentation


15048257

1052899

18

11445277 1024716

When travelling on a public road, it is prohibited to have the Comfort Drive Control (CDC) activated use the steering wheel

1026965

4952173

11 WARNING! Hot surfaces (Spare part number in USA: 14531179)

12 Hot coolant

4948103

15048695

10 WARNING! Before connecting jump-start cables, read the Operator's Manual (Spare part number in USA: 13935004)

1053114

9

NOTICE: R134a AC-SYSTEM System designed acc. to SAE J639 rev.nov91

13 Hydraulic oil level

14 Refrigerant R134a

L67543A

16 Fuel filling point

15 Hydraulic oil filling point

1026932

D 11055037

11104071

17 Emergency exit

L67542A

Volvo Construction Equipment

L67526A

L67541A

Caution: System to be servised by Volvo qualified personel. See Volvo service instruction.

11445056

1020820

18 Use Volvo coolant VCS read the Operator's Manual

Presentation

19

L67530A

11 026 730


L67525A

L68746A 4952167

19

Air cleaner read the Operator's Manual

21 Attaching point for lashing

20 Battery disconnect switch

L WA

L pA 4898

495

dB dB 00000000

L67551A

22 Sound power level outside the machine

L67552A

23 Sound pressure level in cab

24 Point for lifting

1


500 h 250 h

Volvo Construction Equipment AB

50 h

10 h

SE-631 85 ESKILSTUNA, SWEDEN

Coupling Forces

13

12

2

12 11 3 6

4

1026949

11445271

5

7

2

5 6

10

9

1

2

7

1

8

10 h 50 h 250 h

25 Maximum force on towing device read the Operator's Manual

2000h

4000h

6000h

26 Lifting and lashing information

11431140

1030425

500 h 1000h

27 Lubrication and service chart

4952170

29 WARNING! Disconnect the frame joint lock before operating (only USA)

15011966

1027909

28 Transmission read the Operator's Manual

DISCONNECT STEERING FRAME LOCK BEFORE MOVING MACHINE

L67575A

11130942

L68091A

! WARNING

30 WARNING! Electromagnetic fields, EMF read the Operator's Manual

Presentation

20

The USA Federal Clean Air Act

The USA Federal Clean Air Act The Federal Clean Air Act Section 203.a (3) prohibits the removal of air pollution control devices or the modification of an EPA-certified non-road engine to a non certified configuration. The Federal regulations implementing the Clean Air Act for nonroad engines, 40 CFR 89.1003(a)(3)(i), reads as follows:

The following acts and the causing thereof are prohibited: For a person to remove or render inoperative a device or element of design installed on or in a non-road engine vehicle or equipment in compliance with the regulations under this part prior to its sale and delivery to the ultimate purchaser or for a person knowingly to remove or render inoperative such a device or element of design after the sale and delivery to the ultimate purchaser. The law provides a penalty of up to $2,750 USD for each violation.

An example of a prohibited modification is the recalibration of the fuel system so that the engine will exceed the certified horsepower or torque. You should not make a change to an EPA-certified non-road engine that would result in an engine that does not match the engine configuration certified to meet the Federal Standards.

Customer Assistance Volvo Construction Equipment wishes to help assure that the Emission Control System Warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control System Warranty, you should contact the nearest Volvo Construction Equipment Regional office for assistance.

Presentation

The USA Federal Clean Air Act

21

Normal Non-Road Engine Use The Maintenance Instructions are based on the assumption that this conventional machine will be used as designated in the Operators Instruction Manual and operated only with the specified fuel and lubrication oils.

Non-Road Engine Maintenance This is a non-road engine of conventional design and any local dealer may perform the necessary non-road emission control maintenance as defined in this manual. Volvo recommends that the purchaser use the service program for the non-road engine, known as Preventative Maintenance, including the recommended engine emission control maintenance. In order to document that the proper regular maintenance has been performed on the non-road engine, Volvo recommends that the owner keep all records and receipts of such maintenance. These records or receipts should be transferred to each subsequent purchaser of the non-road engine.

Service Performed By Your Local Dealer Your local dealer is best suited to give you good, dependable service since he has trained service technicians and is equipped with genuine original manufacturer's parts and special tools and the latest technical publications. Discuss your servicing and maintenance requirements with your local dealer. He can tailor a maintenance program for your needs. For regular, scheduled service or maintenance, it is advisable to contact your local dealer in advance to arrange for an appointment to ensure availability of the correct equipment and service technician to work on your machine. In this way you will assist your local dealer in reducing the time required to carry out the service of your machine.

Presentation

22

The USA Federal Clean Air Act Preventive Maintenance Program To retain the dependability, noise level and exhaust emission control performance originally built into your conventional non-road engine, it is essential that the non-road engine receives periodic service, inspections, adjustments and maintenance.

Fuel system Fuel recommendations: The fuel used must be clean, completely distilled, stable and noncorrosive. Distillation range, cetane level and sulfur content are most important when selecting fuel for optimum combustion and minimum wear. Engine working conditions and ambient temperature influence the selection of the fuel with respect to cold handling properties and cetane levels. In cold weather conditions, below 32 ºF (0 ºC), the use of lighter distillate or higher cetane level fuel are recommended. (Final boiling point max. 660 ºF (349 ºC) and cetane min. 45.). To avoid excessive deposit formation and to minimize the emissions of sulfur dioxide into the ambient air, the sulfur content of the fuel should be the lowest available. The diesel fuels recommended for use in Volvo engines should meet standards according to ASTM D 975 no. 1D (C-B) or no. 2D (T-T) and have a cetane number not less than 42 as well as a sulphur content not exceeding 0.05 percent by weight. Check for fuel leaks (while the engine is running at fast idle):

Visually check unions and hose connections.

Check the condition of the fuel hoses for:

Ageing

Cracks

Blisters

Scuffing

Check the condition of the fuel tank:

Drain condensation water.

Check for cracks.

Check for leaks.

Check the mounting.

Check the turbocharger:

Visually check for leaks in the intake hoses and exhaust pipe of the turbocharger.

Instrument panels

23

Instrument panels WARNING! Do not operate the machine until you are thoroughly familiar with the position and function of the various instruments and controls. Read through this Operator's Manual thoroughly - your safety is involved! Keep the manual in the cab so that it always is at hand.

2

1

3

5

1015939

4

1053078

Instrument panels 1

Front panel (information display, switches, keypad)

2

Overhead panel (climate control system)

3

Cab post panel (mode selector, switches, ignition switch, hand-throttle control and power socket 12 V.

4

Rear panel with power socket 24 V, hour recorder, electrical distribution box with fuses and relays, socket for service tool)

5

Control panel (optional equipment)

Instrument panels

24

Instrument panel, front

Instrument panel, front 4

4

5

3

2

2

3

5 0 km/h

0 km/h N

N

700 rpm

700 rpm

1

6

1

1027053

Front instrument panel (before 2009-03-04) 3 Separate attachment locking (optional equipment) 5 Hazard flashers

1045162

Front instrument panel (from 2009-03-04) 3 Separate attachment locking (optional equipment) 5 Hazard flashers

1

Parking brake

2

Keyboard

3

Separate attachment locking (optional equipment)

4

Display unit

5

Hazard flashers

6

Unassigned

1 Parking brake Parking brake function, see page 70.

1020380

2 Keyboard Information about keyboard, see page 30.

1026099

6

Instrument panels


25

3 Separate attachment locking (optional equipment) WARNING! Always check that the attachment is mounted correctly on the attachment bracket by pressing the attachment's front end against the ground. This equipment makes it possible for the operator to connect and disconnect attachments from the operator seat, see page 133. 1030216

When disconnecting attachments, the switch must be switched on (upper end of switch pressed in). A catch on the switch ensures that no inadvertent actuation occurs. NOTE! When the switch is switched on, it is possible to operate the tilting and lifting functions simultaneously in order to align the attachment.

11 111 506

L67523A

WARNING

A warning message, "Attachment lock open", will be shown on the display. Connect the attachment according to page 133.

4 Display unit By taking action in time, it is possible to prevent serious damage to the machine. Therefore, look now and then at the instrument panel where the operator is provided with information should something happen that requires his or her intervention. In order to be able to check the function of instruments and controls, the current must be turned on and the ignition switch be in position 1 (running position).

0 km/h N

700 rpm

1027057

5 Hazard flashers Upper end of switch pressed in = All direction indicators on the machine will flash in time with the lamp in the switch together with the control lamp for direction indicators. The hazard flashers can be used even if the ignition switch key has not been turned on.

6 Unassigned

1020381

Instrument panels

26

Instrument panel, front 1

5

6

2

3

9

7 8

10

11

12

13 14

4

0 km/h 700 rpm

N

15

16

17

1027056

1

Central warning (red)

10

Direction indicator, right (green)

2

Central warning (amber)

11

Display

3

Information symbol (green)

12

Activated Boom Suspension System (green)

4

High beams (blue)

13

Engaged differential lock (green)

5

Rotating warning beacon (amber)

14

Activated Comfort Drive Control (green)

6

Working lights (amber)

15

Fuel level

7

Applied parking brake (red)

16

Transmission oil temperature

8

Battery charging (red)

17

Coolant temperature

9

Direction indicator, left (green)

1 Central warning (red) 1021110

The lamp flashes if abnormal operating values or faults arise. Alarm text is shown on the display unit. The buzzer will sound until the required action has been carried out.

2 Central warning (amber) 1021110

The lamp flashes when a function is engaged/disengaged or when a function needs to be kept under observation (e.g. clogged filter). Alarm text is shown on the display unit. The buzzer sounds four times.

3 Information symbol Indicates deviation of some kind. Alarm text is shown for 3 seconds on the display unit. The buzzer sounds four times. 1027075

Instrument panels


27

4 High beams The lamp is alight when the high beams are switched on, see page 72. 1021106

5 Rotating warning beacon The lamp lights when the rotating warning beacon is switched on. See page 62.

6 Work lights The lamp lights when the working lights are switched on, see page 72. 1021107

7 Applied parking brake The lamp is alight when the parking brake is applied. The buzzer sounds and alarm text is shown on the display unit, if a directional gear is selected.

1021109

8 Battery charging If the lamp lights when operating, the cause must be corrected as otherwise the batteries may be damaged.

9 Left direction indicators The light flashes when the lever is moved forward, see page 72. Uneven flashing pulses indicate a faulty bulb, which then should be replaced.

1020767

10 Right direction indicators The light flashes when the lever is moved backward, see page 72. Uneven flashing pulses indicate a faulty bulb, which then should be replaced.

1020768

11 Display

0 km/h 700 rpm

N

In addition to alarm texts the display unit also shows starting sequence, operating information and settings, see page 29.

1026319

12 Boom Suspension System (BSS) 1021111

The lamp lights with a fixed light when the Boom Suspension System is activated.

Instrument panels

28

Instrument panel, front 13 Differential lock The lamp is alight when the differential lock is engaged. The foot switch for the differential lock is positioned on the floor to the left of the steering wheel column.

1021112

14 Comfort drive control The lamp lights when the Comfort Drive Control is activated. It is possible to steer the machine and select gears from the armrest to the left of the operator's seat.

1021113

NOTE! The ordinary gear selector control should be in neutral. For further instructions, see page 107.

15 Fuel level When the pointer indicates at empty, the warning lamp to the left of the gauge lights up and a message is shown on the display unit. The machine should be refuelled as soon as possible to avoid air entering the system. If the tank has been run dry and the fuel system needs to be bled, see page 175. Fuel tank capacity: 269 litres (71.0 US gal) 1021185

16 Transmission oil temperature If the gauge indicates into the red sector, the warning lamp to the right of the gauge lights up. As a precaution the engine speed is at the same time limited. Stop the machine and investigate the cause. The buzzer sounds and alarm text is shown on the display unit, if a directional gear is selected.

1021186

17 Coolant temperature If the gauge indicates into the red sector, the warning lamp to the right of the gauge lights up. As a precaution the engine speed is at the same time limited. Run the engine at low idling for a few minutes. If the gauge continues to indicate within the red sector, stop the engine and investigate the cause. The buzzer sounds and alarm text is shown on the display unit, if a directional gear is selected. 1021187

Instrument panels

Display

29

Display On the display unit are shown, current operating information, vehicle messages and alarm texts. With the aid of the keyboard on the front instrument panel the operator may also have information about the machine status and make settings. When the ignition key is turned to position 1, a test programme starts to verify the system, all control lamps light up for 2 seconds, the pointers in the gauges then move to indicate the correct value for fuel level and temperature. If the machine is equipped with theft protection, the display shows that the code should be entered, see page 55. The test program starts after correct code has been entered.

Operating information If another screen was shown, when the engine was turned off last, this screen will be shown at the next startup. Press ESC to return to the Operating Information screen.

XX yyy zzz zzz ww

vvv rpm

There are two settings for the operating information display, operating information 1 and 2. Use ARROW UP/DOWN to choose operating information 1 or 2.

tt

If any information is missing or fails to occur, will be shown.

ss

1026136

Operating Information screen 1

xx

Travelling Speed

yyy

km/h/mph Selected gear N/F1/F2/F3/F4/R1/R2/R3/R4

zzz zzz

XX yyy zzz zzz

vvv rpm

Shows if another gear selector control has been selected CDC is shown if CDC Comfort Drive Control is activated F/R is shown if the gear selector control on the control lever carrier is activated

vvv

Engine rpm

ww

Time, 12/24, AM/PM

ss

Temperature, C/F

tt

Fuel consumption, average value since it was last set to zero. (Shows remaining operating time on the residual fuel, optional equipment)

1026137

Operating Information screen 2

Symbols Information available to be retrieved, use key with this symbol Vehicle message available to be retrieved, use key with this symbol. Engine preheating activated by E-ECU. Lever lockout activated Only if the machine has electrical control lever lockout.

Instrument panels

30

Display Keypad for display With the aid of the keyboard the operator may have information about the machine status and make settings. Changing display screen is only possible if the speed is below 20 km/h (12.4 mph).

1026099

ESC

Engine

Transmission 1

Axles / Brakes

Hydraulics 2

Electrical system 4

3

Vehicle information 5

6

SETUP Vehicle message

Service 7

SELECT

Settings 8

9

0

The SELECT key is also used for obtaining more information when one information or check message is shown on the display unit. The digit furthest down to the right on each key corresponds to the digit that should be stated during different settings, e.g. the date. On machines equipped with anti-theft device, the digits are used for entering the correct code.

Instrument panels

Display

31

Information Information about the machine status is obtainable by pressing the respective function on the keyboard. Each function group consists of one or more display screens (menus). An arrow pointing downward is shown on the right, if there are more screens under the function group. To browse within the function group, press arrow down or arrow up on the keyboard. Settings can be made in certain menus. The text is then highlighted. To revert to the "Operating Information" screen, press the ESC key. Selected key

Engine Coolant temperature Shows coolant temperature, normal or high.

102799

High

Oil pressure Shows oil pressure, normal or low. 102799b

Low

Oil level Shows oil level, normal or low. 102799b

Low

Air filter

Normal

Shows whether the air filter is normal or when clogged, a text message is shown.

Instrument panels

32

Display Selected key

Engine

Oil temperature Shows oil temperature, normal or high.

102799

High

Engine rpm rpm

Shows current engine speed.

rpm

Shows current fan speed.

r/min Fan speed

Instrument panels

Display

33

Selected key

Engine Rev. cooling fan

The hydraulic oil temperature must exceed 0 °C (+32 °F) to make it possible to reverse the cooling fan. New selection can be made when the text is highlighted.

OFF

Shows that the cooling fan is not reversing. To select a new interval, press SELECT, use the arrow keys to make required selection, then press SELECT.

1027111

Rev. cooling fan Short Interval

Shows that reversing is selected and the selected interval. Shows the duration of the interval in minutes.

1027111

To select a new interval, press SELECT, use the arrow keys to make required selection, then press SELECT.

Mode reversible fan Short Long Manual OFF

For manual reversing make a new selection as above and select Manual.

Rev. cooling fan OFF Interval 1027111

Move down one step with the arrow key. Press SELECT. The cooling fan reverses. The reversing ceases automatically.

To revert to the "Operating Information" screen, press the ESC key.

Instrument panels

34

Display

Selected key

Transmission

Oil temperature Shows oil temperature, normal or high. 102799

High

Oil pressure Shows oil pressure, low or normal 102799b

Low

Oil level Shows if oil level is normal or low.

102799b

Low Oil filter Normal

Shows whether the oil filter is normal or when clogged, a text message is shown.

Trans. diseng. ON OFF

Select with SELECT, engaged or disengaged transmission disengagement (declutch).

Instrument panels

Display

35

Selected key

Hydraulics Oil temperature Shows oil temperature, normal or high.

102799

High

Oil level Shows oil level, normal or low.

102799b

Low

Boom Suspension System (BSS) ON OFF

Shows whether the Boom Suspension System is engaged or disengaged. The Boom Suspension System must first be activated with the switch.

Instrument panels

36

Display

Selected key

Axles / Brakes Brake pressure Shows brake pressure, low or normal. 102799b

Low

Oil temp. Front axle Shows oil temperature, normal or high. 102799

High

Oil temp. Rear axle Shows oil temperature, normal or high. 102799

High

Instrument panels

Display

37

Selected key

Electrical system Voltage Shows system voltage 102799

19

28

Selected key

Vehicle information Operational Data

To see operational data, press the SELECT key.

Selected key

Vehicle information Operational Data Reset Time Distance

Shows operational data since previous setting to zero.

Reset h km

Cycles l/h

Total

l

Instantaneous

Operating time in hours Travelling distance in km/mile Number of cycles

Avg. Resid. time fuel

Set operational data to zero with Select

h l/h

Average consumption litres/USgal per hour Total consumption, litres/USgal Remaining operating time on residual fuel (optional equipment) Current consumption litres/USgal per hour To return to previous menu press ESC.

Instrument panels

38

Display

For information move downward with the arrow key.

Vehicle information Operational Data

h

See previous screen

Model

Lxxxx

Machine model designation

Serial no.

xxxxx

Machine's serial number

Tyres

mm

Machine hours

h

Time

xx:xx

Date

xxxxxxxx

HW/SW

Tyre size Total operating time of machine Real time Current date Only accessible for service personnel

To return to previous menu press ESC.

Selected key

Vehicle messages Message is available for retrieval

Instrument panels

Display

39

Selected key

Service Next Service Central lubrication Test I/0-List

Select but with arrow key, press SELECT

Service Next service

Selected menu

Resid. Time

h

Shows residual time left to service from previously acknowledged service

Interval

h

Shows selected service interval

Confirm service

No Yes

To confirm service: Press SELECT to confirm performed service. "No" will change to "Yes" for a few seconds and then reverts to showing "No". Service is now confirmed. NOTE! Alarm for service is generated eight hours before the end of the interval. Service can only be acknowledged during these eight hours. If the eight hour interval passes without acknowledgement of service, the alarm for service is removed.

To go back and make a new selection, press ESC To go back to Operating Information screen, press ESC twice

Instrument panels

40

Display

Service Central lubrication Interval

Selected menu

Light

Shows the selected interval. To make a new selection, press SELECT. The screen shows an example

To go back and make a new selection, press ESC To go back to Operating Information screen, press ESC twice

Selected key

Service Central lubrication

To change interval, press SELECT

Interval Light Normal Heavy

Select interval by moving up or down with the arrow keys.

To confirm selection of interval, press SELECT To return, press ESC To go back to Operating Information screen, press ESC twice

Service Test

Selected menu

Bulb test

OFF

Brake test

Off

Testing warning and control lamps in the centre instrument See also page, 109. Use SELECT to choose "Off or "On" To return, press ESC To go back to Operating Information screen, press ESC twice

Instrument panels

Display

Selected key

SETUP Settings

Shows previous setting. Select row by moving up or down with the arrow keys.

Date

Shows set date

Time

Shows set time

Language

Shows selected language

Units

Shows set unit

Clock options

Shows set clock option

Date format

Shows set date format

Display

Shows set display, Inverted or Normal

Intensity

Shows display light intensity in %

41

Instrument panels

42

Display Settings To make a new setting, select row by moving up or down with the arrow keys.

Date 1 Press SETUP. 2 Browse with ARROW UP/DOWN to the menu "Date". 3 Press SELECT. 4 Enter the correct date with the aid of the keyboard. 5 Confirm with SELECT. 6 Press ESC to confirm and return to Settings. 7 Press ESC to return to the Operating Information screen.

Time 1 Press SETUP. 2 Browse with ARROW UP/DOWN to highlight the "Time" menu. 3 Press SELECT. 4 Use SELECT to shift between hours and minutes. Enter the correct time with the aid of the keyboard. 5 Press ESC to confirm and return to Settings. 6 Press ESC to return to the Operating Information screen.

Language 1 Press SETUP. 2 Browse with ARROW UP/DOWN to the "Language" menu. 3 Press SELECT. 4 Browse with ARROW DOWN to highlight language. 5 Press SELECT to view the language alternatives. 6 Browse with ARROW UP/DOWN to the required language. 7 Confirm with SELECT. 8 Press ESC to return to Settings. 9 Press ESC to return to the Operating Information screen.

Instrument panels

Display

43

Units 1 Press SETUP. 2 Browse with ARROW UP/DOWN to the "Units" menu. 3 Confirm with SELECT. 4 Browse with ARROW DOWN to highlight unit. 5 Select with SELECT the required unit. 6 Press ESC to confirm and return to Settings. 7 Press ESC to return to the Operating Information screen. The following unit alternatives are available: Metric system US system

Clock options 1 Press SETUP. 2 Browse with ARROW UP/DOWN to the menu "Clock options". 3 Press SELECT. 4 Browse with ARROW DOWN to highlight display alternative. 5 Select with SELECT the required display alternative. 6 Press ESC to confirm and return to Settings. 7 Press ESC to return to the Operating Information screen. The following display alternatives are available: am pm 24 hr

Instrument panels

44 Date format 1 Press SETUP. 2 Browse with ARROW UP/DOWN to the menu "Date format". 3 Press SELECT. 4 Browse with ARROW DOWN to highlight display alternative. 5 Select with SELECT the required display alternative. 6 Press ESC to confirm and return to Settings. 7 Press ESC to return to the Operating Information screen. The following display alternatives are available: year - month - day month - day - year

Display 1 Press SETUP. 2 Browse with ARROW UP/DOWN to the menu "Display". 3 Press SELECT. Day / Night mode 4 Browse with ARROW UP/DOWN to the menu "Day / Night mode". 5 Press SELECT. 6 Browse with ARROW DOWN in order to highlight mode. 7 Select with SELECT the required display alternative. 8 Press ESC to confirm and return to Settings. 9 Press ESC to return to the Operating Information screen. The following display alternatives are available: day night

Intensity 1 Browse with ARROW UP/DOWN to the menu "Intensity". 2 Press SELECT. 3 Browse with ARROW DOWN to highlight intensity. 4 Press SELECT. 5 Browse with ARROW UP/DOWN to the required intensity. 6 Confirm with SELECT. 7 Press ESC to confirm and return to Settings. 8 Press ESC to return to the Operating Information screen.

Instrument panels

45 Alarm texts The information to the operator is provided on the display unit in the form of alarm texts, which are divided into three classes: Warning, Check and Information. For all classes applies that at speeds above 20 km/h (12.4 mph) the alarm text is shown for three seconds and is then alternated with the previous screen which is shown for three seconds. This alternate showing of the two screens continues as long as the error situation remains, or alternatively until the alarm is shown a certain number of times.

Information The information symbol is shown. The buzzer sounds four times. Alarm text is shown for three seconds and then changes to Operating Information screen. Rectify or contact a workshop authorised by Volvo CE for information.

Engine Information

Information

Coolant output reduced Check radiator

Automatic engine shutdown

Transmission Information

Information

Gear selector not in neutral Machine speed too high for current gear

Reduce speed before downshifting

Axles Information

Information

Front axle oil rising temperature

Rear axle oil rising temperature

Instrument panels

46 Steering system Information

Information

Lever carrier deactivated CDC activated

Lever carrier not activated CDC activated

Miscellaneous Information

Information

Accelerate over 20 km/h

Brake to standstill

Low washer fluid level*

Brake test failed

*) The level is checked continuously during operation.

Miscellaneous Brake test

Brake test log 2

Retardation Pressure

x m/s xx bar

1: 2: 3:

xx bar xx bar xx bar

Miscellaneous Check

Information

Lubricant level low Check at next stop

Go to Service mode Information Exit Service mode

x.x m/s2 x.x m/s2 x.x m/s2

Instrument panels

47 Warning Red central warning lamp will be flashing. The buzzer will sound until the required action has been carried out. The alarm text will be shown until the required action has been taken. Take appropriate action or contact a workshop authorised by Volvo CE for information.

Warning

Warning

Stop vehicle

Stop vehicle Turn Off Engine

These two warnings are always followed by a further alarm text. Follow the instructions on the screen and rectify or contact a workshop authorised by Volvo CE. When a warning is shown, the engine should be turned off and the ignition key turned to position 1 in order to show the subsequent alarm text.

Engine Warning

Warning

High coolant temperature engine

High charge-air temperature engine

High engine oil temperature

Low engine oil pressure

Coolant level low*

Engine failure

High fuel temperature

High crankcase pressure

*) The level is checked continuously during operation.

Transmission Warning

Warning

High transmission oil temperature

Low transmission oil pressure

Instrument panels

48 Brakes Warning

Warning

Low brake pressure

Applied parking brake

Brakes failure

Parking brake NOT applied

Axles Warning

Warning

High oil temperature front axle

High oil temperature rear axle

Steering system Warning

Warning

Low steer pressure*

Steering system failure

*) Applies only to machines equipped with secondary steering.

Hydraulics Warning

Warning

Low hydraulic oil level**

High hydraulic oil temperature

Attachment lock open

Low steer pressure*

**) The level is checked continuously during operation.

Miscellaneous Warning

Warning

Reduce speed

Direction change at too high speed

Instrument panels

49 Check Amber central warning lamp will be flashing. The buzzer sounds four times. Press SELECT to obtain more information about the fault. Alarm text is shown until confirmation is done by pressing ESC. Rectify or contact a workshop authorised by Volvo CE for information.

Engine Check

Check

Engine failure

Engine system failure

Cooling fan system failure

Cooling fan reversal failure

Clogged air filter engine

Fuel level sensor

Preheating failure

Fuel level low

Hand throttle failure

High temp. starter motor Wait 5 min. before start

High coolant temperature engine

High charge-air temperature engine

Coolant level low Check at next stop

Injection system failure

High engine oil temperature

Water in fuel Empty cup

Instrument panels

50 Electrical system Check

Check

High system voltage

Low system voltage

ECC failure

Relay failure

Instrument panels

51 Transmission Check

Check

Transmission failure

Transmission oil filter clogged

Gear sel. CDC failure Check at next stop

Gear sel. F/N/R failure Check at next stop

Gear sel. F/R failure Check at next stop

Gear sel. failure Check at next stop

Reduced gearshift function

Reduced gearshift function No reverse gear

Reduced gearshift function No forward gear

Transmission oil level low

Sensor transmission oil filter

Transmission oil pressure sensor

Transmission oil temp. sensor

Transmission failure

Instrument panels

52 Axles Check

Check

Axle failure

Temperature sensor axle oil

Diff. lock failure

Brakes Check

Check

Brake system

Brakes failure

Parking brake failure Check at next stop

Steering system Check

Check

Steering system failure

Secondary steer pump failure

CDC failure

Secondary steer failure

Instrument panels

53 Hydraulics Check

Check

Hydraulic system failure

Attachment lock

Check attachment lock and confirm*

BSS Failure

Hydraulics failure

Return-to-Dig failure

Temperature sensor hydraulics

LS press sensor failure

Hydraulic pump failure

*) Confirm with SELECT

Instrument panels

54 Miscellaneous Check

Check

ECU network Communication Interrupt

ECU network Reduced Communication

APS control

Central lubrication failure

Wiper failure

Rear wiper failure

Accelerator failure

Residual time XXX h Next service YYYY h*

Parameter failure

Accelerator pedal sensor

Ambient temp. sensor

Limp Home safety related failure

*) XXX = number of hours remaining to next service, YYYY = next service interval. *) Computer malfunction between the ECUs. The machine can only be operated in first or second gear. Only operating information and alarms are available on the display unit. **) Contact a workshop authorised by Volvo CE for information.

Instrument panels

55 Anti-theft system The anti-theft device prevents theft of the machine as: the engine does not start the gear selector does not work the parking brake cannot be released.

When starting the engine 1 Turn the ignition key to position 1.

Anti-theft system

2 Wait until the following screen is shown on the display unit.

Enter code ****

3 Enter the four-digit code on the keyboard. When the correct code has been entered, the anti-theft device becomes deactivated and the engine can be started. Use the ESC key to move the cursor to the left to change an incorrectly entered digit. When the code has been entered, and one of the digits is incorrect, the system automatically returns to the position for the first digit. Enter the code again.

1026099

The code can only be changed by a workshop authorised by Volvo CE.

The engine can be restarted within 60 seconds after it was stopped without having to enter the code.

Instrument panels

56

Instrument panel, cab post


1 2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

1

Mode selector, gear-shifting programme (APS III)

2

Unassigned

3

Fully automatic downshifting (1-4), FAPS

4

Unassigned

5

Unassigned

6

Bucket positioner

7

Boom kick-out

8

Hold function, 3rd hydraulic function

9

Return-to-Dig (optional equipment)

10

Floating position

11

Single-acting lifting function (optional equipment)

12

Unassigned

13

Function selector, Boom Suspension System (optional equipment)

14

Front working lights

15

Rear working lights

16

Lights

17

Rotating warning beacon (optional equipment)

18

Electrically adjustable rear view mirrors (optional equipment)

19

Electrically heated rear view mirrors (optional equipment)

20

Wiper and washer, rear window

21

Hydraulic emergency stop (optional equipment)

22

Ignition switch

23

Unassigned

24

Rheostat, instrument lighting, guide light in switches

25

Hand-throttle control (optional equipment)

26

12 V power socket

18 19

20

22

21

23

24

25 26

Instrument panels


57

1 Mode selector, gear-shifting programme (APS III) Position L The machine shifts at low engine speed and low travelling speed.

Position M The machine shifts at slightly higher engine speed as compared with position L. 1020388

NOTE! If the accelerator is depressed fully with the selector in the "L" position, upshifting according to the "H" position will take place. The best utilisation is obtained if the accelerator is not depressed fully, as the difference in upshifting speed between the (L-M-H) modes will be more noticeable.

Position H The machine does not shift until higher engine and travelling speeds have been reached. Preferably used in cases where the machine changes gear when operating uphill or when the rolling resistance is great.

Position AUT The machine itself selects APS mode according to current operating condition to achieve best comfort and economy.

Mode

1023178

(Service mode)

The machine starts and operates in the selected gear position. Upshifts and downshifts on the move are controlled manually. Further gear shifting instructions, see page 103.

2 Unassigned

3 Fully automatic downshifting, FAPS Upper end of switch pressed in = automatic downshifting to 1st gear when required. (Downshifting via any of the kick-down buttons can still be done manually) Lower end of switch pressed in = downshifting to 1st gear can be done via any of the kick-down buttons.

1020386

4 Unassigned

Instrument panels

58

Instrument panel, cab post 5 Unassigned

6 Bucket positioner Switch, upper part pressed in = hold function for tilt position activated, see page 78. Switch, lower part pressed in = hold function for tilt position deactivated.

1020399

7 Boom kick-out Upper end of switch pressed in = adjusting lifting height, see page 78. Lower end of switch pressed in = detent function lifting deactivated. For further instructions, see page 78.

1020398

8 Hold function, 3rd hydraulic function Switch, upper part pressed in = activation of hold function. Switch, lower part pressed in = hold function deactivated

1020396a

9 Return-to-Dig (optional equipment) Upper end of switch pressed in = adjusting lowering position, see page 79. Lower end of switch pressed in = detent function lowering deactivated.

1020401

Instrument panels


59

10 Floating position Upper end of switch pressed in = Floating position engaged when the control lever for lifting/lowering has been moved to floating position. Switch, lower part pressed in = Normal lift/lower function.

1030427

Float mode/Return-to-Dig (optional equipment) Upper end of switch pressed in = Floating position engaged when the control lever for lifting/lowering has been moved to floating position. Switch, lower part pressed in = Normal lift/lower function.

1030426

The function "Return-to-Dig" is engaged when the attachment is above the ground and when the control lever for the lifting arms is moved to detent position for full lowering. The Return-to-Dig function can only be activated when the attachment is above ground. If the attachment is close to the ground, the floating position will be engaged instead.

11 Single-acting lifting function (optional equipment) Upper end of switch pressed in = single-acting lifting function activated. Lower end of switch pressed in = single-acting lifting function deactivated. 1020396

The attachment can now rise, e.g. if it encounters uneven ground, but will return to the original position under its own weight.

12 Unassigned

Instrument panels

60

Instrument panel, cab post 13 Function selector, Boom Suspension System (optional equipment) The switch has three positions. When starting the engine, the function reverts to the previously preselected position. Regarding settings of Boom Suspension System in combination with different attachments, see section "Operating techniques".

1020397

Upper end of switch pressed in = Speed-dependent Boom Suspension System (regardless of the gear selector position). The control lamp for the Boom Suspension System is alight and on the display unit under the menu hydraulics is shown BSS On or BSS Off depending on whether the system is engaged or disengaged (speed-dependent). The Boom Suspension System will be engaged, if a certain speed is exceeded. Below a certain speed (approx. 5 km/h (3.1 mph) in forward drive or approx. 2 km/h (1.2 mph) in neutral or reverse drive) the function will be disengaged. Switch in centre position = Gear-dependent Boom Suspension System. The control lamp for the Boom Suspension System is alight and on the display unit under the menu hydraulics is shown BSS On or BSS Off depending on whether the system is engaged or disengaged (gear-dependent). The Boom Suspension System is engaged in gear positions 2, 3 and 4 when in neutral, forward or reverse drive. When changing down (kick-down) to gear position 1, the function will be disengaged. Lower end of switch pressed in = Deactivated Boom Suspension System.

Instrument panels


61

14 Front working lights Upper end of switch pressed in = working lights by cab roof and lower working lights switched on. Switch in centre position = working lights by cab roof switched on. Lower end of switch pressed in = front working lights switched off.

1020403

If the machine, as optional extra, is provided with working lights, which have a bulb of the HID type (High Intensity gas Discharge lamp), see page 188. There is a delay of up to 90 seconds (depending on the ambient temperature) before a bulb of the HID type reaches full power. Therefore, do not switch off the working lights more often than necessary. Control lamp on the front instrument panel indicates that working lights are switched on.

15 Rear working lights Upper end of switch pressed in = rear working lights are switched on when the reverse is engaged. Switch in centre position = all rear working lights switched on. Lower end of switch pressed in = the function is deactivated.

1020404

Control lamp on the front instrument panel indicates that working lights are switched on. OBS! Working lights should be off when travelling on public roads.

16 Lights Upper end of switch pressed in = travel lights switched on. Switch in centre position = parking and instrument lighting switched on. Lower end of switch pressed in = lights switched off. Switching between high/low beams, see page 72. 1017895

Control lamp on the front instrument panel indicates that the high beams are switched on.

Instrument panels

62

Instrument panel, cab post 17 Rotating warning beacon (optional equipment) Upper end of switch pressed in = Rotating warning beacon switched on, see also page 98. Lower end of switch pressed in = Rotating warning beacon switched off. Control lamp on the front instrument panel indicates that the warning beacon is connected. 1020409

18 Electrically adjustable rear view mirrors (optional equipment) Select left or right rear-view mirror by turning the button in the middle. Adjust the mirror by pressing according to the arrows, upward or downward, left or right. 1026243

19 Electrically heated rear view mirrors (optional equipment) Upper end of switch pressed in = electric heating activated. Lower end of switch pressed in = electric heating deactivated.

1020410

Instrument panels


63

20 Wiper and washer, rear window NOTE! For wiping and washing to take place, the windscreen wiper must be switched on. Upper end of switch pressed in (spring return) = washing and the wiper makes a few strokes. Switch in centre position = rear window wiper operates intermittently. 1020411

When the windscreen wiper is on at the same time as the reverse gear is engaged, the rear window wiper will be on constantly. Lower end of switch pressed in = wiper and washer turned off. Washer reservoir for windscreen and rear window, see page 196.

21 Hydraulic emergency stop (optional equipment) Hydraulic emergency stop for rotating attachment. The emergency stop turns off the power to the attachment and stops its movement. See page 153.

1026244

22 Ignition switch Ignition switch positions

1026348

0

Switched off (key-turn engine stop)

R

Radio position

1

Running position

2

Starting position

Instrument panels

64

Instrument panel, cab post 23 Unassigned

24 Rheostat, guide light in switches Guide light in switches and lighting of the climate control system panel Upper end of switch pressed in = the light intensity increases Lower end of switch pressed in = the light intensity reduces. NOTE! Headlights or work lights must be on. 1021178

25 Hand-throttle control (optional equipment) The accelerator position is transferred electrically.

The accelerator position is altered by turning the control. Turning clockwise increases the speed.

Depending on previous adjustment, the control may first have to be turned counter-clockwise and then clockwise in order to set the speed.

Disengagement takes place when applying throttle pedal or brake pedal.

When starting the engine, the hand-throttle is disengaged, regardless of previous setting.

r / min

L67480A

12 V

26 12 V power socket For charging of, for example, mobile telephone.

1020413

Instrument panels

Instrument panel, overhead

Instrument panel, overhead Climate control system 2

3

4

5

26 24

22

1

20 18

1020417

1

Air conditioning

2

Cab ventilation / interval heating

3

Fan control

4

Temperature control

5

Air distribution control

Information about climate control system, see page 86.

65

Instrument panels

66

Rear cab wall

Rear cab wall 2

1

3 1027058

1 Electric power socket, 24 V (e.g., for cigarette lighter) 2 Operating hour meter 3 VCADS Pro service socket (the cover for the electrical distribution box has been removed)

Fuse test It is possible to test fuses. On the circuit board (behind the cover for the electrical distribution box) there is the marking FUSE TEST. To test whether a fuse has blown or not, hold it against the contact surface under the mark FUSE TEST. If the fuse has not blown, the green light emitting diode above the mark lights up.

FUSE TEST

1027074

Fuse test

Instrument panels


67


A

A The safety seal is broken if the plastic cover (A) is raised. B Hold in the button for 1 second to activate the sprinkler system when fire is indicated. The engine is not stopped. Can be used when the machine has to be moved at the same time as the system is activated.

B C

C The light-emitting diode is red when fire is detected, and the siren and strobe light are activated at the same time. To activate the sprinkler system with the manual activation button, see below.

D E F G

D The light-emitting diode is yellow when there is a malfunction of the activation function. If the light-emitting diode is on, contact a workshop authorized by Volvo CE.

H 1043939

A B C D E F G H

Plastic cover Manual release (activation) Fire alarm Fault actuator Fault detector Manual On Test/Reset

E The light-emitting diode is yellow when there is a malfunction of the detector circuit. If the light-emitting diode is on, contact a workshop authorized by Volvo CE. F The light-emitting diode is yellow when the system is in manual mode, that is, the parking brake is released. G The light-emitting diode is green when the machine is parked and when the system is in automatic mode. The system is supplied with electric power (the system is supplied with electricity even when the battery disconnector is off). H Test button: When the test button is pressed in, a function check takes place of the system and the light-emitting diodes. All light-emiting diodes, the siren, and strobe light are activated for approx. three seconds. Daily test is recommended. NOTE! When using button B on the control panel, the engine is not stopped. The machine can be moved during the time that fire extinguishing is in progress (the system is activated). Operator's choice depending on the situation.

Function check NOTE! The plastic cover should not be raised. Check daily that the system works.

Press the test button (H) on the control panel.

In case of a malfunction indication, contact a workshop authorized by Volvo CE.

Instrument panels

68

Other controls

Controls

69

Other controls Controls 4

3

6

5

7

8

2

9 10,11

1

12,13

14

1015939

1030428

1

Comfort Drive Control, CDC (optional equipment)

8

Headlight dipper / windscreen washer, direction indicators, windscreen wiper

2

Parking brake

9

Accelerator pedal

3

Gear selector control, horn

10

Control lever carrier: working hydraulics, kickdown, engine braking, control lever lockout, forward/reverse shifting, forward/reverse activation, horn

4

Brake pedal

11

Control lever carrier for electric servo lever control (optional equipment): working hydraulics, kickdown, engine braking, control lever lockout, forward/reverse shifting, forward/reverse activation, horn

5

Differential lock

12

Arm rest, adjusting

6

Brake pedal

13

Arm rest, adjusting electric servo lever control (optional equipment)

7

Steering wheel adjustment

14

Emergency stop, engine (optional equipment)

Other controls

70

Controls 1 Comfort Drive Control, CDC (optional equipment)

57179

The equipment consists of a folding arm rest where three operating functions are collected: steering, forward/reverse and kick-down.

The functions are activated by folding down the arm rest and pressing the activating button.

When the system is activated, a control lamp on the centre instrument panel is on.

For further instructions, see page 107.

2 Parking brake

57172

The control lamp lights when the parking brake is applied. If the parking brake is applied when a directional gear is selected, the red central warning lamp begins to flash, the buzzer begins to sound and alarm text is shown on the display unit.

The catch on the switch prevents the parking brake from being released inadvertently.

Application Move the gear selector to neutral. Press in the lower end of the switch. The machine must be at a complete standstill before applying the parking brake. Turn the ignition key to the "0" position.

If the engine is turned off without the parking brake having first been applied, it will be applied automatically.

Releasing Slide down the catch and press in the upper end of the switch. Releasing (if the parking brake has been applied automatically): Press in the lower end of the switch. Slide down the catch and press in the upper end of the switch.

1020380

The following applies up to and incl. serial number: L110F 4391; 61878; 70660 L120F 24924; 66728; 71989 NOTE! If a directional gear has been engaged, the engine speed must be increased to 1600 rpm to allow the parking brake to be released (safety function). This way of releasing the brake must not be used instead of releasing it with the aid of the switch.

Other controls

Controls

71

3 Gear selector control

Shifting between the different speed gears is done by turning the control.

NOTE! Never leave the machine with the gear selector in forward or reverse, while the engine is running. 1027043

For further instructions on gear shifting, see page 103.

Forward/Reverse Selector in position F = Operating forward Selector in position N = Neutral Selector in position R = Operating rearward 1027044

Horn Button pressed in = Horn

1027045

4 Brake pedal

5 Differential lock

L66345A

The differential lock only affects the front axle.

It is engaged by depressing the foot switch and it remains engaged as long as the foot switch is kept depressed.

The control lamp on the centre instrument panel is alight when the lock is engaged.

IMPORTANT! The differential lock may only be used when operating on slippery ground.

When operating on firm ground, particularly when turning, the lock must be disengaged.

If there is danger of getting stuck, engage the differential lock before the machine has got stuck.

If the machine has become stuck and one of the wheels is slipping, the wheel must be stopped before engaging the differential lock. Otherwise the drive axle system may be damaged.

6 Brake pedal

Other controls

72

Controls 7 Steering wheel adjustment The control is positioned to the right under the steering wheel. Control upward = Adjustment of height 1019905

Control downward = Adjustment of steering wheel inclination

8 Headlight dipper Away from steering wheel = High beams 1027047

Neutral position = Low beams Towards steering wheel = Headlight flasher

Direction indicator control Control forward = Left direction indicators Control rearward = Right direction indicators 1027048

Windscreen wiper Position 0 = Neutral position Position --- = Intermittent wiper* Positions I and II = Windscreen wiper (two speeds) 1027046

*) It is possible to change the length of the interval. The start key shall be in position 1. First turn the control to the intermittent wiping position and allow the wipers to operate for a while, then turn the control to position 0 and wait for the period of time you want the new interval to last and again turn the control to the intermittent wiping position. When the engine is turned off by turning the ignition key to position 0, the duration of the interval between the wiping actions returns to the basic setting.

Windscreen washer Button pressed in = Windscreen washer on 1027049

9 Accelerator pedal The accelerator position is transferred electrically.

Other controls

Controls

73

10 Control lever carrier and control functions

4

6

5

9

2

3

5

7

1

8

3

2

6

7

8

1

9 10

1027051

1027050

2

10

Lever (1) for the lifting function has three positions: lifting, neutral and lowering.

1

Detent function, lifting / boom kick-out

A

A

B

B

C

C 1027039

2 A B C

Tilting forward Neutral position Tilting rearward

1 A B C

Lowering position Neutral position Lifting position

Activation and selection of detent function lifting or alternatively boom kick-out is done with the switch. Thereafter the control lever is moved to the max. lifting position. Detent function lifting = the control lever remains in the lifting position even after the lifting arms have reached the max. lifting position, after which the control lever has to be moved back to neutral by hand. Boom kick-out = the control lever remains in the lifting position until the lifting arms have reached a predetermined height. Thereafter it returns to neutral automatically.

Hold function float mode / Return-to-Dig (optional equipment) The function "Return-to-Dig" is activated with the switch. It is the same switch for both floating position and Return-to-Dig function. The function "Return-to-Dig" is engaged when the attachment is above the set lower position and when the control lever for the lifting arms is moved to detent position for full lowering.

1030427

Floating position

1030426

The Return-to-Dig function can only be activated when the attachment is above ground. If the attachment is under the set lower position, then float mode is engaged instead.

Float mode/Return-toDig (optional equipment)

Tilting lever (2) has three positions: rearward, neutral and forward. Detent function tilting (bucket positioner) Activation of bucket positioner, is done with the switch. Thereafter the control lever is moved to max. rearward tilting position. When the rearward movement of the attachment reaches a predetermined position, the control lever returns to neutral automatically. 1020399

Bucket positioner

1020398

Boom kick-out

Other controls

74

Controls Control lever (3) for the 3rd hydraulic function (optional equipment)

Double-acting hydraulic outlets are used, if the machine, for example, is equipped with a timber grapple. May also be used for hydraulically powered rotating attachments. When such attachments are used the control lever can be equipped with detent function. The detent function can be quickly disengaged with an emergency stop.

Control lever (4) for the 4th hydraulic function (optional equipment)

Double-acting hydraulic outlets, are used, for example, for a further function in the timber grapple.

Kick-down (5)

The function can be selected from the control lever carrier, the gear selector control (see page 105) and from the Comfort Drive Control (optional equipment), see page 107.

Horn (6) Engine braking / downshifting (7)

Is used to obtain an immediate downshift when operating downhill, or to prevent undesired upshifting, see also page 105.

Directional gear F-N-R (8)

To be able to use the forward/reverse function on the control lever carrier, the activating button (10) must first be depressed.

After activation F/R is shown: in front of the selected directional gear on the display unit on the Operating Information screen Switch in the forward position = Operating forward Switch in centre position = Neutral Switch in rearward position = Operating in reverse

If the ordinary gear selector control by the steering wheel is moved from neutral, while operating with the F/R switch, the gear selector at the steering wheel will override the switch.

A new activation of the system requires that the activating button (10) is pressed again.

Control lever lockout (9)

Locks the control levers in neutral. The control lever lockout is used in order to avoid involuntary actuation of the control levers, for example when servicing or transporting the machine.

NOTE! On machines with a 4th hydraulic function, the control lever lockout is electrical. Control lever lockout is achieved with the switch, thus disengaging the hydraulic function of the control levers.

o 1027060

Switch, control lever lockout

Activating directional gear (10) NOTE! The ordinary gear selector control by the steering wheel and the switch on the control lever carrier must, when activating, be in neutral. The Comfort Drive Control (optional equipment) must not be activated. If the ordinary gear selector control is actuated, the gear-shifting function at the control lever carrier is lost and the selection made with the ordinary gear selector control applies.

Other controls

Controls

75

11 Control lever carrier and control functions, electric servo lever control (optional equipment) 2

1

5

6

7

A A

B

B

C

C

D

3

2

8

1

4

9

10

1016158

2 A B C

Tilting forward Neutral position Tilting rearward

1 A B C D

Floating position Lowering position Neutral position Lifting position

1030437

Control lever carrier and control functions, electric servo lever control (optional equipment) When working in an area where there is risk of electromagnetic fields, EMF, see page 129. Lever (1) for the lifting function has four positions: lifting, neutral and lowering and floating. Detent function, lifting / boom kick-out Upper end of switch pressed in = adjusting lifting height (spring-return position), see page 79. Switch in centre position = detent function for lifting to set height activated. 1020398

Lifting / boom kick-out

Lower end of switch pressed in = detent function lifting deactivated. The detent function is activated with the switch. Thereafter the control lever is moved to the max. lifting position. The control lever remains in the lifting position until the lifting arms have reached a predetermined height. Thereafter it returns to neutral automatically. Detent function Return-to-Dig Upper end of switch pressed in = adjusting lowering position (spring-return position), see page 79. Switch in centre position = detent function lowering to set lowering position activated. Lower end of switch pressed in = detent function lowering deactivated.

1020401

Return-to-Dig

Thereafter the control lever is moved to the max. lowering position. The control lever remains in lowering position until the lifting arms have returned to a predetermined position. Thereafter it returns to neutral automatically. NOTE! For the lever to remain held in position by the detent function, the attachment must be in a level position or be moving towards a level position.

Other controls

76

Controls Detent function floating position The function is activated with the switch. Position 0 = Not activated Position 1 = Lower end of switch pressed in = Floating position connected.

1030427

NOTE! Return-to-Dig has priority over floating position. To be able to engage floating position, the switch for Return-to-Dig must be in position 0.

Floating position

Tilting lever (2) has three positions: rearward, neutral and forward. Detent function tilting (bucket positioner) Upper end of switch pressed in = setting tilting position (spring-return action), see page 79. Switch in centre position = detent function for tilting position activated. 1020399

Bucket positioner

Switch, lower part pressed in = hold function for tilt position deactivated. The detent function is activated with the switch. Thereafter the control lever is moved to max. rearward tilting position. When the rearward movement of the attachment reaches a predetermined position, the control lever returns to neutral automatically. Control lever (3) for the 3rd hydraulic function (optional equipment) Double-acting hydraulic outlets, are used if the machine, for example, is equipped with a timber grapple. May also be used for hydraulically powered rotating attachments. When such attachments are used the control lever can be equipped with detent function. The detent function can be quickly disengaged with an emergency stop. Control lever (4) for the 4th hydraulic function (optional equipment) Double-acting hydraulic outlets, are used, for example, for a further function in the timber grapple. Horn (5) Kick-down (6) The function can be selected from the control lever carrier or the comfort drive control (optional equipment), see page 106.

Other controls

Controls

77

Engine braking / downshifting (7) Is used to obtain an immediate downshift when operating downhill, or to prevent undesired upshifting, see page 106. Directional gear F-N-R (8) To be able to use the Forward/Reverse function on the control lever carrier, the activating button (7) must first be depressed. After activation F/R is shown: in front of the selected directional gear on the display unit on the Operating Information screen Switch in the forward position = Operating forward Switch in centre position = Neutral Switch in rearward position = Operating in reverse If the ordinary gear selector control by the steering wheel is moved from neutral, while operating with the F/R switch, the gear selector at the steering wheel will override the switch. A new activation of the system requires that the activating button (10) is pressed again. Activating directional gear F-N-R on control lever carrier (9) NOTE! The ordinary gear selector control by the steering wheel and the switch on the control lever carrier must, when activating, be in neutral. The Comfort Drive Control (optional equipment) must not be activated. If the ordinary gear selector control is actuated, the gear-shifting function at the control lever carrier is lost and the selection made with the ordinary gear selector control applies. Control lever lockout (10) The control lever lockout is used in order to avoid involuntary actuation of the control levers, for example when servicing or transporting the machine. Lower end of switch pressed in = Hydraulic function of control levers disengaged. The switch is provided with a catch to prevent involuntary actuation. 1021207

Switch, control lever lockout

Amber central warning and text on the display unit show that the control lever lockout function is activated.

Other controls

78

Controls Bucket positioner The bucket positioner enables the bucket to stop automatically in a preset position. This will result in shorter cycle times and reduces wear. Adjust to desired bucket position according to the following instructions.

Adjusting tilting rearwards 1 Move the bucket to the required position.

1020399

Bucket positioner

2 Stop the engine, but leave the ignition key in running position. 3 Slacken the nuts for the bracket and move the sensor to its rear position. 4 Switch on the switch for the bucket positioner. 5 Move the tilting lever to the rear detent position. 6 Displace the sensor toward the rod until the light emitting diode lights up. 7 Tighten the nuts for the bracket.

Operation L67077A

Sensor, bucket positioner

When the control lever is moved to tilt-back (with switch on), the lever is locked and the movement continues to preset position, after which the lever returns to neutral position. IMPORTANT! The distance (A) between the sensors and the actuating part of the machine should be 35 mm (0.12 0.20 in). See the adjacent figure.

A

L41037A

Boom kick-out The boom kick-out enables the lift arms to stop automatically in a preset position. This will result in shorter cycle times and reduces wear. Adjust to desired lifting height according to the following instructions.

Adjusting lift height 1020398

Boom kick-out

1 Raise the lifting arms to the required position. 2 Stop the engine, but leave the ignition key in running position. 3 Slacken the nut for the bracket and move the sensor to its rear position. 4 Switch on the switch for the boom kick-out. 5 Move the lifting lever to the rear detent position. 6 Displace the sensor forward until the lifting lever returns to neutral. 7 Tighten the nut for the bracket.

Operation L67078A

Sensor, boom kick-out

When the control lever is moved to lift (with switch on), lever is locked and the movement continues to preset position, after which the lever returns to neutral position.

Other controls

Controls

79

Boom kick-out and bucket positioner (Electric servo) Boom kick-out and bucket positioner causes the attachment and the lifting arms automatically to stop in predetermined positions. This will result in shorter cycle times and reduced wear. The adjustments of the required position for the attachment or the required height when lifting are done according to the instructions given below. During all adjustments the machine should be at normal working temperature. Adjustment is done from the operator position with the engine running.

Operation

When either of the control levers is moved to lifting, lowering or tilting rearwards (with switched on switches) the lever is kept in the detent position and the movement continues to a predetermined position, whereafter the lever returns to neutral.

Adjusting lift height 1 Raise the lifting arms to the required position. 2 Press and keep the switch pressed in in the spring-return position. After approx. 2 seconds the setting is confirmed through a short signal from the instrument panel buzzer.

1020398

Switch, boom kick-out

Adjusting tilting rearwards 1 First tilt the attachment forward. 2 Then tilt the attachment upward to the required position. 3 Press and keep the switch pressed in in the spring-return position. After approx. 2 seconds the setting is confirmed through a short signal from the instrument panel buzzer. 1020399

Switch, bucket positioner

Return-to-Dig 1 First lay the attachment on the ground. 2 Then lift the attachment to the required position above the ground.

1020401

Switch, Return-to-Dig

3 Press and keep the switch pressed in in the spring-return position. After approx. 2 seconds the setting is confirmed through a short signal from the instrument panel buzzer.

Other controls

80

Controls 12 Arm rest, adjusting The arm rests for control lever carrier and Comfort Drive Control (optional equipment) and the control lever carrier can be adjusted to give the operator an as comfortable operating position as possible.

Adjusting arm rest for control lever carrier

B

A Up/down 1 Loosen handle A and adjust to required height and angle. 2 Tighten the handle.

Adjusting control lever carrier B Forward/rearward 1 Loosen locking knob B and adjust to required angle.

A

2 Tighten locking knob.

1027072

Adjusting arm rest for Comfort Drive Control C Adjusting sideways 1 Loosen locking knob C and adjust sideways to required position. 2 Tighten locking knob. D Adjusting vertically 1 Loosen locking knob D and adjust vertically. 2 Tighten locking knob.

C

D

1030655

Other controls

Controls

81

13 Arm rest, adjusting electric servo lever control (optional equipment) The arm rests for control lever carrier and Comfort Drive Control (optional equipment) and the control lever carrier can be adjusted to give the operator an as comfortable operating position as possible.

Adjusting control lever carrier and arm rest 1 Control lever carrier, vertically Loosen the locking knob and adjust the control lever carrier vertically to the required position and then tighten the locking knob. 2 Control lever carrier, longitudinally

1 2

Loosen the locking knob and adjust the arm rest together with the control lever carrier longitudinally to the required position, then tighten the locking knob. 3 Arm rest, sideways Loosen the locking knob and adjust the arm rest sideways to the required position and then tighten the locking knob. 4 Arm rest, vertically

3

Loosen the locking knob and adjust the arm rest vertically to the required position and then tighten the locking knob.

4 1030436

Adjusting arm rest for comfort drive control (CDC) 5 Longitudinal Loosen the locking knob and adjust longitudinally to the required position, then tighten the locking knob. 6 Sideways Loosen the locking knob and adjust the arm rest sideways to the required position and then tighten the locking knob.

5

7 Vertically Loosen the locking knob and adjust the arm rest vertically to the required position and then tighten the locking knob.

6 7 1027613

Other controls

82

Controls 14 Emergency stop, engine (optional equipment) NOTE! When the emergency stop is activated, the following steps 13 always take place. Step 4 only takes place if fire is detected.

C

The following takes place when the machine is operated, the parking brake is released, the system detects fire, and you activate the emergency stop (C): 1 The engine is stopped automatically

B

2 The main electric power is turned off 3 The parking brake is applied

A

4 The sprinkler system is activated (only when fire is detected) (Fire suppression system, optional equipment). NOTE! Flashing hazard lights can be activated to bring attention to the situation.

1044230

A B C

Control panel Plastic cover Emergency stop

1043940

In case of fire, activate the emergency stop

Other controls

Operator comfort

83

Operator comfort Operator's seat The operator's seat meets the standards according to EN ISO 7096:2000. In short this means that the seat is designed to minimise, in the best possible way, the whole body vibrations to which the operator is exposed while operating the machine. The size of the vibrations depends on different factors, many of which are not related to the construction of the machine, such as ground conditions, speed and operating techniques. Note the following: Adjust the seat according to the operator's weight and height. Keep the ground on the work site in good condition Choose the correct operating technique and speed for the existing circumstances. Correctly adjusted operator seat increases operator comfort and safety. Incorrectly adjusted seat may lead to injuries. The adjustments that should be made are: A Back-rest inclination B Lumbar support C Inclination and raising/lowering seat D Operator weight E Longitudinal (leg room) (The controls for the different adjustments may vary depending on seat model.) The mounting bracket for the operator seat has several holes for attaching the seat. Thereby the operator seat can be moved on the attaching bracket, thus providing further adjustment possibilities longitudinally. If the operator's seat has to be replaced, then the new seat must be tested according to ISO 7096, which means that the seat manufacturer has designed and adapted the seat's vibration-damping properties to the machine type in which it is to be installed. It is forbidden to change to a new seat that does not have the correct damping capacity. Moving the operator seat should be carried out by a workshop authorised by Volvo CE. NOTE! Do not adjust the seat while the machine is moving. For lubricating operator's seat, see page 196.

Other controls

84

Operator comfort

Mechanical seat 90 2 KG

100

4

C

LBS

30

0

50

70

260 20 110 1

14

180

0

D

B F KG

LBS

KG

KG

E

KG

LBS

LBS

LBS

A

L66340A L66341A

A Back-rest inclination Pull the handle upward and adjust to the required inclination. B Lumbar support Turn the knob to the required setting (hard/soft). C Height and inclination Pull the handles upward to raise and downward to lower the rear and front end of the seat. Never adjust the height of the seat with the weight adjusting wheel D Adjusting for weight Adjust the seat according to the relevant weight with the adjusting wheel. While sitting in the seat try to adjust so that the upward and downward movement ranges are equally distributed. Should not be used for adjusting height. E Longitudinal (leg room) Pull the bar upward and push the seat (forward/rearward). F Electrically heated (optional equipment) When electric seat heating is turned on, a thermostat controls when heating is activated and deactivated. Heating is activated at 14 ±3 °C (5263 °F) and deactivated at 25 ±3 °C (7283 °F).

Air-suspended seat

L66529A

D

B

The adjustments are carried out in the same way as for the mechanical seat, except for lumbar support and weight adjustments. B Adjusting lumbar support Using the buttons it is possible to fill and empty the upper and lower lumbar supports separately as required. D Adjusting for weight By pressing the button marked + for filling and for emptying, the seat suspension can be adjusted according to the relevant operator weight. While sitting in the seat try to adjust so that the upward and downward movement ranges are equally distributed. Should not be used for adjusting height.

Air-suspended seat (heavy-duty) The operator's seat meets the standards according to EN ISO 7096:2000. In short this means that the seat is designed to minimise, in the best possible way, the whole body vibrations to which the operator is exposed while operating the machine. The size of the vibrations depends on different factors, many of which are not related to the construction of the machine, such as ground conditions, speed and operating techniques. Note the following: Adjust the seat according to the operator's weight and height. Keep the ground on the work site in good condition Choose the correct operating technique and speed for the existing circumstances. The mounting bracket for the operator seat has several holes for attaching the seat. Thereby the operator seat can be moved on the attaching bracket, thus providing further adjustment possibilities longitudinally. Moving the operator seat should be carried out by a workshop authorised by Volvo CE. Correctly adjusted operator seat increases operator comfort and safety. Incorrectly adjusted seat may lead to injuries. The adjustments which should be carried out are shown below. NOTE! Do not adjust the seat while the machine is moving.

Other controls

Operator comfort

85

A Switch, heated seat When electric seat heating is turned on, a thermostat controls when heating is activated and deactivated. Heating is activated at 14 ±3 °C (5263 °F) and deactivated at 25 ±3 °C (7283 °F). B Back-rest inclination Pull the handle upward and adjust the backrest to the required inclination.

A

C Inclining/raising, front end of seat Lift the handle and adjust inclination/height of the front end of the seat.

B

G

F

E

C 1027663

D

D Inclining/raising, rear end of seat Lift the handle and adjust inclination/height of the rear end of the seat. E Adjusting for weight By pressing in the button for filling and pulling out the button for emptying, the seat suspension can be adjusted according to the relevant operator weight. While sitting in the seat try to adjust so that the upward and downward movement ranges are equally distributed. Should not be used for adjusting height. F Longitudinal Lift the handle upward and adjust the seat longitudinally. G Lumbar support The lumbar support is adjusted manually with an air pump. The air pump together with valve is positioned on the right side of the seat.

Seat belt The seatbelt supplements the safety design of the cab, or the canopy, and must be used to prevent the operator from being ejected from the cab, if the machine should turn over. A fastened seatbelt also helps the operator to maintain control of the machine if it should pitch or rock violently or operate in other rough conditions.

The seatbelt with associated parts must be inspected at regular intervals. Replace the entire seatbelt immediately if it is worn, has loose stitching, or if buckles or the seatbelt roller does not work.

Replace the seatbelt if the machine has been involved in an accident where the belt has been subjected to high strain or loading.

Changes to the belt or its mountings must never be made.

The seat belt is intended for one grown up person only.

Keep the belt rolled-up when not in use.

Only clean with warm water, not soap or cleaners. Allow the belt to dry while it is fully pulled out, before rolling it up. Make sure the belt is installed in a correct way.

Other controls

86

Operator comfort Climate control system 2 1

1

1015939

3

4 1

Air nozzles, front

2

Panel, climate control system

3

Air nozzles, rear

4

Temperature sensor for cab climate

1027038

NOTE! Make sure that the space in front of the temperature sensor is clear. Do not point an air nozzle directly at the temperature sensor.

Other controls

Operator comfort 2

3

4

87

5

26 24

22

1

20 18

1020417

1

Air conditioning

2


3

Fan control

4

Temperature control

5


1 Air conditioning (optional equipment) Press in the switch to switch on the air conditioning. The control lamp in the switch shows that the function is switched on. 1026312

1

Air conditioning

If the control lamp starts to flash, the air conditioning has become turned off. The cause may be clogged condenser, see page 198. NOTE! (The switch is installed on machines without this optional equipment, but does then not have this function.)

2 Cab ventilation / interval heating (interval heating is optional equipment) 1026313

2


Cab ventilation / interval heating takes place with the aid of the cab fan at the same time as the engine is turned off and the ignition key is in position 0. Works even when the ignition key has been removed from the ignition switch. The battery disconnect switch must be switched on. Activation: Press in switch (2) to activate the cab ventilation / interval heating. Activation can be done max. 1 minute before, or max. 15 seconds after the ignition key is turned to position 0, thus turning off the engine. The control lamp in the switch is alight and shows that the function is active. Warm outdoor climate, cab ventilation: The cab is ventilated while the machine is parked. Fan speed at position AUT is recommended. The time is max. 2 hours.

Other controls

88

Operator comfort Cold outdoor climate, interval heating (optional equipment): The engine coolant is circulated and thereby provides the cab with heating. The duration of the interval heating is as long as the temperature of the coolant is sufficiently high or up to 1 hour. Fan speed at position AUT is recommended. The temperature is adjustable with the temperature control. Deactivation is done or takes place: With switch (2). When the time has elapsed. When the engine is started.

3 Fan control Position 0 = fan turned off. Position AUT = automatic control, stepless fan speed. Marked area = manual setting, fixed positions for fan speed. 1026309

3

NOTE! If the cab door is opened at the same time as the fan control is in position AUT, the fan speed will automatically be lowered in certain cases.

Fan control

26

4 Temperature control

24

Position upward = max. heating, red marking. 22

Position left = selection of required temperature. Position downward = max. cooling, blue marking.

20 18

4

1026310

Temperature control

5 Air distribution control Position AUT = automatic control. Position left, towards the symbol = maximum air recirculation. Marked area = mixed, air recirculation ambient air. Position right, towards the upper symbol = maximum ambient air. 1026311

5


B

Ventilation nozzles Open the ventilation nozzles and adjust the direction of the air to obtain the best possible air distribution.

A

C A B C

Position right = defroster, ventilation nozzles at the windows open and directed towards the windows.

Open Closed Air flow direction

L68569A

Other controls

Operator comfort

89

Adjusting heating and ventilation The instructions below are basic recommendations. Each operator should experiment to achieve the best possible working environment in the cab, i.e. the right temperature without a draught. For the best temperature control in the cab try to have as many nozzles as possible open. Maximum recirculation set with the air distribution control May be used as a setting for reducing the intake of bad-smelling air. This also reduces the accumulation of dust in the cab ventilation filters. If the windows mist up, turn the control to Maximum ambient air. When required check and clean or replace the cab ventilation filters, see page 195.

How to achieve ... ... comfortable working temperature:

All nozzles fully open.

During warm outdoor climate air conditioning switched on.

Fan control in position AUT.

Temperature control set to required temperature.

Air distribution control in position AUT.

... demisting all windows:

The front nozzles directed towards the windscreen.

Floor nozzles under instrument panel closed.

The rear nozzles should be directed towards the rear window/ side window.

The air distribution control in defroster position, which provides:

Maximum ambient air. Maximum heating. Maximum cooling, if the machine is equipped with air conditioning. Highest fan speed. When the required effect has been reached and the air distribution control is turned back to the required position, the climate control system returns to selected temperature and selected fan speed. Open the floor nozzles.

Provide for good ventilation Do not operate the machine for long periods without ventilation or with the cab fully closed without having the fan turned on. Poorly ventilated air can cause tiredness (lack of oxygen).

Other controls

90

Operator comfort Rear vision system, screen, colour (optional equipment) The rear vision camera, together with the visual display unit in the cab provide the operator with a better view rearwards. The lens on the rear vision camera should be cleaned with a damp rag when required. 1 SB/ON. On: The screen is on all the time when the start key is in operating position. SB: The screen is only on when the gear selector is in reverse position. The distance indicator is shown. This position is recommended as the normal position in order not to disturb when operating forwards. 2 LED Lit when the screen is on. Halved light intensity (brightness) when the screen is in standby mode. 3 CAM-SELECT. Used to adjust the camera. The menu with different adjustments is shown if the button is held in approx. 2 seconds on the condition that the gear selector is not in reverse. Press the button again to access the desired adjustment. Hold in the button approx. 2 seconds to close the menu. It is also closed automatically after 10 seconds. 4 Used to adjust the volume under "VOICE" on the "INPUT"menu. The buttons are also used to scroll in the menu. 5 DIM. Used to adjust light intensity (brightness) of the screen. 6 NOR/BLC. A sensor senses the light around the camera and automatically adjusts the light intensity (brightness) on the screen. Do not cover over the sensor.

1 2 3

4

5

1044899

6

Rear vision system, screen, colour (optional equipment)

8 7 6 5 4 3 2 1010814

1

(Older version) The rear vision camera, together with the visual display unit in the cab provide the operator with a better view rearwards. The lens on the rear vision camera should be cleaned with a damp rag when required. 1 SB / ON. With the button pressed in to the "ON" position, the monitor is on all the time, when the ignition key is in running position. With the button in "SB" position, the monitor will only be on when the gear selector is in reverse. At the same time the distance indicator is shown. This is recommended as the normal position in order not to disturb when operating forwards. 2 Switches between rear vision camera and external signal, e.g. video. 3 Light control. Adjustment for brighter or darker image. 4 Switches between camera one and camera two, if such a camera is installed. 5 Contrast. Adjustment for weaker or stronger image. 6 Exposure button. Improves the image in strong sun light or when it is dark. The button must be kept pressed in. Therefore, do not make any adjustments while operating. 7 Colour. Adjusting colour. 8 Light sensor. The sensor registers the brightness around the monitor and adjusts the light intensity automatically for best possible image. Do not cover over the sensor.

Other controls

Operator comfort

91

Rear vision system, screen, black/white (optional equipment)

6

5 4 32

1

L69024A

(Older version) The rear vision camera, together with the visual display unit in the cab provide the operator with a better view rearwards. The lens on the rear vision camera should be cleaned with a damp rag when required. 1 On and Off button. When the button is pressed in, a rearward view is shown on the display unit provided that the ignition key is in position 1 (running position). 2 Contrast. Adjustment for weaker or stronger image. 3 Light control. Adjustment for brighter or darker image. 4 Light sensor. 5 Exposure button. Improves the image in strong sun light or when it is dark. The button must be kept pressed in. Therefore, do not make any adjustments while operating. 6 Automatic light control takes place if the button is not pressed in. If the button is pressed in, the light control has a fixed setting.

Other controls

92


93

Operating instructions This chapter contains rules which must be followed to make working with the machine safe. However, these rules do not relieve the operator from following laws or other national regulations for traffic safety, industrial safety and labour welfare. To avoid the risk of accidents, alertness, judgement and respect for applicable safety regulations is a condition.

Running-in instructions During the first 100 hours, the machine should be operated with particularly great care. During the running-in period it is important to check oil and fluid levels often. Wheel bolts should be check-tightened after 8 hours operation, see page 194.

Engine protection - Software The function informs the operator and limits the engine speed and torque and also the travelling speed of the machine in order to prevent any engine damage. Engine shutdown does not take place until the speed has dropped to below 2 km/h (1.2 mph). This makes it possible always to be able to move the machine away from dangerous situations before engine shutdown takes place. The function is monitored by the engine control unit E-ECU and depending on which component is causing the alarm any of the following functions will be activated: reduction of engine torque limiting engine speed limiting travelling speed of machine engine shutdown

Auto engine shut-off (optional equipment) The equipment is standard Fire Suppression System. Engine shutoff takes place after a predetermined time. The time is set with VCADS Pro service tool. The following conditions are required for engine shut-off: The machine is stationary The engine is running at low idling The gear selector is in neutral position The hand-throttle is not actuated When the conditions have been met and there is one minute left of the predetermined time, a message is shown on the display unit. Engine shut-off can then be interrupted by activating the accelerator pedal, hand throttle, or gear selector. When automatic engine shut-off has taken place: The parking brake is applied The ignition key remains in position 1, running position Lights or other connected current consuming devices remain connected.


94

Visibility

Visibility WARNING! Some attachments and equipment may affect the operator's visibility. Pay attention to dead angles, where there is no visibility, when operating on work sites and on public roads. If needed, get help from a signal man. The following information applies to machines delivered to countries within the EU and may also apply to machines delivered to other countries outside the EU. It may be impossible to obtain visibility to all areas around the machine. Optional devices and equipment such as warning systems, mirrors, back-up alarm, and monitoring cameras (CCTV), etc., may be used to obtain acceptable visibility. NOTE! Some parts of the basic machine may restrict visibility, e.g., the cab's pillars and frames, exhaust pipe, engine hood, as well as optional equipment such as buckets, pallet forks, grapples, etc. The load that is handled with these attachments may also restrict visibility. To minimize risks caused by restricted visibility, the management shall establish rules and procedures for the work site. For example:

Make sure that operators and persons on the site have received thorough safety instructions.

Conduct training for operators and staff on the site.

Control traffic flow for machines and other vehicles.

Restrict the machine's work area.

Use a signal man to assist the operator. Use hand signals according to the signal diagram, see page 156.

Make available equipment for two-way communication when needed.

Make sure that persons on the site communicate with the operator before approaching the machine.

Restrictions for maximum permitted speed as well as for reversing the machine over long distances.

Visibility standards to meet EU's machine directive

The standard ISO 5006 "Earthmoving machinery Operators field of view" deals with the operator's visibility around the machine and is intended to be used to measure and evaluate visibility. Conforming to this standard is a requirement in EUcountries and offers improved visibility around the machine.

The machine is tested according to methods and criteria according to this standard. The method used to evaluate visibility cannot include all aspects concerning the operator's visibility, but gives information to determine if optional equipment for indirect visibility is necessary, e.g., warning systems. The test was performed on a stationary machine without load, with standard equipment and standard attachment, and with the bucket in carry position.


Visibility

95

ISO 14401 "Earthmoving machinery - Field of vision of surveillance and rear-view mirrors".

ISO 16001 "Earthmoving machinery - Hazard detection systems and visual aids - Performance requirements and tests"

If the machine is modified or retrofitted with other equipment or attachments, which result in reduced visibility, it shall be tested again according to ISO 5006, ISO 14401, and ISO 16001, and provided with optional visibility-enhancing equipment as needed. Actions before and during operation

The danger area around an operating machine forms a circle with a radius of least 7 m (23 ft).

Walk around the machine and check that there are no obstacles next to the machine.

Check that mirrors and other visibility-enhancing equipment is in good condition, clean, and properly adjusted.

Check that the horn, back-up warning signal, and the rotating beacon (optional equipment) work correctly.

Check if the management has established rules and procedures for the work site.

Always keep a look-out and pay attention to the area around the machine so that any obstacles can be identified.

Prevent persons from entering or remaining in the danger area, i.e. the area around the machine and at least 7 m (23 ft) beyond the maximum reach of the attachment. The operator may allow a person to remain in the danger area, but should then observe caution and operate the machine only when the person is visible or has given clear indications of where he or she is.


96

Safety rules when operating

Safety rules when operating Operator duties WARNING! No unauthorized personnel shall be in the machine's work area. Pay attention in all directions to avoid running over other personnel or running in to objects. Do not touch control levers or switches when starting. Sound the horn before using the machine.

The danger area around an operating machine forms a circle with a radius of least 7 m (23 ft).

The machine operator must operate the machine in such a way that the risk of accidents is minimised both for the operator, other road users and persons present at the work site. The machine operator must be thoroughly familiar with how to operate and maintain the machine and should preferably undergo required training on the machine. The machine operator must follow the rules and recommendations given in the Operator's Manual, but also pay attention to any statutory and national regulations or specific requirements or risks that apply at the work site. The machine operator must be thoroughly rested and must never operate the machine under the influence of alcohol, medicine or other drugs. The machine operator is responsible for the load of the machine both when travelling on public roads as well as when working on site. There must be no risk of the load falling off while operating. Refuse to take a load which is an obvious safety risk. Respect the rated load capacity of the machine. Note the effect of varying distances to the centre of gravity and the effect of additional units. The machine operator must be in charge of the working area of the machine. Prevent persons from walking or standing under raised lifting arms, unless they have been made safe or supported. Prevent persons from entering or remaining in the danger area, i.e. the area around the machine and at least 7 m (23 ft) beyond the maximum reach of the attachment. The operator may allow a person to remain in the danger area, but should then observe caution and operate the machine only when the person is visible or has given clear indications of where he or she is. The machine operator is responsible for the machine not being used to transport or lift persons, unless it is equipped and approved for this purpose. Contact a dealer for more information.

Accidents WARNING! Only the operator, sitting in the operator's seat, may be in the cab during operation. All other personnel must remain a safe distance from the machine.

Accidents and also incidents should be reported to the site management immediately. If possible leave the machine in position. Only take necessary action so as to reduce the effect of damage, especially personal injuries. Avoid action which may make an investigation more difficult. In case of an accident, take active part in actions included in planned accident preparedness or follow other regulations. Wait for further instructions from the site management.



97

Machine operator safety

Always use the seatbelt.

Always sit in the operator's seat with the seatbelt fastened when starting the machine (engine) and when operating levers and switches.

Check that the seatbelt is not worn, see page 85.

The machine must be operational, i.e. faults which can cause accidents must be rectified.

Suitable clothing for safe handling and a hard hat should be worn.

A loose mobile telephone must not be used, as it may interfere with important electronics. The mobile telephone must be connected to the electrical system of the machine and have a fixed external aerial installed according to the instructions of the manufacturer.

Keep your hands away from areas where there is a risk of crushing, e.g. covers, door and window.

Use steps and handholds when entering or leaving the machine. Use the three-point grip, i.e. two hands and one foot or two feet and one hand. Always face the machine do not jump!

The door must be closed during work and transport operations.

The vibration (shaking) which arises when operating may be harmful to the operator. Reduce this by:

L66347A

adjusting the seat and tightening the seal belt. picking the smoothest operating surface for the machine (levelling the surface when necessary). adapting the speed.

The cab is for the protection of the machine operator and it meets the requirements for Roll Over Protective Structures according to the testing standard "ROPS". Therefore, hold firmly onto the steering wheel if the machine should roll over Do not jump!

The cab is also designed to meet the requirements for falling objects, the weight of which agrees with testing methods according to "FOPS".

Only walk and stand on surfaces which have slip protection.

Do not enter or leave the machine during a thunderstorm. If you are outside the machine, keep a good distance away from the machine until the thunderstorm has passed. If you are inside the cab, stay there with the machine stationary until the thunderstorm has passed. Do not touch any controls or anything made of metal.

1030480

(Principle diagram) Stepping surfaces

Check that the attachment is properly attached and locked.

The cab has two emergency exits, the door and the right side window.


98

Safety rules when operating Operating (working) on a public road

Road signs, traffic restricting arrangements and other safety devices, which may be required when considering traffic speed and intensity or other local conditions, must be used.

When moving a machine with a suspended load, special attention must be observed. When required, a signal man must be used.

Rotating warning beacon may be used: on vehicle during road maintenance work, e.g. snow clearing. on attached or connected implement, which is wider than the vehicle itself. when the vehicle constitutes a hindrance or danger to other traffic when working on or by the side of the roadway.

Travelling on public road

As a machine operator you are considered to be a road user and therefore required to know and follow local regulations and national traffic regulations.

It is important to bear in mind that the machine, in comparison with the rest of the traffic, is a slow moving and wide vehicle, which may cause obstruction. Bear this in mind and pay attention to the traffic behind you. Facilitate overtaking.

The use of SMV-plate (Slow Moving Vehicle) is recommended. It should be placed in a position at the rear on the machine where it is clearly seen, not inside the rear window or any other window. It should be positioned at a height of 0.61.8 m (26 ft) above the ground, measured from the lower edge of the plate.

The attachment should be empty, lowered to the carry position (3040 cm = 1216 inches above the ground) and tilted fully backward. The front end of the material handling arm must be marked with a red flag.

Lock the control levers with the control lever lockout.

All working lamps and any rotating warning beacon should be switched off.

Hazard flashers must not be used.

Attachments and buckets which obscure the vision must not be used.

Make sure that large attachments/buckets do not obscure the travelling lights. According to traffic regulations the area in front of the machine must be sufficiently illuminated and visible.

Additional attachments such as buckets, spades and iron bars must be thoroughly secured with tensioning straps or chains.

If a trailer is to be pulled behind the machine, follow national laws and regulations, e.g. regarding requirements as to brakes, steering, lights, approved towing devices and the direction of forces permitted on the towing devices on both machine and trailer.

1003922

L66358A

SMV-plate



99

Safety rules in case of fire If your own safety is not immediately compromised, take the following actions.

In case of fire on the work site 1 If possible, move the machine away from the hazardous area. 2 Lower the attachment to the ground. 3 Turn off the engine by turning the start key counter-clockwise or by pressing in the emergency stop (optional equipment) in the cab. 4 Leave the cab. 5 Turn off the main electric power with the battery disconnector inside of the radiator casing. 6 If possible, take active part in putting out the fire and call the fire department if needed.

In case of fire in the machine If the machine is being operated: 1 If possible, park in a fireproof location. 2 Lower the attachment to the ground. 3 Turn off the engine by turning the start key counter-clockwise or by pressing in the emergency stop (optional equipment) in the cab. 4 Leave the cab. 5 If possible, turn off the main electric power with the battery disconnector inside of the radiator casing. 6 When needed, continue putting out the fire with a handheld fire extinguisher. Be ready with the handheld fire extinguisher since there may still be fire deep inside the machine which could reignite other parts. 7 Call the fire department if required. In case of fire in machine with Fire Suppression System (optional equipment) If the machine is operated (operator-dependent activation of sprinkler system): 1 If possible, park in a fireproof location. 2 Turn off the engine with the emergency stop (optional equipment) in the cab or by turning the start key counter-clockwise. NOTE! The sprinkler system is activated if fire is detected. 3 Leave the cab. NOTE! It is also possible to activate the sprinkler system with the manual activation button (outside the cab), see page 9. 4 If possible, turn off the main electric power with the battery disconnector inside of the radiator casing. 5 When needed, continue putting out the fire with a handheld fire extinguisher. Be ready with the handheld fire extinguisher since there may still be fire deep inside the machine which could reignite other parts. 6 Call the fire department if required. NOTE! If the machine is not operated or if the parking brake is applied, the sprinkler system is activated automatically.


100

Actions before operating

Actions before operating WARNING! When travelling on a public road, it is prohibited to have the Comfort Drive Control (CDC) activated use the steering wheel 1 Carry out daily service, see page 211. 2 Clean/scrape the windows. 3 Clean and adjust mirrors and cameras. 4 Check that there are no faulty/loose parts or leaks which can cause damage. 5 Check that the battery disconnect switch is switched on. 6 Check that the frame joint lock has been disconnected. 7 Check that the wheels are not blocked. 8 Check that engine and access covers are closed and that the radiator casing is closed and secured. 9 Check that there are no persons in the vicinity of the machine, see page 96. 10 Adjust the operator seat (see page 83) and the steering wheel (see page 72). 11 Fasten the seatbelt. 12 Check that there is sufficient fuel in the tank. After operating

Fill the fuel tank, as this will counteract the formation of condensation water.

Make sure that there is enough anti-freeze in the cooling system (see page 181) and in the washer fluid at temperatures below 0 °C (32 °F).


Starting engine

101

Starting engine WARNING! The engine must only be stared with the ignition switch in the cab. If the machine is equipped with anti-theft device, see page 55. 1 Place the gear selector to neutral. 2 Turn the key in the ignition switch to running position (1) so that a system test can take place, the duration of which is 45 seconds.

1026348

3 At the same time check that all lamps light up and that the gauges indicate. 4 Turn the ignition key to starting position (2). If the engine does not start, turn the key back to the "0" position, before making a new starting attempt. 5 Check that all control and warning lamps are extinguished. 6 Check that the attachment is securely fastened to the machine by pressing it against the ground. 7 Sound the horn. 8 Release the parking brake. 9 Select gear position and increase the engine speed.

Turbocharger The turbocharger is lubricated and cooled through the engine lubrication system. Important for the function of the turbocharger is that:

L66718A

Air Lubricating oilExhaust

lubrication and cooling is safeguarded by: not racing the engine immediately after it has been started. allow the engine to run at low idle for at least 30 seconds before it is turned off.

A

D

in case of an encased (heat-insulated) type turbocharger and manifold, it is important that the engine, after it has been working hard, is allowed to run at low idle for at least two minutes before it is turned off.

C

B L67289A

A B C D

Exhaust inlet To exhaust system Air inlet Compressed air

engine oil is changed and oil filters are replaced at prescribed intervals.

the air cleaner is serviced regularly and that the exhaust system and lubricating oil lines do not leak.

In case jarring noises can be heard, or if the turbocharger vibrates, it must be reconditioned or replaced immediately. Any work on the turbocharger should be carried out by a workshop authorised by Volvo CE.


102

Starting engine Starting engine in cold weather The preheating function is controlled by the engine ECU. 1 Turn the ignition key to running position (1).

WARNING! Starting gas such as ether, etc., may cause an explosion in the engine's inlet manifold. Contact a workshop authorised by Volvo CE if the engine does not start.

2 If there is a need of heating, the function will be activated automatically. 3 A symbol lights up on the display unit that shows that the preheating is connected, see page 29. 4 When the symbol is extinguished, the engine can be started by turning the ignition key to starting position (2).

Leave the engine running at low idle for 60 seconds so that the oil in the engine, transmission, hydraulic system and axles has warmed up and become sufficiently fluid to provide proper lubrication.

To race the engine immediately after it has been started may also endanger the lubrication and cooling of the turbocharger with great risk of bearing seizure as a consequence.

Starting with booster batteries WARNING! Batteries may explode if a fully charged battery is connected to a completely discharged battery (due to the current surge) or a frozen battery. Risk of personal injuries. Check that the booster batteries or any other power source has the same voltage as the ordinary batteries. 1 Move the gear selector to neutral. 2 Apply the parking brake.

D

3 Connect one of the jump leads from (+) on the booster battery, to (+) on the battery, which is connected nearest to the starter motor.

C B

4 Connect the other jump lead from () on the booster battery, to for example the lifting eye on the cylinder head.

B

5 Make sure that the battery disconnect switch is switched on. 6 Start the engine with the start key in the cab.

1027351

A A WARNING! (Principle diagram) A Booster batteries B Ordinary batteries C Cylinder block D Starter motor

Do not under any circumstances disconnect the leads from the ordinary batteries. 7 Leave the batteries connected for 510 minutes after starting the engine. 8 If the ordinary batteries are greatly discharged, it is possible that the alternator will not be able to provide any charging current. Therefore, switch on a number of current consuming devices, e.g. travel lights, working lights and preheating, in order to get the charging going. 9 First remove the jump lead between (), e.g. the lifting eye on the cylinder head and () on the booster battery. 10 Then remove the jump lead between (+) on the battery, which is nearest to the starter motor and (+) on the booster battery. 11 Re-install the insulating caps on the battery terminals.


Gear shifting

103

Gear shifting Manual gear shifting

Select a suitable gear by turning the gear selector control to the required gear position and then select travelling direction forward or rearward.

1027043

Directional gear

WARNING! The gear selector may never be moved to neutral when operating downhill since this results in a complete loss of engine braking capacity. 1027044

WARNING! Never leave the machine with the selector in forward or reverse while the engine is running there is a risk that the machine may begin to move. Selector in position N = Neutral Selector in position F = Operating forward Selector in position R = Operating rearward When changing from forward to reverse or vice versa, the speed of the machine and of the engine should be reduced as much as possible, particularly if the machine is working on firm ground. Shifting between forward and reverse may only take place in 1st and 2nd gear.


104

Gear shifting Automatic shifting (APS) (Gear selector in speed gear position 3 or 4) The shift modulation allows the machine operator to select different automatic shifting programmes (modes) depending on the operating conditions.

Operating in the APS position

Turn the gear selector control to gear position 3 or 4.

Select operating programme with the mode selector (position AUTO is recommended)

Select directional gear.

Accelerate and the machine will start in 2nd gear (basic gear). If the machine is already moving, it will engage 3rd gear automatically.

Up- and downshifts are made between 2nd 3rd 4th gears forward, and between 2nd 3rd 4th gears rearwards.

When the direction of travel has been changed the machine will start off in 2nd gear.

Downshifting to 1st gear, see "Fully automatic downshifting" page 57 or "Kick-down function" on page 105.

1020388

Mode selector

Positions L and M

Position "L" means that shifting will take place at low engine speeds.

Position "M" means that shifting will take place at slightly higher engine speeds.

With the accelerator fully depressed, upshifting takes place according to position "H".

The best utilisation is obtained if the accelerator is not depressed fully, as the difference in upshifting speed between the different modes (L, M and H) will be distinct.

Results in lower fuel consumption and lower noise level.

Position H

The machine does not shift until higher engine and travelling speeds have been reached.

Preferably used in cases where the machine changes gear when operating uphill or when the rolling resistance is great.

Position AUT

The machine chooses APS-program according to the operator's operating method.

Mode

1023178

(service mode)

After starting gear shifting is done manually, see page 103.

The machine starts and operates in the selected gear position. Upshifts and downshifts on the move are controlled manually. NOTE! Service mode shall only be used during service or for troubleshooting.


Gear shifting

105

Kick-down function Kick-down is obtained, if the mode selector is within the automatic range, the gear selector control is in either of positions 2, 3, or 4 and either of the kick-down buttons is actuated.

A

1027069

A

When the kick-down button is pressed, 1st gear will be engaged if the travelling speed already is below 8 km/h (5.0 mph) or if the speed drops below 8 km/h (5.0 mph) within 8 seconds after the button was depressed.

When 1st gear has been engaged the buzzer will give off one short pip.

1st gear will remain engaged unless the kick-down function switch is actuated a second time or if the engine speed becomes extremely high (when the switch is actuated a second time, 2nd gear will be engaged).

If the direction of travel is changed, the machine will start off in 2nd gear, provided automatic shifting is selected.

NOTE! If the machine, as optional extra, is equipped with lever steering (CDC) the kick-down function is also available on the arm rest.

Kick-down button, control lever carrier

Engine braking / downshifting A

With the aid of the button for engine braking / downshifting it is possible to obtain an immediate downshift one or two steps or to prevent unwanted upshifting. In this way the warming up of the axle oil is reduced.

One press of the button at higher speeds, will result in a downshifting from 4th to 3rd gear.

One further press of the button at a lower speed, will result in a downshifting to 2nd gear.

If the switch is kept in the pressed-in position, upshifting to the next higher gear is prevented, which can be used when operating downhill or when approaching a vehicle which is to be loaded.

NOTE! If certain critical rotational speeds and travelling speeds are exceeded, upshifting takes place.

1027070

A

Engine braking / downshifting

Under these circumstances, lower the travelling speed, or select a higher gear to reduce the engine speed.


106

Gear shifting Kick-down function, electric servo (optional equipment) Kick-down is obtained, if the gear selector control is in position 2, 3 or 4 and either of the kick-down buttons is actuated.

1

1030435

1

Kick-down

2

When the kick-down button is pressed, 1st gear will be engaged, if the travelling speed already is below 8 km/h (5.0 mph) or if the speed drops below 8 km/h (5.0 mph) within 10 seconds after the button was depressed.

When 1st gear has been engaged the buzzer will give off one short pip.

1st gear will remain engaged unless the kick-down function switch is actuated a second time or if the engine speed becomes extremely high (when the switch is actuated a second time, 2nd gear will be engaged).

If the direction of travel is changed, the machine will start off in 2nd gear, provided automatic shifting is selected.

NOTE! If the machine, as optional extra, is equipped with lever steering (CDC) the kick-down function is also available on the arm rest.

Engine braking/downshifting, electric servo (optional equipment) With the aid of the button for engine braking / downshifting it is possible to obtain an immediate downshift one or two steps or to prevent unwanted upshifting. In this way the warming up of the axle oil is reduced.

1030434

2

One press of the button at higher speeds, will result in a downshifting from 4th to 3rd gear.

One further press of the button at a lower speed, will result in a downshifting to 2nd gear.

If the switch is kept in the pressed-in position, upshifting to the next higher gear is prevented, which can be used when operating downhill or when approaching a vehicle which is to be loaded.

NOTE! If certain critical rotational speeds and travelling speeds are exceeded, upshifting takes place.

If the engine or transmission speed become too high, the red central warning lamp flashes, the buzzer sounds and alarm text is shown on the display unit.

Under these circumstances, lower the travelling speed, or select a higher gear to reduce the engine speed.

Engine braking / downshifting


Steering

107

Steering The machine has articulated frame steering, which is hydrostatically controlled.

15011966

1027909

Comfort Drive Control, CDC (optional equipment) IMPORTANT! When operating in areas with risk of electromagnetic fields, EMF, the Comfort Drive Control (CDC) shall always be deactivated, see page 129. By alternating between using Comfort Drive Control and steering wheel steering the operator will have a more varied pattern of movement. The system consists of a folding arm rest where three functions are concentrated, i.e. steering, forward/reverse and kick-down function. The system is activated with the button on the arm rest (see the next page). The arm rest must be lowered in order to be able to activate the function. Comfort Drive Control (CDC) is deactivated by raising the arm rest. For adjustment of arm rest for comfort drive control, see page 80. 1049023

Comfort Drive Control (CDC) is deactivated by raising the armrest or by moving the gear selector from neutral position.

The CDC-function is also deactivated when the gear selector is moved from neutral position. The control light on the instrument panel is turned on when Comfort Drive Control (CDC) is activated. The machine's max. speed is limited when Comfort Drive Control (CDC) is activated.

WARNING!

1021113

Control lamp, comfort drive control

Always use the steering wheel when operating on public roads and on work sites at speeds over 20 km/h (12.4 mph). When operating on public roads the armrest must always be raised. It is forbidden to operate with activated lever steering (Comfort Drive Control, CDC) on public roads. Small physical effort is required to operate the Comfort Drive Control. The distance the lever is moved is proportional to the speed at which the steering system reacts. The function of the steering wheel always have priority over the CDC function. This means that if you attempt to steer to the right with the CDC and to the left with the steering wheel, the machine will steer in the direction the steering wheel was moved.

11445277 1024716


108

Steering 1 Activating (CDC) In order to be able to use the steering, forward/reverse and kickdown functions from the arm rest, the arm rest must be lowered and the system activated with button 1.

1021113

Control lamp, comfort drive control

To make it possible to activate the system, the following steps must first have been carried out: The arm rest must be lowered to its lowest position. NOTE! In certain positions the arm rest must be moved to the right, in towards the seat in order to reach its lowest position. The directional gear selector on the arm rest, the ordinary gear selector control and at the control lever carrier must be in neutral position.

1049023

Comfort Drive Control (CDC) is deactivated by raising the armrest or by moving the gear selector from neutral position.

4

1

3

The engine must be running, but the machine must be stationary. When the system is activated, a control lamp on the instrument panel is on. NOTE! Comfort Drive Control (CDC) is deactivated by raising the arm rest. Comfort Drive Control (CDC) is also deactivated by moving the gear selector from neutral position.

2 Steering lever

2

A small physical effort is required to operate the Comfort Drive Control in either direction and the speed at which the steering system reacts is proportional to the distance the lever is moved. The steering wheel always remains functional.

3 Kick-down button With the kick-down button pressed in = The machine shifts down to 1st gear if the gear selector control is in either of positions 2, 3 or 4. For further instructions, see page 105.

4 Directional gear selector With the front end of the switch pressed down = Forward drive. With the rear end of the switch depressed = Reverse drive. There is a neutral position between the forward and reverse positions.

5

NOTE! The ordinary gear selector control always has priority, i.e. if the ordinary gear selector control is actuated, the selection made from the armrest is cancelled.

6 1030657

1 2 3 4 5 6

Activating CDC Steering lever Kick-down button Directional gear selector Adjusting arm rest, sideways Adjusting arm rest, vertically

5 Adjusting arm rest, sideways Loosen the locking knob and adjust the arm rest sideways to the required position. Then tighten down the locking knob.

6 Adjusting arm rest, vertically Loosen the locking knob and adjust the arm rest vertically to the required position. Then tighten down the locking knob.


Braking

109

Braking WARNING! The transmission disengagement function must not be used during transport operation. Brake smoothly. This is particularly important when operating with a load and on slippery ground. If required during certain operations, the power transmission can be made to automatically disengage (declutch) when the brakes are applied. Activating this function is carried out from the keyboard, see page 30. Engine braking with the aid of the downshift button may be advantageous, particularly when operating downhill. In this way it is possible to reduce the warming up of the axle oil, see page 105.

Brake test (Checking service brakes)

WARNING! A brake test may only be carried out in an area where there is no risk of accidents. The brake test is carried out with the aid of computer software, which measures the average retardation of the machine. The test can be carried out by the machine operator from the display unit.

Conditions 1 Brake test must only be done within an area where it cannot cause accidents (risk of being run into from behind etc.). 2 The ground must be level and the surface have good friction. 3 The machine must not be loaded. 4 The travelling speed of the machine must exceed 20 km/h (12.4 mph) when the service brakes are applied. NOTE! Acceptable values can only be obtained if the test is carried out on dry asphalt, dry concrete or other similar surfaces.


110

Braking Measuring procedure Make sure that the prerequisites according to the previous page are met. 1 Select SERVICE on the keyboard, see page 30. 2 Select the sub menu with the arrow key. 3 Move off (gear selector position A). When the speed exceeds 20 km/h (12.4 mph) there will be a short pip signal and the display unit will show "0.0 m/s2 0.00 g", which means that the speed required for the test has been reached. 4 If the display unit instead shows "X.X m/s2 X.XX g", the speed is too low (below 20 km/h = 12.4 mph). To obtain credible and useful test values, the brake application must be carried out:

Without wheels locking or skidding.

With the brakes applied as hard as possible and without letting up the brake pedal during the test.

Result and evaluation The test result will be shown on the display unit when the machine has stopped, i.e. the speed is 0 km/h, and remains on the display until the speed again exceeds 10 km/h (6.2 mph). In order to eliminate tests during which the wheels have locked, brake applications where the retardation exceeds 8 m/s2 (0.82 g) are not registered. In this case X.X m/s2 X.XX g will be shown on the display unit.

Minimum value for brake test: 4.75 m/s2 (0.48 g)

If the measured retardation is less than 4.75 m/s2 (0.48 g), a new test has to be carried out.

If this test too shows a value below 4.75 m/s2 (0.48 g), the brake system must be checked at a workshop authorised by Volvo CE.


Stopping machine

111

Stopping machine 1 Lower the engine speed. 2 Apply the brakes and when the machine is stationary, move the gear selector control to neutral. 3 Lower the attachment to the ground. 4 Apply the parking brake after the machine has come to a complete standstill. IMPORTANT! Run the engine at low idle for at least 30 seconds before stopping it in order to safeguard the lubrication and cooling of the turbocharger. In case of encased (heat-insulated) type turbocharger and manifold, it is important that the engine, after it has been working hard, is allowed to run at low idling for at least two minutes before it is turned off. 5 Turn the ignition switch key counter-clockwise so that the control lamps go out and the engine stops.

WARNING!

L64417A

Always use the three-point method to climb in to or exit the cab, that is, two hands and one foot or one hand and both feet. Use available steps and handles. Always face the machine when climbing up on or down from the machine. Do not jump! If the operator has to leave the cab with the engine running, care has to be taken so that the steering wheel is not turned inadvertently as the operator leaves the cab. This applies particularly if the steering wheel is provided with a knob.


112

Parking

Parking 1 If possible, place the machine on level ground. If this is not possible, block the wheels so that the machine cannot start rolling. Lower the attachment against the ground. 2 Check that all switches and controls are in the "off" position or in neutral. L68292A

3 Apply the parking brake after the machine has come to a complete standstill. 4 Remove the keys. 5 Turn off the current supply with the battery disconnect switch, if the machine is to be left unattended for some time. 6 Make sure that there is enough anti-freeze in the cooling system (see page 181) and in the washer fluid at temperatures below 0 °C (32 °F). 7 Lock all covers, windows and the door. Remember that the risk of theft and break-in can be minimised if one: removes the ignition key when the machine is left unattended. locks doors and covers after the end of the working shift. turns off the current with the battery disconnect switch and removes the handle for the switch. avoids parking the machine in places with high risk of theft, break-ins and malicious damage. removes all valuable items from the cab, e.g. mobile telephone, computer, radio and bags. chains the machine to an immobile object. It is easier to identify stolen machines if PIN number or registration number is etched onto the windows.

Long-term parking

The temperature may not be below -40 °C (-40 °F) or above +70 °C (158 °F).

Check that the batteries are fully charged.

Carry out the measures as described above.

Wash the machine and touch up the paint finish to avoid rusting.

Treat exposed parts with anti-rust agent, lubricate the machine thoroughly and apply grease to unpainted surfaces like lifting and tilting cylinders etc.

Fill the fuel tank and the hydraulic oil tank to the max. marks.

Cover the exhaust pipe (parking out-of-doors).

Remove the fuse for the voltage converter. Otherwise there is a risk that the batteries will be discharged.

Check the tyre pressure and protect the tyres against strong sunlight.

Check after long-term parking

all oil and fluid levels

tension of all belts

air pressure

air cleaner


What to do if the machine gets stuck

113

What to do if the machine gets stuck If the machine has got stuck, it is usually best to reverse out. If you cannot reverse or drive forward, try the following: 1 Engage the differential lock with the foot switch. 2 Select a low gear (1st or 2nd). 3 Reverse and steer the machine fully to the left and then to the right alternately, etc. (duck's waddle). If only the front wheels have got stuck proceed in either of the following ways: 1 Lift the front wheels, supporting the machine on the bottom of a flat bucket and reverse. 2 Steer to the right or to the left, press the bucket against the ground, lift up the front wheels and steer the other way, raise the bucket slightly and reverse. 3 Lift up the front wheels using the bucket. Manually fill the holes under the wheels with branches, pieces of wood or similar and reverse. 4 If the machine needs to be recovered, see page 114. You must never engage the differential lock when one of the wheels is slipping. Lower the engine speed until the wheel has stopped. Then engage the differential lock.


114

Recovering/towing

Recovering/towing WARNING! If braking and steering functions are limited, the machine may only be towed in an emergency, the shortest possible distance, and under supervision of specially trained personnel. If possible, transport the machine on a trailer. To release the parking brake, see mechanical release of parking brake for each machine type.

Measures

If possible, the engine should be running to make the brakes and steering operational.

If it is not possible to start the engine or for any other reason it is not possible to build up pressure needed to release the parking brake, it is possible to release it mechanically, see page 116.

NOTE! The coupling device on the counterweight or the eyes on the rear frame inside the rear wheels must not be used when recovering or towing.

Recovering

Use a towbar or other suitable means for pulling the machine to a suitable place or trafficable road.

When recovering rearwards, use the eyes under the counterweight, which are intended for lashing the machine.

When recovering forwards, use the eyes by the front axle attachment intended for lashing the machine.

To avoid oblique loading, pull the machine straight rearwards/ forwards. Try to distribute the load by connecting to both eyes.

Towing Eyes under counterweight when towing and lash- The towing vehicle or machine must weigh at least as much as ing the machine to be towed and must have sufficient engine pow-

er and braking capacity to pull and brake both machines on any up or down hills.

L67530A

11 026 730

Connected to eyes by front axle attachment

Attaching point for lashing

Do not tow further than absolutely necessary as otherwise the transmission may be damaged.

When towing further than 10 km (6 miles) or when towing at a speed exceeding 10 km/h (6 mph), both the front and the rear propeller shafts must be disconnected, see page 115, or, as an alternative, the machine must be transported on a trailer.

Connect in a corresponding way as when recovering.

NOTE! It is not possible to start the engine by towing. Follow national regulations where required.


Recovering/towing

115

Disconnecting propeller shafts

WARNING! Before taking any steps in preparation for recovering or towing, the parking brake must be applied and the wheels blocked to prevent the machine from rolling. The greatest care must be taken in connection with towing to avoid serious injury which at worst could be fatal. 1 Place the machine in service position, see page 159. 2 Block the wheels in a suitable way, for example using spacer wedges. 3 Release all brakes. 4 Remove the propeller shaft bolts and detach the propeller shafts from the drive axles.

After recovering and towing Before the towbar or wire rope is removed, the following safety measures should be taken: 1 Stand the machine on level ground. 2 Block the wheels to prevent the machine from rolling. 3 Restore the parking brake, if it has been mechanically released. 4 Restore the propeller shafts. NOTE! The parking brake will not have any effect once the propeller shafts have been disconnected. If the machine is left without having restored the parking brake, this must be indicated by a label on the steering wheel with the information that the parking brake has been disabled.

Connecting device on counterweight NOTE! The connecting device on the counterweight must not be used when recovering, towing, or when travelling on road. Follow national regulations.

1003911

Connecting device on counterweight

Maximum temporary force on the towing device (towbar) on the counterweight including attachment bracket must not exceed the following: L110F, a horizontal force of 150 kN (33721 lbf) and a vertical force of 10 kN (2248 lbf). L120F, a horizontal force of 150 kN (33721 lbf) and a vertical force of 10 kN (2248 lbf). The connecting device may only be used temporarily to transport necessary maintenance supplies needed by the machine on the work site (attachments, tools, fuel, oils, etc.). The new total weight (machine as well as unbraked trailer with load) may not be heavier than maximum machine weight, see page 5.


Volvo Construction Equipment AB SE-631 85 ESKILSTUNA, SWEDEN

11445271

1026949

Coupling Forces


116

Recovering/towing Parking brake, mechanical release WARNING! Block the wheels to prevent accidental machine movement. If it is not possible to start the engine or for any other reason it is not possible to build up pressure needed to release the parking brake, it is possible to release it mechanically. NOTE! However, this is only allowed in order to enable towing. Immediately after the towing has been completed, the parking brake must be restored.

Releasing Remove the three plugs according to figure. Oil will leak out. Temporarily replace these with three bolts (M10 x 90 mm) and washers (the bolts are included in the tool bag for the machine). L46965

Releasing parking brake

Tighten the bolts alternately until they bottom.

Restoring Unscrew the bolts alternately. Oil will leak out. Re-install the plugs. Put the bolts back in the tool bag for the machine. NOTE! If the machine is left without having restored the parking brake, this must be indicated by a label on the steering wheel with the information that the parking brake has been disabled.

WARNING! If the machine is left without having restored the parking brake, this must be indicated by a label on the steering wheel with the information that the parking brake has been disabled. The machine must not be used until the parking brake has been restored, which must be carried out at a workshop authorised by Volvo CE


Transporting machine

117

Transporting machine Actions before transporting machine WARNING!

A B C

Attaching points for lashing Block the wheels Guard on exhaust pipe

If the machine is driven across from a loading dock onto the platform of a truck or trailer, make sure that this vehicle is securely braked, i.e. the wheels blocked and that there is no risk that the vehicle will tip or tilt in a dangerous way as the machine is driven across. NOTE! To avoid air being forced down the exhaust pipe when transporting, it should be covered with suitable protection (C) (not plastic). Otherwise the turbocharger may be damaged.

On another vehicle

If the machine is lifted up onto another vehicle, the frame joint must be locked. Use intended attaching points for lifting.

L64522A

Frame joint lock

Lock the frame joint.

If the machine is driven up on to another vehicle, the frame joint must not be locked. The frame joint must be locked first when the machine has been driven up on the trailer.

Tie down (lash) the machine.


118

Transporting machine On vehicles on other roads and on Baltic Sea transport The instructions on pages 119122 are according to the Swedish Road Administration's regulations VVFS 1998:95, Swedish Maritime Administration's decree SJÖFS 2003:14, as well as the standard SS-EN 12195-1, and applies if the following conditions are fulfilled:

The machine is from Volvo Construction Equipment AB and is loaded with or without mounted attachment. The machine's weight is max. 23,000 kg (50,706 lb) (L110F), 24,000 kg (52,911 lb) (L120F).

The machine is loaded on a vehicle with trailer bed of wood, plyfa (plywood), grooved aluminum plates, unpainted or painted steel plates.

The machine has new or normally used rubber tires or woodcovered rims of pine or birch. If the wood-covering is made of birch, then rubber spacers shall be used between wood-covering and ground surface for the friction 0.5. If rubber spacers are not used the friction is only 0.2.

The machine stands centred (± 5 cm (2 in)) and is supported on at least half of the tires' width.

The parking brake is applied and functional, and can handle an inclination (grade) of at least 14°. The frame joint is locked.

The distance sideways between tie-down points on the loadcarrying transport vehicle is approx. 2,500 mm (8 ft 2.4 in).

The lashings are pre-loaded to at least 4,000 N (400 kg (882 lb)) during the whole transport.

The tie-down points on the trailer have at least the same breaking strength as the lashings.

The lashings are located symmetrically in pairs. The lashings may not rub or chafe on tires or painted surfaces.

It shall not be possible for the tie-down hooks to lose their grip if the lashings become slack.

Safe loading in the chain (MSL/LC/SWL) is at least 50% of the breaking strength (MBL). The safety factor for uneven loading in the lashings is set to 1.35, according to IMO's regulatory system.

Dampers may be needed on lashings that are short and vertical to reduce the jerking and shocks to which the chains may be subjected.

These dampers may be needed especially on machines transported with rubber tires.

When using blocks, these must be well fastened, have an angle of approx. 37° (3:4:5), a height of at least 25 cm (9.8 in), and are located in pairs; 1, 2, 3, or 4 pairs according to above tables with block placement.

Placement of rubber tires/wood-covered rims against wheel slots corresponds to the use of blocks.

Blocking against goose-neck or corresponding in forward direction replaces chocks in the direction of movement.



119

L110F C

F

D

1

E

2

Lm F

3 4 Lf

A-A

Lb

Lm

A

B

A

Lf

Lm

Lb

B 1053061

B-B

Machine loaded with front facing forward (F=Travel direction) Blocks

Lashings' permitted distance intervals in metres Chain min. class 8 Ø10 mm MBL 12 ton, LC 60 kN (6 ton)

Chain min. class 8 Ø13 mm MBL 20 ton, LC 100 kN (10 ton)

Lf (crossed)

Lf (crossed)

Friction surfaces

(placement acc. to above)

Rubber, pine, birch with rubber (dry or wet): μ = 0.5

No blocks

Not permitted lashing alternative

0,8 2,5

0,4 1,4

1,8 3,0

1 pair

1,6 2,8

0,4 1,4

1,7 2,9

0,8 2,5

0,2 1,4

0,8 2,5

2 pairs

0,5 2,5

0,4 1,4

1,7 2,9

0,5 2,5

0,2 1,4

0,8 2,5

0,5 2,5

0,0 1,4

0,5 2,5

0,5 2,5

0,0 1,4

0,5 2,5

0,8 2,5

0,4 1,4

1,8 3,0

0,8 2,5

0,2 1,4

0,8 2,5

Lb

Lm

Lb

3 pairs 4 pairs

Frost, ice, snow, dirt, birch without rubber: μ = 0.2

Lm

No blocks 1 pair 2 pairs

Not permitted lashing alternatives 0,5 1,2

0,4 1,2

1,7 2,4

0,5 2,5

0,2 1,4

0,8 2,5

0,5 1,7

0,0 1,2

0,6 1,7

0,5 2,5

0,0 1,4

0,5 2,5

3 pairs 4 pairs


120

Transporting machine L110F C

F

D

1

E

2 Lm

F

3 4 Lf

Lm

A

A

A-A

Lb B

Lf

Lm

Lb

B

1053062

B-B

Machine loaded with front facing backward (F=Travel direction) Blocks

Friction surfaces



No blocks

Lashings' permitted distance intervals in metres Chain min. class 8 Ø10 mm MBL 12 ton, LC 60 kN (6 ton) Lb (crossed)

Chain min. class 8 Ø13 mm MBL 20 ton, LC 100 kN (10 ton) Lb (crossed)

Lf

Lm


0,8 2,5

Not needed

1,8 3,0

1 pair

1,7 2,9

0,6 1,2

1,7 2,9

0,8 2,5

Not needed

0,9 2,5

2 pairs

0,5 2,5

0,6 1,2

1,7 2,9

0,5 2,5

0,5 2,5

0,0 1,2

0,7 2,5

0,5 2,5

Not needed

0,5 2,5

0,8 2,5

Not needed

1,8 3,0

0,5 2,5

Not needed

0,9 2,5

0,5 2,5

Not needed

0,5 2,5

Lf

Lm

3 pairs 4 pairs Frost, ice, snow, dirt, birch without rubber: μ = 0.2

No blocks Not permitted lashing alternatives 1 pair 2 pairs

0,5 1,1

0,5 1,1

1,6 2,1

0,5 1,6

0,0 1,1

0,5 1,6

3 pairs 4 pairs



121

L120F C

F

D

1

E

2

Lm F

3 4 Lf

A-A

Lb

Lm

A

B

A

Lf

Lm

Lb

B 1053061

B-B

Machine loaded with front facing forward (F=Travel direction) Blocks

Lashings' permitted distance intervals in metres Chain min. class 8 Ø10 mm MBL 12 ton, LC 60 kN (6 ton)


Lf (crossed)

Lf (crossed)

Friction surfaces



No blocks


0,8 2,5

0,5 1,4

1,7 2,9

1 pair

1,7 2,9

0,5 1,4

1,6 2,8

0,8 2,5

0,2 1,4

0,8 2,5

2 pairs

0,5 2,5

0,5 1,4

1,6 2,8

0,5 2,5

0,2 1,4

0,8 2,5

0,5 2,5

0,0 1,4

0,5 2,5

0,5 2,5

0,0 1,4

0,5 2,5

0,8 2,5

0,5 1,4

1,7 2,9

0,8 2,5

0,2 1,4

0,8 2,5

Lb

Lm

Lb

3 pairs 4 pairs


Lm

No blocks 1 pair 2 pairs

Not permitted lashing alternatives 0,5 1,1

0,5 1,1

1,6 2,1

0,5 2,5

0,2 1,4

0,8 2,5

0,5 1,6

0,0 1,1

0,5 1,6

0,5 2,5

0,0 1,4

0,5 2,5

3 pairs 4 pairs


122

Transporting machine L120F C

F

D

1

E

2 Lm

F

3 4 Lf

Lm

A

A

A-A

Lb B

Lf

Lm

Lb

B

1053062

B-B

Machine loaded with front facing backward (F=Travel direction) Blocks

Friction surfaces



No blocks


Chain min. class 8 Ø13 mm MBL 20 ton, LC 100 kN (10 ton) Lf

Lm

Lb (crossed)


0,6 2,5

0,6 2,5

2,0 3,2

1 pair

1,2 2,5

0,6 1,2

1,9 3,1

0,6 2,5

0,2 1,2

1,2 2,5

2 pairs

0,5 2,5

0,6 1,2

1,9 3,1

0,5 2,5

0,2 1,2

1,2 2,5

0,5 2,5

0,0 1,2

0,8 2,5

0,5 2,5

0,0 1,2

0,5 2,5

0,6 2,5

0,6 1,2

2,0 3,2

0,6 2,5

0,2 1,2

1,2 2,5

0,5 2,5

0,2 1,2

1,2 2,5

0,5 2,5

0,0 1,2

0,5 2,5

Lf

Lm

Lb (crossed)

3 pairs 4 pairs


Lashings' permitted distance intervals in metres

No blocks 1 pair

Not permitted lashing alternatives

2 pairs 3 pairs 4 pairs

0,5 1,5

0,0 1,0

0,8 1,8



123

Across ramp

489849 5

2m

First check that the ramp is amply wide enough and has the required strength and that it will not be displaced.

L67514

A

In elevator or other narrow space

5m

6,5 m

1 Reverse the machine in. 2 Apply the parking brake and stop the engine before starting the elevator. Also follow national or state regulations.

Lifting the machine L64512B

Lift the machine by the therefore intended lifting eyes (see figure) and lock the frame joint.

Attaching points when lifting

Lashing of machine

A Attaching points for lashing B Block the wheels C Guard on exhaust pipe

Block the wheels (B).

Tie (lash) the machine down using attaching points (A) intended for this purpose, so that it cannot tip or begin to roll.


124


Economical operation

125

Operating techniques The following pages contain advice and instructions on how to operate the machine and examples of how the most common attachments are used. It is important that the correct operating techniques are used to carry out the work in a safe and efficient way.

hp 300 250 200 150 100

220

1200

800

180

1000 700

160

800

140 120 100 80 800

Power kW 220

100

1000 15

hp

150

600

Power Torque

300

200

lbf ft

200

L110F

250

Torque Nm

Power kW

1200

1400

20

1600 25

1800

500 400

400

2000

30

600

r/min

1030472

35 r/s

Torque Nm 1200

lbf ft

200

800

180

1000 700

160

800

140 120 100

Power Torque

80

L120F

600

800

1000 15

1200 20

1400

1600 25

Economy speed (grey area) Power .... Torque

1800 30

2000

600 500 400

400 r/min

35 r/s

1030471

Economical operation To utilise the system in the best way and to achieve low fuel consumption, the engine should be run at low speed during all operations. Exceptions are: when filling the bucket, the rpm should be adapted to the material's hardness. during the acceleration phase in longer work cycles (e.g., load and carry). When transport speed is reached, you can ease off on the throttle. Lifting speed and power are sufficient already at low engine speed, which will result in a lower fuel consumption, lower sound level and higher comfort with maintained high productivity. A fuel-saving way of operating also means less wear on the machine and sparing the environment. Always strive to:

Operate within the economy rpm range See tables on the left. A high engine rpm rarely means higher productivity, but often higher fuel consumption. When filling the bucket, the rpm should be adapted to the material's hardness and during the acceleration phase in longer work cycles (e.g., load-carry) high throttle can be used until transport speed is reached.

Adapt operation to the application Follow recommendations for the applications described in the section.

Select attachment according to the application Using attachments adapted to the application means higher productivity and lower fuel consumption and machine wear - at the same time. Follow recommendations described in the section.

Maintain correct air pressure in the tires On page 231 there are recommendations for air pressure in tires. Correct air pressure in the tires reduces fuel consumption and machine wear.

Do not let the machine idle unnecessarily However, follow recommendations for stopping the machine, see page 111, to ensure the turbo's lubrication.

Plan the work site Evaluate and plan your work area and its layout based on the machines that are going to work there, to make work more organized and effective. Keep the ground surface even and free from large stones and other potential obstacles.

Cooperate Cooperate with other operators to enable as effective work as possible with the machines.

Contact your dealer for more information and for the possibility of participating in a Volvo course for the area.


126

Whole-body vibrations

Whole-body vibrations Whole-body vibration emissions on construction machinery are affected by a number of factors, such as the working mode, ground conditions, speed, etc. To a large extent the operator can influence the actual vibration levels, because the operator controls the speed of the machine, its working mode, the travel path, etc. Therefore, the result can be a range of different vibration levels for the same type of machine. For cab specifications, see page 234.

Guidelines for reducing vibration levels on earthmoving machines

Use the proper type and size of machine, with optional equipment and attachments for a certain application. Make sure that the ground is kept in good condition. Remove larger stones and obstacles. Fill in any ditches and holes. Provide equipment and schedule time for maintaining terrain conditions.

Adjust the machine speed and chose a suitable travel path to minimise the vibration level. Travel around obstacles and uneven ground. Reduce the speed when it is necessary to go over rough terrain.

Maintain machines according to the manufacturer's recommendations. Tire pressures. Brake and steering systems. Controls, hydraulic system and linkages.

Make sure that the operator seat is maintained and correctly adjusted: Adjust the seat and its suspension according to the operator weight and height. Inspect and maintain the operator seat suspension and adjustment mechanism. Use the lap-type seat belt and adjust it correctly.

Steer, brake, accelerate, shift gears, and move the attachments smoothly.


Whole-body vibrations

127

Minimise vibrations during long work cycle or long distance travelling. Use Boom Suspension System about the machine is equipped with such a system. If the machine is not equipped with Boom Suspension System, lower the speed to avoid bouncing. Transport machines when there are long distances between worksites.

Back pain associated with whole-body vibrations may be caused by other risk factors. The following guidelines can be effective to minimize risks of back pains: Adjust the seat and controls to achieve good posture. Adjust the mirrors to minimize twisted posture. Provide breaks to reduce long periods of sitting. Avoid jumping down from the machine. Minimize repeated handling and lifting of loads.


128

Working within dangerous areas


Do not operate too close to the edge of a quay, ramp etc.

Operate slowly in tight spaces and check that there is enough room for machine and load.

Operating under ground requires special equipment, e.g., certified engine within the EU and EEA-countries. Talk to your dealer.

Use the machine's lights when working in poor light conditions, e.g., indoors and in tunnels.

Do not work with or operate the machine when visibility is poor, e.g., in thick fog, heavy snowfall or rain.

The machine must be specially equipped when operating and working in a contaminated environment or health-hazardous area. Talk to your dealer. Also check the local regulations before you enter the area with the machine.

14607307

1053054

Overhead power lines for high voltage

Always contact the power company or owner of the facility before starting to work near a high voltage facility.

Voltage

Distance

WARNING! Make sure that the machine does not come into contact with the power lines. Risk of personal injury if any body part comes into contact with a 'live' machine (machine conducting electric power). High voltage is lethal and powerful enough to destroy both machine and attachment. Always contact the power company before starting to work near high voltage power lines. Review the special instructions that the power company has issued for working or being near power lines.

m

ft

~50,000

3

10

50,000~69,000

4,6

15

Always consider all power lines to be 'live', even those assumed to be without power supply. It is a very serious risk to work when the machine or its load at any time is closer to the power line than the minimum safe distance, see table on the left.

69,000~138,000

5

16,4

138,000~250,000

6

20

Keep in mind that the voltage in the power line decides the safe distance. Electrical flashovers can damage the machine and injure the operator at relatively great distances from the power line.

250,000~500,000

8

26

500,000~550,000

11

35

Find out what actions are to be taken if an operator has been injured by an electrical flashover.

550,000~750,000

13

43

750,000~

14

46

Volt (V)

IMPORTANT! Pay attention to overhead power lines when transporting the machine.



129

Railroad overhead contact lines

WARNING! Keep in mind that the line for the adjacent track may also be 'live' (conduct electric power). Loading and unloading is only permitted between the posted signs. Signs may hang from the contact line or be placed on special posts.

Contact authorized railroad staff to obtain permission to load or unload.

After a temporary break in the work, always contact the railroad staff again.

Electromagnetic fields, EMF Working in areas with electromagnetic fields, EMF

15011966

1027909

WARNING! Machines equipped with Comfort Drive Control (CDC) and/ or electric servo lever control must not be used on sites where static or low frequency magnetic fields could occur (for example aluminium smelting plant). In these areas there may be interference with safety-related functions. If you are uncertain about whether there are low frequency magnetic fields occurring at the work site, ask the site management.

The site management has an obligation to know whether there are areas where there are strong electromagnetic fields and to inform the machine operator about these.

The operator should seek information whether the work site may be exposed to strong electromagnetic fields.

Electromagnetic fields, EMF, may affect the machine, if it is equipped with electric servo lever control and comfort drive control (CDC). For Comfort Drive Control (CDC), see page 107.

Underground cables and pipelines Make sure that authorities or companies responsible for cables and pipelines have been contacted, and follow their instructions. Also check what rules apply to those working on the ground with regards to exposing cables and pipes. Normally only the power companies' own staff may expose and arrange temporary suspension of cables. Get help from a signal man when you cannot see where the job is being done or when placement of the cable is critical, see page 156. Placement of the cable may be different from the drawing or the distance assessment may be incorrect. Consider all power lines and cables to be 'live'.


130

Working within dangerous areas Working on a grade WARNING! When working on a steep grade the attachment shall be tilted back and kept as close as possible to the ground.

A

A

When working on a grade, pay attention to weather and ground conditions in order to not jeopardize safety.

Be careful when opening the door since it may be more difficult to control with the machine at an angle. When you close it, make sure that it is completely closed.

Operate slowly when approaching or running on a downhill grade.

Do not run faster down a grade than the machine can run up the same grade.

Do not change travel direction when operating on a grade, and do not operate across a grade.

If the machine slides, lower the bucket to the ground immediately. The machine may roll over if it becomes unbalanced. Do not turn with a load in the bucket, unless the machine is stable. If absolutely necessary, pile up dirt on the grade so that the machine can be placed on a level and stable surface.

If the engine stops when the machine is on a grade, lower the attachment to the ground.

IMPORTANT! Follow the recommendations for maximum permitted angle in the table below. The machine's function is compromised, e.g. lubrication, if recommendations are not followed and this may lead to machine damage.

B B 1053521

Maximum permitted angle A Machine affected in longitudinal direction B Machine affected sideways

Maximum permitted angle See figure to the left to see how each angle (A and B) affects the machine. Machine affected in longitu- Machine affected sideways dinal direction (angle A) (angle B) Continuous action

Temporary action

Continuous action

Temporary action

A = 15°

A = 25°

B = 10°

B = 20°



131

Working in water IMPORTANT! The water must not reach over the lower edge of seals for hubs, propeller shafts, and real axle oscillation bearing. When crossing a body of water with the machine, the water level may not go over the centre of the wheel hub. Operate carefully if the water is turbid or dark as it may conceal underwater obstacles or dangerous deep holes in the bottom. Do not operate the machine in water if you are not sure that it is safe to do so.

After working in water, all grease points that have been under water must be greased so that the water is forced out.

Check that no water has penetrated into the transmission or axles.

Working in the cold WARNING! At very low temperatures, the machine's hydraulic system will respond slowly. Be very careful before the system has reached operating temperature to avoid any accidents. Read the advice for start, see page 102. The windows should be free ice and snow before starting to use the machine.

Watch out for slippery parts on the machine. Only step on slipprotected areas.

Use an ice scraper to remove ice from the windows. If needed, use a scraper with a long handle or a ladder.

WARNING! Avoid contact between unprotected skin and very cold metal parts - skin will freeze to the metal.

WARNING! Disconnect the electric engine heater when servicing the machine. Risk of burn injuries and electric shock.


132

Attachments

Attachments WARNING! Do not use attachments to lift or transport a person or several persons. Risk of personal injury. Using the correct attachment for a particular job is a deciding factor when it comes to the capacity of the machine. The machines have either direct-mounted attachments or attachments mounted in a bracket which allows rapid changes of attachments. Always follow Volvo CE's recommendations when selecting attachments. Follow instructions in the Operator's Manual. According to the EU Machine Directive the CE marking must be shown on the machine product plate. This marking therefore also covers the attachments which are designed by Volvo CE, as they are an integrated part of the machine and adapted to the machine. Attachments in the category "interchangeable equipment"1) (attachments that can be changed by operator) designed by Volvo CE are CE-marked and adapted for Volvo wheel loaders and are supplied with a "Declaration of Conformity" as well as instructions. The machine owner is responsible for the attachments being approved for installation on the machine. The machine owner is responsible for the safety of the combination machine attachment. For more detailed information about selecting attachments, contact a Volvo CE dealer to get a copy of the attachment catalogue. The machine is prepared for different attachments. In order to connect these hydraulically to the machine, the hydraulics must first be depressurized, see page 135. The machine's stability may vary depending on the attachments. 1) "interchangeable equipment" (attachments that can be changed by operator) means that the attachment requires the combination hydraulic attachment lock ("hook-on") and quick-couplings for optional hydraulics (3rd and 4th hydraulic function).

Transporting attachments with another vehicle for road and sea transport Follow the instructions according to standard SS-EN 12195-1, as well as local transport rules.


Attachment brackets

133

Attachment brackets IMPORTANT! When changing to another attachment, the holes for the lock pins in the new attachment should be cleaned and lubricated.

WARNING! Never use an attachment until you have checked that it is securely fastened and that the attachment including hydraulic hoses, connections and similar are undamaged your safety is involved.

Connecting If the attachment requires optional hydraulics (3rd and 4th hydraulic function), see page 135.

L67276A

Attachment bracket locking pins in unlocked position

Tilt forward approx. 15° and hook the bracket into the upper attaching points on the attachment

Lift, tilt rearward until level and lock with the locking pins of the attachment bracket

1 Release the locking pins by pressing the switch. NOTE! A warning message, "Attachment lock open", will be shown on the display. 2 Tilt the attachment bracket forward approx. 15° and align the upper attaching points of the bracket with the upper attaching points on the attachment. 3 Raise the lifting arms until the attachment rests in the bracket and tilt the bracket rearward until the attachment is level. 4 Lock the attachment with the switch. 5 Check that the attachment is properly locked by pressing the front edge against the ground. If it is locked, the front wheels will begin to rise. 6 Confirm locking of the attachment by pressing in SELECT on the keypad.

1030216

Attachment locking

11 111 506

L67523A

WARNING

WARNING! Check that the attachment is properly locked by pressing the front edge of the attachment against the ground, so that the front end of the machine begins to rise slightly, see the figure below. NOTE! On machines with Boom Suspension System and single-acting lifting function, these functions must be deactivated with the switches in order to be able to carry out the check that the attachment is properly locked. If you are uncertain as to whether the attachment is securely locked, you must visually check that the locking pins of the attachment bracket are in the locked position.


134

Attachment brackets Disconnecting 1 The attachment should be in a level position on the ground. 2 Release the locking pins by pressing the switch. NOTE! A warning message, "Attachment lock open", will be shown on the display. 3 Lower the lifting arms so that they disengage from the attachment. 4 Reverse away from the attachment.

WARNING! The switch for attachment locking must only be actuated in connection with the changing of attachments. Otherwise the pressure may be lost and as a consequence the attachment may work loose and cause injuries.


Hydraulic function, 3rd and 4th

135

Hydraulic function, 3rd and 4th Make sure that the hydraulic oil in the attachment, which is to be connected, is not contaminated (foreign particles, water etc.) and that it is of the same quality as that of the machine itself.

WARNING! When connecting attachments, the operator should make sure that the expected effect is obtained when moving the control levers. An unexpected movement may possibly result in an accident. Always check the function before the machine is put to work and that hydraulic hoses etc. for the attachment can move freely and are sufficiently long throughout the whole working range of the lifting arms and the tilting function. Extension hoses are available contact an authorised dealer workshop.

The illustration on the left shows couplings for 3rd and 4th hydraulic function on the boom's right side. Couplings on the boom's left side are found in the same position.

Connecting 1 See page 133. Follow step 16 to connect. 2 Place the attachment level on the ground. 3 Depressurize the 3rd and 4th hydraulic function, see below. 4 Connect the attachment's hydraulic hoses to the machine. NOTE! Always test the control functions for the attachment before starting to work!

Disconnecting 1 Place the attachment level on the ground. 2 Depressurize the 3rd and 4th hydraulic function, see below. 3 Disconnect the attachment's hydraulic hoses from the machine. 4 Make sure that the attachment cannot fall over after disconnecting. 5 See page 134. Follow steps 24 to disconnect the attachment from the machine.

B A

Depressurizing, 3rd and 4th hydraulic function Residual pressure in the hoses makes it very difficult to part or join up the quick-action coupling halves. This is facilitated, by releasing the pressure in the hydraulic system, when, for example, you want to disconnect a hydraulic hose: 1 Stop the engine. 1053058

Hydraulic function, 3rd and 4th A Coupling, 3rd hydraulic function B Coupling, 4rd hydraulic function

2 Ignition switch in position 1. 3 Move the control levers for the relevant function back and forth, and hold the levers in their end-positions for three seconds. The pressure in hoses from timber grapples can be released in the following way: 1 Close the clamping arm fully. 2 Make a quick movement with the lever in the opposite direction. The hoses become "slack" when the pressure is released. The attachment should always rest on the ground when releasing the pressure. Excess pressure in a hydraulic attachment can be released by slackening the lock nut between the hose and the hydraulic pipe and then tightening it again. Meanwhile watch the attachment. Collect the surplus oil.


136

Buckets

Buckets 1

When the machine is used with a bucket, a working load of 50 % of the tipping load for a fully steered machine is permissible. Depending on application and/or machine size the manufacturer often recommends a utilisation lower than 50%. For information regarding weight, capacity, load, edge savers, etc., see the Attachment Catalogue. Bucket teeth, changing, see page 199.

2 WARNING! Never use the attachment, e.g., a bucket, to transport or lift persons. Make sure that all persons are at a safe distance from the attachment before starting to use the machine.

3

NOTE! Excavating or surface stripping must not be carried out at high speed, if the bucket is tilted more than 15°, and a fully tilted bucket must be avoided.

Choosing bucket

The choice of bucket is dependent on the condition of the material (hard/loose), its density (heavy/light) and on the tipping load of the machine.

A too large bucket relative to the density of the material and the tipping load of the machine will give the impression that the machine is weak and unstable and will not increase the productivity.

4

5

6

1053065

1 2 3

4

5 6

The six most common buckets: Straight bucket without teeth (Loose material, sand, earth, fertiliser) Straight bucket with teeth (Hard material, gravel, clay, surface stripping) Spade-nose bucket without teeth (Material which requires good penetration force, gravel, finely blasted rock and ore) Spade-nose bucket with teeth (Hard and rocky material, hard gravel and blasted rock) Levelling bucket (Finer stripping work, moving top soil and levelling filling material). Bucket for stockpile loading (Loose sand, gravel, and crushed material)

For guidance on the choice of bucket, see the Attachment Catalogue. IMPORTANT! Check-tighten the bolted joints at the edge savers and segments to prescribed torque after approx. four hours of operation. Thereafter check the torque now and then.

Tightening torque for edge savers and segments with bolted joints (bolt grade 10.9) Size

Tightening torque

M16

275 ±45 Nm (203 ±33 lbf ft)

M20

540 ± 90 Nm

M24

900 ± 140 Nm

1 1/4

2160 ±345 Nm (1593 ±254 lbf ft)

Bucket operation To obtain efficient and safe operation it is important to bear the following points in mind:

Select the correct bucket.

Level the ground at the work site as far as possible and make sure the ground is firm.

Avoid wheel spin by adapting the engine speed and by transferring as much weight onto the front wheels as possible. This is achieved by slightly raising the bucket after it has begun to enter the material.

Work with a straight machine against the material to obtain the greatest penetrating ability. This also contributes to reduced tyre wear.


Buckets

137

Bucket with clamping arm (optional equipment) This bucket is the best for loading bulky materials, e.g., waste, tree branches, etc. The clamping arm is used to hold the bulky material in the bucket or to pick up materials in tight spaces. NOTE! For connecting and disconnecting hydraulic hoses for 3rd hydraulic function, see page 135. Always test the control functions for the attachment before starting to work! 1053105

The clamping arm is operated with control lever (3), see page 74 and 76 (electric servo). IMPORTANT! Make sure that the clamping arm is completely open if the bucket is used to push aside or compress materials. Otherwise the clamping arm may be damaged.

Check the hydraulic lines at regular intervals for leaks and visible damage.

Grease the bearings for the clamping arm and cylinder every 250 hours and every 50 hours in aggressive/corrosive conditions. For grease quality, see page 217.

Always depressurize the hydraulic system before starting maintenance or repair work, and before disconnecting the attachment.

Work on the hydraulic system may only be done by authorized personnel.


138

Buckets High-tip bucket (optional equipment) The high-tip bucket is a combination of carrier and bucket. When tipping, the carrier acts as an extension of the boom, which gives great tipping height. When loading and transporting the bucket is tilted back between the carrier, and the bucket is in almost the same posisiton as a standard bucket, and thus there are barely any disadvantages with regards to breakout force, lifting force, and tipping load. NOTE! For connecting and disconnecting hydraulic hoses for 3rd hydraulic function, see page 135. Always test the control functions for the attachment before starting to work! M300099A

The bucket cylinder is activated in "tilt function" with control lever (3), see page 74 and 76 (electric servo). For loading, transporting, and lifting the bucket should be tilted back completely. Only empty the bucket when the desired lifting height has been reached. NOTE! Avoid tipping the high-tip bucket with the standard tipping function, or if that is the case, use low tipping speed, so that the bucket remains completely tilted back on the carrier. Avoid tipping the high-tip bucket forward or back against the end-stops with full force in order to prevent damage to the bucket and cylinders.

Clean the carrier arms from dirt at regular intervals.

Check the hydraulic lines at regular intervals for leaks and visible damage, replace if needed.

Check the dampers (buffers) on the tilt-back stops at regular intervals, replace if needed.

Grease the bucket support and the cylinder bearings every 250 hours and every 50 hours in aggressive/corrosive conditions. For grease quality, see page 217.

Always depressurize the hydraulic system before starting maintenance or repair work.



Buckets

139

Gravel and heap loading 1 Adjust the bucket so that it is level and lower it to the ground just in front of the gravel heap.

1003925

2 Enter the material in 2nd gear + kick-down. When the machine has nearly come to a standstill because the maximum tractive effort of the machine has been reached, begin to raise the bucket while at the same time tilt backward with short control lever movements. If possible avoid tilting the bucket forward when filling it. Exaggerated lever movements causes wheel spin. Never move into the material at a high speed.

Suitable bucket:

Straight bucket with or without teeth.

Suitable gear:

Gear selector in position 2 or 4

Mode selector:

M- or AUT-mode

Boom Suspension System:

Gear-dependent position

WARNING! 1003926

Pay attention - risk of falling materials. Falling materials can cause serious accidents in case of careless operation.

Excavating

When excavating and surface stripping, start by angling the bucket 23° downward.

Operate in 1st gear and at low engine speed. Gradually increase the engine speed at the same time as you raise the bucket slightly.

If the ground conditions are poor and the wheels tend to spin, use the differential lock.

NOTE! You must never engage the differential lock when one of the wheels is spinning. Let up the accelerator until the wheel stops. Suitable bucket:

Straight with or without teeth (alt. levelling bucket)

Suitable gear:

Gear selector in position 2

Fully automatic downshifting

Activated

Mode selector:

AUTO-position


Not activated


140

Buckets Rock loading

Correct engine speed is of great importance too high engine speed causes wheel spin.

Drive into the material head on to avoid oblique stresses which can harm the lifting arm system.

The edge of the bucket must find its way under and between the stones, which means that you must watch the bucket carefully as it enters the material.

If a stone has become wedged, try a new angle of approach, but avoid exerting pressure on the corner of the bucket.

Avoid driving up into the material, as there is then a great risk of damage to the tyres by the sharp blasted pieces of rock. Also remove stones that have fallen out of the bucket.

Suitable bucket:

Spade-nose bucket with or without teeth.

Suitable gear:

Gear selector in position 2

Mode selector:

M- or AUT-mode



Transporting load (loading carrying)

The bucket should be fully tilted backward and kept in the carrying position 3040 cm (1216 in) above the ground.

Keep the transporting road even and free from stones and other objects. There is always spillage from a too full bucket.

Even out the road on the way back if necessary.

Suitable maximum speed:

Approx. 15 km/h (9.3 mph)

Suitable gear:

M- or AUTO-mode

Mode selector:

AUTO position



When operating where gear-shift hunting arises, select the H mode as the machine then must reach a higher travelling speed before upshifting takes place. Example: When operating up long inclines during loading/ carrying work. NOTE! Remember that the stability of a heavily loaded machine changes when it is steered.


Buckets

141

Dumping load WARNING! If visibility is limited by the load or the attachment, great care must be taken. Walk around the machine before starting and make sure that no persons remain in or enter the working area of the machine. If you are uncertain, raise the load and check the conditions in the operating area by looking under the load and operate at low speed. If necessary, arrange for a signalling person to take charge and to help the operator under "tricky" circumstances. Great care must be taken to prevent injuries and damage to property.

If you are working on an incline, try to arrange so that the load can be dumped uphill. This affects the stability of the machine in a positive way.

Keep the bucket as close to the platform or bin as possible to achieve a smooth dumping and better control of the positioning of the load.

When loading rock, try to fill the first bucket with as fine material as possible in order to soften the impact of subsequent larger pieces.

Positioning of transporting vehicle

The positioning of the hauler (transporting vehicle) is of great importance for making the loading operation efficient.

The operator should indicate where the transporting vehicle is to stand, suitably by "pointing" with the bucket. Having done so the operator is then responsible for that the place is safe.

Levelling

The bucket should lie flat against the ground. To be able to fill any hollows you should have material in and in front of the bucket when operating forwards.

To finish off the levelling operation, keep the edge of the bucket slightly downward and reverse while pressing the bucket lightly against the ground.

If a dozer blade, snow plough or sweeper etc. is used, it may advantageous to have the single-acting lifting function engaged. This allows the attachment to follow any unevenness in the ground by "floating". This means that steering ability and traction power is maintained. The attachment returns to preset position, see page 59.

Suitable bucket:

Straight without teeth (alt. grading bucket)

Suitable gear:

Gear selector in position 1 or 2

Fully automatic downshifting

Activated

Mode selector:

AUTO-position


Not activated


142

Log grapples (optional equipment)

Log grapples (optional equipment) NOTE! For connecting and disconnecting hydraulic hoses for 3rd hydraulic function, see page 135. Always test the control functions for the attachment before starting to work! The clamping arm is operated with control lever (3) and counterhold (optional equipment) with control lever (4), see page 74 and 76 (electric servo).


Grease the bearings for the clamping arm and cylinder every 250 hours and every 50 hours in aggressive/corrosive conditions. For grease quality, see page 217.



There are four types of log grapples: A Unloading grapple has short tines which makes it easier to fill the grapple when unloading a transporting vehicle. B Sorting grapple has a relatively long clamping arm, which can be set parallel to the ground. This facilitates filling the grapple when taking from a stack and a sorting bin. C General purpose grapple has longer fork tines than the sorting grapple and can be used for handling whole trunks when sorting or grabbing single trunks. Tropical grapple also is wide and has two separate clamping arms in order to get a secure grip on large, heavy logs.

A

B

C L64526A

The CEN standard EN 474-3 applies within the EU, which means that nominal operating load is expressed as a percentage of the tipping load. In accordance with this, Volvo CE have chosen to adapt its internal standard for stating the capacity of timber grapples. The recommended maximum loads apply for combinations of timber grapples and wheel loaders which are equipped with approved counterweights for timber handling. Any equipment added to the attachment reduces the rated operating load. In countries outside the EU and EEA other safety requirements may apply, therefore, always observe local regulations.


Log grapples (optional equipment)

143

Working with log grapples Unloading vehicle Take great care when filling the grapple so that the stakes and the frame of the truck are not damaged. 1 Approach the vehicle which is to be unloaded with a raised and fully open grapple. 2 Tilt the grapple forward and lay it down over the load. 1003945

Close the clamping arm and begin to tilt slightly upward. Then repeat alternate closing and upward tilting of the grapple until it is full. NOTE! Take great care when unloading a vehicle, particularly when there are only a few logs left. If the grapple should grip round the far edge of the platform this could lead to damage.

Loading vehicle with timber grapples 1 Make sure that each log lies correctly in the grapple to avoid crows nest. 2 Approach the vehicle to be loaded while at the same time raising the attachment so that the logs clear the stakes. 3 Lower the grapple until it is level on the bunks or the platform and deposit the bundle against the stakes on the far side. 4 Open the clamping arm fully and carefully reverse out.

1003944

Stacking For machines with Boom Suspension System it is recommended that speed-dependent function should be selected. The precision increases and the risk of "crows nest" reduces. 1 Keep the grapple as near the stack as possible to prevent logs falling down. 2 Tilt the grapple slightly forward. 3 Carefully open the clamping arm fully so that the logs can roll out of the grapple. 4 Reverse carefully and at the same time lower the grapple and hold it close to the load to prevent logs from falling.

The grapple's counterhold can be used as heel kick-out and therefore you do not have to tilt the grapple forward. The lifting height of the machine is better utilised and one can build higher stacks. The heel kick-out can also be used as a counter hold when handling single logs.

Basic rule: Make sure that the logs leave the grapple without falling. Suitable gear:

Gear selector in position 4.

Mode selector:

L- or AUTO-mode


Speed-dependent position


144

Log grapples (optional equipment) Picking up from a stack Low stack: 1 Keep the grapple tines flat against the ground with the grapple fully open. 2 Enter the grapple into the stack and close the clamping arm as far as possible. 3 Carefully reverse while closing the grapple further. High stack: 1 Begin as high as possible and tilt the grapple tines slightly forward with the grapple fully open. 2 When the grapple is well into the stack, close it. 3 Follow through with the grapple so as to avoid logs falling down under the grapple tines. If logs fall between the grapple tines, carefully lower the load to the ground, reverse and try to pick up the load again. Make sure not to damage the logs. A heel/kick-out makes it possible to stack the logs higher and to keep the ground in front of the wheels of the machine clear of logs.

Operating with whole trunks

Pay special attention to that the centre of gravity of the timber is correctly positioned so as to maintain a satisfactory side-stability of the machine.

Make use of a signal man when operating where the view is restricted, see page 156.

WARNING! Long objects such as logs must be handled with extreme care! Make sure that all persons are outside the machine's work area.


High-Lift grapple (optional equipment)

145

High-Lift grapple (optional equipment) The high-lift grapple, which is connected to the attachment bracket, handles 23 metre lengths of pulpwood. It is suitable for unloading vehicles to stack or feed table, and for transport from stack to feed table. NOTE! For connecting and disconnecting hydraulic hoses for 3rd and 4th hydraulic function, see page 135. Always test the control functions for the attachment before starting to work! 1053111

The grapple arms are operated with control lever (3) and the high-lift grapple is rotated with control lever (4), see page 74 and 76 (electric servo).


Grease the bearings for the grapple arms and cylinder every 250 hours and every 50 hours in aggressive/corrosive conditions. For grease quality, see page 217.




146

Pallet forks (optional equipment)

Pallet forks (optional equipment) B

A (90o) C L66614A

IMPORTANT! Only pallet forks approved for the machine by Volvo CE may be used. Pallet forks are only to be used for intended purpose: Must, for example, therefore not be used as a crowbar for prizing loose a tree stump, large stone or similar. Must not be overloaded or loaded obliquely. Must not be used as lifting equipment together with chains or slings for lifting objects. IMPORTANT! To avoid damage to the pallet forks it is recommended that single-acting lifting function should be activated, especially when reversing and if the fork points contact the ground. This is especially important when the ground is uneven.

Checking fork tines A Angle B Attaching lugs C Thickness

Fork tine back frame and fork tines must be dimensioned to withstand loads which the lifting capacity of the machine permits. Pallet forks and fork retainer must be kept free from dirt and rust and be well greased for best possible function. The fork arms are dimensioned according to ISO 2330 and are classified together with the machine according to the norms in force.

D

IMPORTANT! Make sure that the stops that prevent the fork arms from sliding off the fork frame are in place. Particularly important when the fork arms are moved sideways manually. Make sure that the fork tines are locked against the fork carrier, so that the fork tines are prevented from moving sideways.

1027071

Fork frame D Stop

WARNING! The supports must be lowered before the pallet fork is removed from the machine.

Check the pallet forks regularly as regards wear. It is particularly important to check the heel of the fork tine.

Check that stops (D) for the fork arms are properly located.

Check that the fork arms are locked against the fork frame.

The fork tine should not be used any more if: the fork tine has been worn down to 90% of its original thickness

L66613A

the angle between fork tine and shank has become greater than 93°. Marking 1 Max. load per tine (kg) *) 2 Distance to centre of gravity in mm for maximum load 3 Thickness of fork tine at delivery *) Must not be confused with rated operating load for the respective loader model.

the attaching lugs are worn or cracked.

Cracks or wear must not be made good by welding.

Fork tine extensions Fork tine extensions are used when handling light material with low density and it is marked with maximum load.



147

Operating with pallet forks The most important points for work with pallet forks are:

The operator should have suitable training.

The operator is responsible for that permissible load values are not exceeded.

The fork makes a semicircular movement when it is raised. Therefore, start raising the fork a little bit away from the place where the load is to be placed.

The fork must not be raised other than when stacking or depositing pallets.

When operating without a load in the fork, the tines should be held low and tilted upward.

When stacking material, the fork tines should be kept horizontal.

Choose the most suitable travel path with the smoothest surface or, when required, rectify by levelling off the ground.

The travelling speed should be adapted to the ground conditions.

For increased stability, when working with pallet forks, it is important that the tyre pressure is correct according to recommendations.

With a wide load it may be advantageous to move the fork arms out on the fork frame to obtain increased stability of the load. Also make sure that the load is centred sideways with regard to the centre of gravity.

When operating downhill with a heavy load it may be better to reverse the machine.

1003933

NOTE! For heavy work which require great break-out force, e.g. breaking out tree stumps and carrying marble blocks use attachments approved by Volvo CE. Suitable gear:


Mode selector:

L- or AUTO-mode


Speed-dependent position or not activated

Single-acting lifting function

Activated


148

Pallet forks (optional equipment) Picking up a load

Choose fork tines with a correct length so that they do not protrude outside the load. Previously deposited pallet or goods may be damaged as the penetrating force of the fork tines is very great.

Place the load as close to the vertical shank of the fork as possible.

Lift the load with the least possible inclination of the pallet fork.

There may be deviations from the complete parallel movement (see the Specifications) and this may affect the use of the fork.

Operating with a load

1003936

Keep the load low 3040 cm (1216 in) above the ground to achieve the best possible stability and vision.

Tilt the load rearward to hold it more secure.

If the load obscures the vision, reverse the machine to the place where the load is to be deposited.

Adapt the speed to the existing conditions.

When handling high loads, use a special load support.

Combi forks (optional equipment) The combination grapple is a good alternative when handling material that require a certain amount of holding. Here a special combi-fork back frame is used where standard fork tines are installed. The combi fork is suitable for:

Palletised goods and round timber.

Within the pulp industry and on building sites, where both palletised goods and compressed material (waste paper, packaging material etc.) are handled.

NOTE! For connecting and disconnecting hydraulic hoses for 3rd hydraulic function, see page 135. Always test the control functions for the attachment before starting to work! The clamping arms are operated with control lever (3), see page 74 and 76 (electric servo). 1053106


Grease the bearings for the clamping arms and cylinder every 250 hours and every 50 hours in aggressive/corrosive conditions. For grease quality, see page 217.



WARNING

WARNING! L67323A

The supports must be lowered before the pallet fork is removed from the machine.



149

Sideshift forks (optional equipment) Sideshift forks are designed for use when the width of the load varies. The fork tines are adjusted hydraulically according to the width of the load. NOTE! For connecting and disconnecting hydraulic hoses for 3rd and 4th hydraulic function, see page 135. Always test the control functions for the attachment before starting to work! The fork tines are operated with control lever (3) and (4), see page 74 and 76 (electric servo). 1053107

WARNING


Grease the bearings for the fork tines and cylinder every 250 hours and every 50 hours in aggressive/corrosive conditions. For grease quality, see page 217.



WARNING! The supports must be lowered before the pallet fork is removed from the machine.

Approval and legal provisions L67323A

The permissible rated operating load capacity according to CEN standard EN 474-3 is given as a percentage of the tipping load. The percentage values, which must not be exceeded, are as follows: Uneven ground:

60 % of tipping load

Firm and even ground:

80 % of tipping load

It must be possible to control and handle the load hydraulically in all likely positions at the same time as all other hydraulic circles are actuated. The maximum permissible load capacity is determined either by the stability of the machine or its hydraulic capacity whichever is less. In countries outside the EU/EEA other regulations may apply. Therefore, always check which local rules apply.


150

Material handling arm (optional equipment)

Material handling arm (optional equipment) The material handling arm is available in two versions. One version has an extension boom that is adjusted mechanically, and the other version has an extension boom that can be lowered hydraulically. The material handling arm with hydraulic lowering function is used when loads have to be lowered under ground level or when there is a need to pass obstacles. The material handling arm with hydraulic lowering function features a hose rupture valve and the extension boom can be lowered with limited speed. NOTE! For connecting and disconnecting hydraulic hoses for 3rd hydraulic function, see page 135. Always test the control functions for the attachment before starting to work! Lowering of the material handling arm is operated with control lever (3), see page 74 and 76 (electric servo).


Grease the bearings for the extension boom and cylinder every 250 hours and every 50 hours in aggressive/corrosive conditions. For grease quality, see page 217.



IMPORTANT! Only a material handling arm approved by Volvo CE for use with the machine, may be used. Maximum permissible load for the machine using a material handling arm is shown in an operating load table on pages 247248, and may not be exceeded. The rated operating load capacity given applies when the machine is operated on firm and level ground and is, at the most, half of the tipping load. When operating on uneven ground, the load must be adapted to the ground conditions. A mounting check must be carried out every time the attachment has been mounted to check that the attachment is locked. Check that the attachment is locked by pressing it against the ground. In certain countries it is a legal requirement that regular checks are carried out by an authorised person, who should also keep a special inspection diary over these checks.

Positioning of machine It is important that the ground where the machine is to be placed is level and firm. If the ground is soft, contact the management so that necessary action can be taken.


Material handling arm (optional equipment)

151

Loading

Apply the load table to the actual extension of the material handling arm.

Make sure that the pressure in the front tyres are according to the recommendations, if the maximum permissible load is utilised frequently.

Do not lift until you know: where the load is to go. that it can be placed there. that the correct lifting device is used (wire, chain, etc.). that the sling is connected to the load in a correct way. that you have been given the signal to lift, if a signal man is assisting. NOTE! The material handling arm must not be used for a heavier load than has been specified for the particular arm extension.

WARNING! Never use the attachment, e.g., a bucket, to transport or lift persons. Make sure that all persons are at a safe distance from the attachment before starting to use the machine.

Operating with material handling arm

Remember that a small movement at the attachment bracket becomes a large movement at the outer end of the material handling arm.

Operate the machine and the material handling arm with gentle and careful movements, so that the load does not start to swing.

Never exceed the maximum permissible load of the material handling arm.

Operating load table is found on pages 247248.

When transporting on, for example, a public road, the material handling arm should be fully retracted and the front end should be tilted rearward.

Extending or shortening the arm length should be done manually (be aware of the risk of pinching).

NOTE! If the length of the material handling arm has been changed, check that the pins at the ends of the respective sections have been locked in a secure way (special locking pins).

Only use lifting attachments which are approved and which do not overload the machine.


152

Material handling arm (optional equipment) Operating with a load WARNING! A swinging load may lead to the machine rolling over. Note that stability is affected when the machine turns.

When moving with a suspended load, keep the material handling arm as low as possible. The speed should be limited to 6 km/h (3.7 mph).

Use slings to stabilise and to prevent the load from swinging.

A lift should not be carried out when the force of the wind and the bulk of the load are such that the load cannot be handled with safety.

Keep your eyes on the load at all times. If, at any time, you cannot see the load, a signal man must be called in before starting the job. (See page156).

Operate the material handling arm as smoothly as possible.

Do not move a load above persons, office and personnel huts.

Under no circumstances should the material handling arm be used for pulling up boards or planks which have been nailed down. Pulling obliquely must not be done.

Suitable gear:


Mode selector:

AUTO-position


Speed-dependent position or not activated


Rotating attachments

153

Rotating attachments Hydraulically powered, rotating attachments WARNING! A machine with a hydraulically powered attachment must be provided with an emergency stopping device inside the cab. The stopping device turns off the power to the attachment and stops its movement. For the position of the emergency stop, see page 56 If the machine is used with hydraulically powered, rotating working parts, e.g. brush, bush clearer, sand spreader, the following general safety rules must be followed: 1026244

The fitting of such attachment for the first time must only be done by a trained person.

Read, understand and follow the instructions supplied with the attachment.

Always stop (turn off the hydraulic supply) the rotating/moving part of the attachment before you leave the cab.

When servicing or maintaining the attachment or in case of the working parts having come to a standstill while operating, the hydraulic hoses to the attachment must be disconnected in order to prevent accidental engagement of the hydraulic power, which might result in an accident.

Hydraulic emergency stop

Check that the attachment in question is CE marked, if the attachment is not made by Volvo CE. Make sure that the dealer has written the attachment into the "Declaration of Conformity" for your machine as being an approved attachment.

WARNING! To avoid accidents, always find out from the manufacturer what instructions for safe handling apply BEFORE you fit and start using a hydraulically powered attachment.


154

Lifting objects

Lifting objects WARNING! Objects may only be lifted using purpose-built lifting devices. The lifting devices that are used shall be adapted to and approved for the machine on which they are used. IMPORTANT! Do not use damaged, defective, or uncertified lifting devices. IMPORTANT! Different countries have their own regulations with regards to using the machine for lifting, e.g., to lift freehanging loads. Contact an authorized Volvo CE dealer for more information. IMPORTANT! Follow the permitted nominal loads for the machine in lifting and transport operations.

Stability The stability of machines at work changes and is subject to great variations. For work to be done safely, the operator must keep in mind and consider the special conditions at the time.

Standing the machine on a horizontal, stable and secure surface is one prerequisite for high stability.

Watch out for soft, uneven, or sloping ground, as well as ground where there is risk of landslides. Be very careful with loading the machine sideways and in connection with other similar high-risk work. If the machine stands on sloping ground, the centre of gravity is displaced and the machine may end up in a position where it rolls over.

Make sure that the ground surface is stable and secure. Unstable ground, e.g. loose sand or wet earth can make work unsafe.

Do not turn suddenly with a suspended load. Remember the centrifugal force.

Operate the machine slowly and carefully.

Make sure that visibility is not reduced by big loads. If needed, get help from a signal man.


Lifting objects

155

Slinging long loads

Boards, planks, reinforcing irons or similar should have the sling(s) arranged so that the load cannot fall out.

When lifting girders, a pair of girder scissors should preferably be used.

Padding made from, for example, cut up compressed-air hoses may be used in order to protect the slings.

The sling should be well tightened.

Running checks of lifting attachments Continuous supervision should be carried out at regular intervals by a knowledgeable and experienced person and arranged by the employer. Should wear, cracks or other deficiencies, which may jeopardise the safety of the machine or the lifting equipment, be noticed during the running checks, the machine or the lifting equipment must not be used.

L64488A


156

Signalling diagram

Signalling diagram If the operator's view is restricted because of, for example, an obscuring load, a signal man must be used. The faster lifting or lowering movements that are required or the faster the machine should move, the more lively should the signal man's movements be carried out. If two or more operators make use of the same signal man, there should be an agreement beforehand how the lift is to be carried out and how the signals are to be given to the respective operator.

L67279A L67281A

L67280A

START Both arms are extended horizontally with the palms facing forward

STOP Right arm pointing upward with the palm facing forward

END Both hands are clasped at chest height

L67283A L67278A

L67282A

RAISE Right arm pointing upward with the palm facing forward and the hand slowly making a circle

L67277A

MOVE FORWARD Both arms bent with the palms turned upward and the forearms slowly moving toward the body several times

LOWER Right arm pointing downward with the palm facing forward and the hand slowly making a circle

L67284A

MOVE REARWARD Both arms bent with the palms turned downward and the forearms slowly moving downward away from the body several times

VERTICAL DISTANCE The hands indicate the relevant distance

L67285A

DANGER (EMERGENCY STOP) Both arms pointing upward with the palms facing forward


Signalling diagram

L67286A

OPERATE IN INDICATED DIRECTION The arm extended horizontally with the palm facing downward and the arm making small slow movements to the right

L67287A

OPERATE IN INDICATED DIRECTION The arm extended horizontally with the palm facing downward and the arm making small slow movements to the left

157

L67288A

HORIZONTAL DISTANCE The hands indicate the relevant distance


158


Service position

159

Safety when servicing This section deals with the safety rules which must be followed when checking and servicing the machine. Volvo CE disclaim all responsibility if other tools, lifting devices or working methods are used than those described in this publication. L68293A

Further safety rules and warning texts are given within the respective sections. NOTE! Lifting with a jack must only be carried out by trained personnel.

WARNING! If you have to do work on the machine before it has cooled down: Be very careful with hot fluids and machine parts to avoid scalding and burn injuries.

Service position BEFORE you begin service work, the machine must be placed on level ground and prepared as shown below. AFTER you have completed the service, any guard plates must be re-installed and all engine covers are to be closed and locked. 2 3

4

P

5

!

8

1

L61721C

6

7

1

The attachment should be resting on the ground.

5

Attach a black and yellow label to the steering wheel.

2

Apply the parking brake.

6

Connect the frame joint lock.

3

Stop the engine and take out the ignition key. (Does not apply when checking oil level in transmission).

7

Block the wheels in a suitable way (with, for example, wedges).

4

Carefully release the pressure in pressure lines and pressure vessels to avoid risks.

8

Allow the machine to cool.


160

Before service read

Before service read Prevent personal injuries

L64527A

Read the instructions in the Operator's Manual before starting any work on the machine. It is also important to read and follow the information and instructions given on plates and decals. Do not wear loose-fitting clothing or jewellery that may get caught and cause injuries. Always wear a hard hat, protective eyeglasses, work gloves, and protective work shoes when required by the job. Make sure that ventilation is adequate if the engine is going to be started indoors. Do not stand in front of or behind the machine while the engine is running. Turn off the engine before you remove any protective covers or open the engine hood. There remains an accumulated pressure in the system, even when the engine has been turned off. If a system is opened without first being depressurized, high-pressure fluid may jet out. Use a piece of paper or cardboard when checking for leaks, never use your hand. Make sure that stepping surfaces, handholds and slip protected surfaces are free from oil, diesel fuel, dirt and ice. Only step on machine parts that are provided with slip-protection. It is important that correct tools and equipment are used. Faulty tools or defective equipment must be repaired or replaced. If service work has to be done under a raised blade or attachment, make sure that it is secured before starting any work. Engage the control lock-out and apply the parking brake, if installed on the machine.

Prevent machine damage

Use equipment with adequate lifting capacity when lifting or supporting the machine or parts of the machine. Volvo CE will not accept any responsibility if other lifting devices, tools, work methods, lubricants, and parts than those described in this Operator's Manual are used. Make sure that no tools or other objects that can cause damage have been forgotten in or on the machine. Release the pressure in the hydraulic system before beginning service work. Never adjust a relief valve to a higher pressure than that recommended by the manufacturer. Machines used in contaminated conditions or health-hazardous areas must be equipped for such operations. Also, special safety rules apply when servicing such machines. When installing two-way radio, mobile telephone or similar equipment, the installation must be carried out according to the instructions from the manufacturer in order to eliminate interference with the electronic system and components intended for the function of the machine, see page 14. Actions to be taken in connection with electric welding, see page 185. Make sure that all belly plates, guards, covers, and hoods on the machine are in place before starting the engine and using the machine. Use the three-point method (two feet and one hand) when cleaning or scraping the windscreen.


Before service read

161

Prevent environmental influence Be conscious of the environment when carrying out service and maintenance. Oil and other liquids dangerous to the environment and released into the environment will cause damage. Oil degrades very slowly in water and sediment. One litre of oil can destroy millions of litres of drinking water. NOTE! In common for all points below is that all waste is to be handed over to a treatment and disposal firm approved by the authorities.

When draining, oils and liquids must be collected in suitable vessels and steps taken to avoid spillage.

Used filters must be drained of all liquid before they are passed on as waste. Used filters from machines which work in environments with asbestos or other dangerous dust, must be placed in the bag supplied with the new filter.

Batteries contain substances dangerous to the environment and health. Used batteries must therefore be handled as waste dangerous to the environment.

Consumables, e.g. used rags, gloves and bottles may also be contaminated with oils and liquids dangerous to the environment and must in that case be treated as waste dangerous to the environment.


162

Fire protection

Fire protection WARNING! Special equiment is required if the machine is used in areas with very high fire hazard, e.g., explosive environments. There is always a risk of fire. Find out which type fire extinguisher that is used at your place of work and how it is used. A fire extinguisher is optional equipment and is available from your dealer. If the machine is equipped with a fire extinguisher, it should be located on the back part of the front fender. If the machine is equipped with a portable fire extinguisher it should be of the type ABE (ABC in North America). The designation ABE means that it can be used to put out fires in both solid organic materials and fluids, and that the fire extinguishing agent does not conduct electricity. Efficiency class I means that the fire extinguisher must operate effectively for at least 8 seconds, efficiency class II at least 11 seconds, efficiency class III at least 15 seconds. In general, a portable fire extinguisher ABE I corresponds to an effective content of 4 kg (8.8 lbs) (EN-class 13A89BC), standard EN 3-1995 part 1, 2, 4, and 5.

Fire prevention

It is forbidden to smoke or have an open flame near a machine when filling with fuel or when the fuel system has been opened and in contact with the surrounding air.

Diesel fuel is flammable and must not be used for cleaning. Instead use car care products intended for cleaning or degreasing. Also keep in mind that certain solvents may cause skin rash, damage the paint finish, and constitute a fire hazard.

Keep the place where the service is to be carried out clean. Oil and water can make floors and steps slippery. This may also be dangerous in connection with using electrical equipment or electrically powered tools. Oily or greasy clothes are a serious fire hazard.

Check daily that the machine and equipment are free from dust and oil. This reduces the risk of fire and also makes it easier to detect loose or damaged parts.

NOTE! Be very careful when using a high-pressure washer for cleaning since electrical components and cable insulation may be damaged at relatively low pressure and temperature. Protect electrical components and cables in an appropriate way.

Take extra care when cleaning a machine that is used in a firesensitive environment, e.g. sawmill and refuse dumps. The risk of spontaneous combustion can be further reduced by, for example, installing insulation on the muffler.

The fire extinguisher must be maintained so that it works when it is needed.


Fire protection

163

Check that fuel lines, hydraulic and brake hoses and electrical cables have not been damaged by chafing or are not in danger of being damaged in that way because of incorrect installation or clamping. This applies particularly to unfused cables, which are red and marked R (B+) and routed: between the batteries between battery and starter motor between alternator and starter motor Electrical cables must not lie directly against oil or fuel lines.

Do not weld or grind on components which are filled with flammable liquids, e.g. tanks and hydraulic pipes. Exercise care with such work in the proximity of such places. A fire extinguisher should be kept near to hand.

Actions in case of fire If conditions allow and it is possible without risking your own safety, take the following actions at the slightest sign of fire: 1 Stop the machine if it is moving. 2 Lower the attachments to the ground. 3 Move the control lock-out, if installed, to locked position. 4 Turn the ignition key to the stop position. 5 Leave the cab. 6 Call the fire department. 7 Turn off the battery disconnector, if it can be reached safely. 8 If possible try to put out the fire. Otherwise move away from the machine and the danger area.

Actions after fire When handling a machine which has been damaged by fire or been exposed to other intense heat, the following protective steps must under all circumstances be taken:

Use protective goggles and thick protective gloves made of rubber.

Never touch burnt components with your bare hands to avoid contact with melted polymers. First wash thoroughly with plenty of lime water (a solution of calcium hydroxide, i.e. slaked lime in water).

Handling of heated fluoro-carbon rubber, see page 165.


164

Handling hazardous materials

Handling hazardous materials Heated paint

WARNING! Heating of painted surfaces, rubber, or plastic parts can generate health-hazardous or environmentally hazardous substances. Be very careful when, e.g., welding, grinding, or cutting with a torch. Use suitable protective equipment. When heated, paint gives off poisonous gases. Therefore, the paint must be removed from an area of at least 10 cm (4 in) from the spot where welding, grinding or gas cutting is to be carried out. In addition to the health hazard, the weld will be of inferior quality and strength, which in the future may cause the weld to break. Methods and precautionary measures when removing paint

Blasting

Paint remover or other chemicals

use respirator and protective goggles use a portable air extractor, respirator and protective gloves

Grinding machine use a portable air extractor, respirator and protective gloves and protective goggles

Painted parts that have been discarded must never be burnt. They must be taken care of by an approved refuse handling plant.

Rubber and plastics which have been heated Polymer materials can, when heated, form compounds which are dangerous to health and environment and must therefore never be burned when scrapped. If gas cutting or welding is to be carried out near such materials, the following safety instructions must be followed: Protect the material from heat. Use protective gloves, protective goggles and an approved respirator.



165

Fluoro-carbon rubber which has been heated

WARNING! Seals that have to tolerate high temperatures may be made of fluor rubber (fluoro-carbon rubber). At very high temperatures, fluor rubber (fluoro-carbon rubber) may generate compounds that are very corrosive to the skin and lungs. Use suitable protective equipment. When handling a machine which has been damaged by fire or been exposed to other intense heat, the following protective steps must under all circumstances be taken:

Use thick, gloves made of rubber and wear protective goggles.

Discard gloves, rags etc. that been in contact with heated fluoro-carbon rubber after having first washed them in lime water (a solution by calcium hydroxide, i.e. slaked lime in water)

The area around a part that has been very hot and which may be made of fluoro-carbon rubber must be decontaminated through thorough and ample washing with lime water.

As a precautionary measure all seals (O-rings and other oil seals) must be handled as if they were made from fluoro-carbon rubber.

The hydrofluoric acid may remain on the machine parts for several years after a fire.

If swelling, redness or a burning sensation occurs and one suspects that the cause may be contact with heated fluoro-carbon rubber contact a medical doctor immediately. Symptoms may not appear until after several hours without any previous warning.

The acid cannot be rinsed or washed away from the skin. In stead treat with Hydrofluoric Acid Burn Jelly or similar before contacting a doctor.

Refrigerant NOTE! All types of service of the air conditioning unit must be carried out at accredited workshops by, or under the supervision of, a person in a position of authority with certified competence.

WARNING! R134a is moderately hazardous to personal health. When handling refrigerant, wear tight-fitting safety goggles and protective gloves. In liquid form, the refrigerant may cause frostbite. At high concentration in gas form, the refrigerant may have an anaesthetic effect. At lower concentrations the gas may have an effect primarily on the nervous system. The air-conditioning unit of the machine is filled with refrigerant R134a at the factory. R134a has no damaging effect on the ozone layer of the atmosphere, however, it contributes to the greenhouse effect and must therefore never purposely be released into the open air. IMPORTANT! R134a may never be mixed with other refrigerants, e.g. R12, since this will cause failure of the unit.


166

Handling hazardous materials In case of contact with escaping refrigerant, the following actions must be taken:

The gases, which are formed when refrigerant is heated may have seriously harmful effects on lungs and the nervous system even at low concentrations and when no smell is detectable. High concentrations have a narcotic effect. An exposed person must be moved out of the danger area out into the open air. Seek medical advice if there are remaining symptoms.

In liquid form, the refrigerant may cause frost-bite. Carefully heat the injured area with lukewarm water or warm clothes. Seek medical advice, if there are remaining symptoms.

Seek medical advice, if liquid refrigerant has come into contact with someone's eyes.

If a leak is suspected, leave the dangerous area and contact an accredited workshop to obtain information about what action should be taken.

Batteries

WARNING! Handling of batteries may lead to electrolyte (battery acid) coming into contact with eyes, skin, or clothes. Use suitable protective equipment. In case of acid splash in the eyes, rinse the eyes immediately with water. Electrolyte spilled on skin must be washed off immediately with soap and water. Seek medical advice.

Do not smoke near batteries, as these give off explosive gases.

Make sure that metal objects, e.g. tools, rings and watch straps, do not come into contact with the battery pole studs.

Make sure that the battery terminals' caps always are installed.

Do not tilt a battery in any direction. Battery electrolyte may leak out.

Do not connect a discharged battery in series with a fully charged battery. Risk of explosion.

When removing a battery, disconnect the ground cable first and when installing, connect the ground cable last to reduce the risk of sparks.

Discarded batteries must be taken care of according to current national regulations.

Charging batteries, see page 185. Starting with booster batteries, see page 102.



167

Dust of crystalline silicon dioxide (silica dust)

WARNING! Work in conditions with health-hazardous dust, e.g., asbestos, may cause serious health problems. Special actions must be taken to prevent spreading of dust. Contact a workshop authorised by Volvo CE for more information. Crystalline silicon dioxide is a basic component part of sand and granite. Many activities on building sites and in mines, such as ditching, sawing and drilling, generate dust that contains crystalline silicon dioxide. This dust may cause silicosis (miner's consumption). The employer or the management of the work site should inform the operator about any occurrence of crystalline silicon dioxide on the work site and provide special work instructions, necessary protective equipment and what actions are to be taken. Also check local/national regulations regarding crystalline silicon dioxide and silicosis.

Asbestos dust

It is important that the cab is kept free from dust / asbestos dust as far as possible: Enter and leave the machine in a place away from the asbestos contaminated area. Keep clothes and shoes clean from dust. Tidy and vacuum-clean the cab often and use personal protective equipment, for instance respirator (dust mask) intended for asbestos contaminated areas. Make sure that the cab door is kept closed while operating.

The cab should be ventilated through its ventilation system, which also provides excess pressure in the cab.

With regard to risks to health and environment, used filters must be placed in the sealable plastic bag which is supplied together with new filters. The bag with the used filter should then be deposited at a place authorised to take care of asbestos waste.


168


169

Service and maintenance Lubrication and service chart This section of the operating instructions describes the maintenance work that can be carried out by the operator. This is summarized in the section "Lubrication and service chart" as an illustration with associated table for each interval, see page 210. Other work requires trained service personnel or special equipment. Contact a workshop authorized by Volvo CE for learn more about these.

Service journal The service journal shall be filled in after every completed service at a workshop authorized by Volvo CE, see page 249. The service journal is a valuable document that can be used when, e.g., selling the machine. L52168B

Arrival and Delivery Inspection Before the machine leaves the factory, it is tested and adjusted. The dealer must also, if the warranty is to apply, carry out "Arrival and delivery inspections" according to applicable form.

Delivery Instructions When handing the machine over, the dealer must give the buyer "Delivery instructions" according to applicable form, which must be signed, if the warranty is to apply.

DELIVE DE VERY INS RUCTIONS INSTRU NS Machines manufactur ed by Volvo Construc tion Equipment

Construct ion Equipment

Serial no.

Machine model

Page

Customer no.

Owner

1 (2) Operator(Recipient)

Delivery instruction carriedout on the

The inspection programme “Delivery Instructions” is to be used for checking the machine with the customer/owner and for presenting the machine to the customer/owner.

Please pay atten tio n to the safety an d en viron mental ins truc tio ns in Op erator´s and Service Man uals for th e mach in es conc erned.

Performing, sign ing and submitti ng the delivery inst ruct ions is a pre-condit ion for a valid machine warrant y.

ARRIVAL L AND AN AR DELIVE DE VERY INSPEC ECTI TION ON Machines manufactur ed by Volvo Construc tion Equipment


2 Presentation of the machine including optional equipment.

Serial no.

Machine Model

Operating hours

Delivery date

Arrival date

Page

1 (2)

Review o f the Operator ’s Manual with e mphasis on the following point s. Arriv al inspection by

Delivery inspection by

(Depending on machine type, certain points are omitted.) Dealer

Perfo rmed

3 Opera tion The inspection programme “Arrival and Delivery Inspection” is to be used as a check on a machine upon its arrival from the factory and for an – Running-in instructions. inspection before its delivery to the customer.

– Cab, instruments and operating controls. Please pay atten tio n to the safety an d en viron mental ins truc tio ns in Op erator´s and Service Man uals for th e mach in es conc erned. – Contronic functions.

MAINTENANCE OF STORED MACHINES Machiines manufactured by Volvo Construc tion Equipment

– Start/stop, warming up. Arri val inspection Transmission, The arrival inspection is the first check of the product–after transport. shifting gears.


Perfo rmed

– Retarder 1 Any deviations or transport damage must be reported to thefunction. carrier, and then immediate corrective actions must be Customer taken. Page no. Serial no. Owner Machine model – Service brakes and parking brake. 1 (2) 2 Check that the machine is equipped according to– the order confirmation, and that tools and manSteering, secondary steering. Operator(Recipient) Delivery instruction carriedout on the uals are supplied with the machine. Any deviations should be reported to the sales department. – Operator environment, heating, ventilation and air conditioning. 3 Check that no caps for the oil filler points, fuel tanks, radiator or expansion tank are missing, in The inspection programme “Delivery Instructions” is to be used for checking the machine withorthe customer/owner and for presenting thethat no caps incorrect position broken. When applicable, check for the brake, clutch fluid reser-and use of attachments. – Attachment bracket (attaching an attachment) machine to the customer/owner. voirs and washer fluid are missing. – Loading, digging, dumping, lifting and grading operations. 4 As soon astio possible the and machine hasMan been it should be washed with fresh water. Please pay atten tio n to the safety an d en viron mental ins truc ns in Opafter erator´s Service ualstransported for – Operation on a public road. th e mach in es conc erned. 5 After the inspection, the anti-corrosion treatment of the machine should be renewed. If it is to be – Towing. stored again for a longer period, follow the instructions in "MAINTENANCE OF STORED Performing, sign ing and submitti ng the delivery inst ruct ions is a pre-condit ion for a valid MACHINES". – Tyre pressure. machine warrant y. Perfo rmed Delive ry inspe ction 4 Service, maint enance 1 Check together with the owner/operator that theThe delivered machine corresponds the order. delivery inspection is a checktobefore the product is delivered to the customer. Perfo rmed Engine, cooling system and fuel system. 2 Presentation of the machine including optional equipment. 6 Check the engine coolant level and the oil level in the engine, transmission, axles and hydraulic Electrical system including of charging and starting with booster batteries (jump startsystem. Check the freezing point of the coolant. When applicable, check thebattery level instate all brake fluid ing).washer system. See the Operator’s Manual. reservoirs. Check the water level in the windscreen Review o f the Operator ’s Manual with e mphasis on the following point s. Note: Do not start engine with battery charger connected. (Depending on machine type, certain points are omitted.) 7 Remove transport protection from the hydraulic cylinders. Perfo rmed Power transmission / axles. Clean any anti-corrosion agent from the piston rods. 3 Opera tion 8 Check and adjust tyre pressure or on excavatorsBrake checksystem. the track slack adjustment. – Running-in instructions. 9 Start the engine and run the machine until normal operating temperature has been reached. – Cab, instruments and operating controls. Check that the following systems function normally: Volvo Construction Equipment Customer Support AB Please esnd commentsaboutthe Inpection Programm e to 85 Eskilstuna [email protected] – Electrical system: Check that instruments,SE-631 control lamps and other lights are working. – Contronic functions. Sweden – Brake system: Test the service brakes, parking/emergency brakes and engage the retarder – Start/stop, warming up. (where applicable). – Steering system: Turn the steering wheel to both full steering lock positions. When applicable, – Transmission, shifting gears. check electrical secondary steering function. On Motor Graders, lean the front wheels left and right. – Retarder function. – Hydraulic system: Run all hydraulic cylinders to their respective end position. Check all equipment and functions. – Service brakes and parking brake. 10 Check that there are no fuel, water or oil leaks. If necessary, check-tighten connections, clamps and fittings. – Operator environment, heating, ventilation and air conditioning. 11 Any malfunctions or defects must be corrected, noted and reported to the supervisor. – Attachment bracket (attaching an attachment) and See use page of attachments. 2. – Steering, secondary steering.

– Loading, digging, dumping, lifting and grading 12 operations. Turn off the battery disconnect switch. – Operation on a public road. – Towing. – Tyre pressure.

Volvo Construction Equipment Customer Support AB SE-631 85 Eskilstuna Sweden

4 Service, maint enance Engine, cooling system and fuel system. Electrical system including battery state of charging and starting with booster batteries (jump starting). Note: Do not start engine with battery charger connected. Power transmission / axles. Brake system.

Volvo Construction Equipment Customer Support AB SE-631 85 Eskilstuna Sweden

Service programme

Perfo rmed

1 Check together with the owner/operator that the delivered machine corresponds to the order.

Please esnd commentsaboutthe Inpection Programm e to [email protected]

1015444

The service programme is available at the workshop and includes all service and maintenance jobs, both those that can be done by the operator and those that should be done in the workshop. The Service Programme should be used in connection with warranty inspections and during maintenance carried out by a workshop authorised by Volvo CE. The intervals recommended between checks, oil changes and lubrication apply provided that the machine is used under normal environmental and operating conditions. Warranty Inspection

Please send com ments about the Inspection Programm e to [email protected]

Two Warranty Inspections should be carried out at an authorised dealer workshop. The first within 100 operating hours and the second at the latest at 1000 operating hours. The carrying out of these warranty inspections is a condition for the warranty to apply. During these inspections, oil and other liquids have to be changed before the end of the regular intervals.


170 Cleaning the machine The machine should be cleaned regularly with conventional car care products in order to eliminate the risk of damage to the paint finish and other surfaces on the machine. IMPORTANT! Avoid using strong cleaning agents or chemicals in order to minimise the risk of damage to the paint finish. NOTE! Daily clean the areas on the machine where dust, chips and similar may collect in order to minimise the risk of fire, see page 171. Recommendations for cleaning the machine:

Place the machine in a place intended for cleaning.

Follow the instructions supplied with the car care product.

The water temperature must not exceed 60 °C (140 °F).

If high-pressure wash is used, keep a distance of at least 20 30 cm (812 in) between nozzle and machine surface. Too high push and too short distance may cause damage. Protect electrical leads in an appropriate way.

IMPORTANT! If you are using a high-pressure wash, take care so that the decals do not loosen.

Use a soft sponge.

Finish by rinsing the whole machine with only water.

Always lubricate the machine after washing.

Touch-up the paint finish when required.

Paint finish maintenance Machines which are used in corrosive environment are more prone to rusting than others. As a preventive measure it is recommended that the paint finish should be maintained every sixth months. If there is any doubt whether an environment is corrosive or not, contact your dealer.

At first clean the machine.

Apply Dinol 77B (or corresponding transparent waxy anti-rust agent) at a thickness of 7080 μ.

A protective layer of underseal Dinol 447 (or corresponding) may be applied under the mudguards where mechanical wear is expected.

Touch-up painting

At first clean the machine.

Check if any areas of the paint finish are damaged.

Rectify any damage to paint finish in a professional way.


171 Cleaning, engine compartment

1

2

3 4 5

Machines operating in dusty, fire-hazardous environments, e.g., log handling, woodchip handling, grain handling, and animal feed industries, require daily inspection and cleaning of the engine compartment and surrounding areas. When operating in other environments, inspection and cleaning is required at least once a week.

6 WARNING!

7

Always turn off the engine and let it cool before cleaning the machine.

1016394

Areas that need checking and cleaning: 1 The hydraulic tank top 2 Air intake, engine (air-cooled alternator) 3 Inside engine covers on both sides, accumulation on the engine valve cover and other surfaces, particularly on hot surfaces such as silencer, turbocharger, exhaust pipe, exhaust manifold, preheating element and alternator. Also check and clean by starter motor, oil filling point, oil filter and fuel filter 4 The space between engine and radiator 5 Inside radiator casing 6 Fuel filling point 7 The top of the fuel tank and surrounding areas

Preferably, the machine should be cleaned at the end of the work shift before it is parked.

Use personal protective equipment such as protective goggles, gloves, and protective breathing equipment.

Start with the highest areas on the machine and finish with the lowest on top of the fuel tank and areas near the fuel tank.

Loose material is removed with, e.g., compressed air.

After cleaning, check and repair any leaks. Close all covers and hoods.

1

5

6

2

3

(Principle diagram) 1 Silencer 2 Turbocharger 3 Exhaust pipe 4 Exhaust manifold

4

1016395

1016396

(Principle diagram) 5 Preheating element 6 Alternator


172

Service points

Service points

1026969

1026970

1

Level sight glass, hydraulic oil

15 Filling point for engine oil

2

Breather filters, transmission and hydraulic oil

16 Secondary fuel filter

3

Air cleaner

17 Primary fuel filter and water trap

4

Air filter intake

18 Battery

5

Filling point, fuel

19 Battery disconnect switch

6

Breather filter, front axle

20 Expansion tank

7

Level sight glass, transmission

21 Filling point, washer fluid (in the tool-box)

8

Filling point, transmission

22 Filling point and return oil filter, hydraulic system

9

Draining, hydraulic oil

23 Ventilation filters, cab

10 Breather filter, rear axle

24 Battery

11 Breather filter, fuel system

25 Alternator belt, right side Belt for coolant pump and fuel feed pump, left side Compressor belt, left side (optional equipment)

12 Oil dipstick, engine

26 Suction strainer, transmission

13 Oil filter, engine

27 Oil filter, transmission

14 Draining, engine oil and coolant


Engine

173

Engine Engine oil, checking Check the oil level every 50 hours.

B

A

When checking the machine should stand on level ground.

The check should be carried out when the oil is cold and has had time to run down to the bottom of the sump.

The level should be within the marks on the oil dipstick.

Engine oil, changing Change oil every 500 hours or at least once a year. The conditions for the 500 hour interval between oil changes are that: the oil filter is replaced every time the oil is changed. the oil filters are genuine Volvo "long life" filters and "bypass" filter. 1020365

A B

the diesel fuel sulphur content does not exceed 0.3 % by weight. the correct oil viscosity for the ambient air temperature is selected according to diagram, see page 215.

Oil dipstick Filler pipe

the oil is of a certain quality grade, see page 216. If the above conditions are not fulfilled, the recommended change interval shall be followed according to the oil's grade classification and the sulphur content of the fuel, see page 216. If any of these conditions are not met, the oil should be changed and the filters replaced every 250 hours. If the diesel fuel sulphur content exceeds 0.5 percent by weight or if the oil grade is below ACEA-E3 or API CE the oil should be changed every 125 hours. NOTE! Interval shorter than 500 hours also means shorter interval for replacing fuel filters, see page 176.

Draining

A WARNING! Take care when changing oil, as hot oil can cause burns to unprotected skin. Drain the oil while the engine is still warm. 1 The draining points for engine oil and coolant are positioned under the machine, inside the rear left wheel. 1026927

A

Draining point, engine oil

2 Unscrew the protecting cover for the engine oil draining point, connect the draining hose and drain into a suitable vessel. Remove the hose and re-install the protecting cover. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

Filling Fill with oil through filler pipe (B). Oil capacity when changing: approx. 20 litres (5.3 US gal) including filter. Oil quality grades, see page 216.


174

Engine Engine oil filters, replacing Replace the oil filter every time the oil is changed. The oil filter is of the disposable type, i.e. it cannot be cleaned, but must be replaced.

Removing Use a filter clamp or loosen the centre bolt (depending on filter type).

Installing Fill the filter with oil and apply oil to the gasket.

1020366

Engine oil filter

Screw on the filter until the gasket just touches the sealing surface. Then tighten a further half of a turn by hand. Start the engine and check that the gaskets seal. If it does not, remove the filter and check the sealing surface. Usually it does not help to tighten harder. NOTE! After replacing oil filters, the engine must run at low idling for at least one minute to make sure that the engine is lubricated before the machine is put to work. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

IMPORTANT! It is important that the filter is filled with oil before it is installed. This is to ensure lubrication of the engine immediately it is started.


Fuel system

175

Fuel system Fuel filling point Clean fuel is essential for trouble-free running of the diesel engine.

Carefully clean around the filler cap before removing it.

Avoid spills when filling. Keep the top of the fuel tank clean. Saw dust, dust, and dirt drenched in diesel on top of the tank are all serious fire hazards!

During the cold season keep the fuel tank full to prevent water condensing in the tank.

Fuel tank capacity: approx. 269 litres (71.0 US gal). L67709A

Fuel quality, see page 217.

Fuel tank cap

Fuel system, air bleeding 1 First, make sure that there is sufficient fuel in the fuel tank.

A

2 Press in and turn the hand pump counter-clockwise until it is in a working position. 3 Pump with the hand pump until a resistance becomes noticeable, 150200 strokes. 4 Lock the hand pump by pressing it in and turning it clockwise. 5 Start the engine and leave it running at low idling for at least 10 minutes to purge the system of any remaining air. 6 If the engine is difficult to start, again pump with the hand pump until a resistance is felt. 7 After start, check that there are no leaks. The hand pump must not be used when the engine is running. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

1020588

A

Hand pump on filter head


176

Fuel system Fuel filter, replacing Replace fuel filters (primary and secondary filters) every 500 hours, or when replacing the engine oil filter, which may mean a shorter interval. NOTE! If the filters become clogged earlier, they must be replaced. The fuel filters are positioned inside the engine cover on the left side of the machine. The primary fuel filter and the water trap are integrated to form one unit. In the filter head there is a hand pump which is used when bleeding the system. The primary fuel filter works as a prefilter for the feed pump. When installing the filters, they should only be tightened by hand. The fuel system must be bled after filter replacement. The way the fuel flows is: 1020367

Primary fuel filter with water trap

tank hand pump primary fuel filter with water trap feed pump secondary fuel filter common rail injectors cylinders The feed pump is belt-driven. The belt is in common with the coolant pump. For checking and adjusting belt tension, see page 183. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

A 1020368

A

Secondary fuel filter


Fuel system

177

Water trap Drain the water trap every 250 hours or when the message Water in fuel - empty cup is shown on the display, see page 49. Draining water from the fuel has to be done by hand. A non-return valve in the filter head prevents the fuel from running back to the tank. 1 Place the end of the hose in a collecting vessel 2 Loosen the draining nipple until fuel runs out through the hose. 3 Tighten the draining nipple after draining is completed. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

A A

Draining nipple with hose

1020369


178

Fuel system Fuel prefilter, changing (optional equipment) Change the filter insert every 250 hours. More frequent changes may be necessary depending on fuel consumption and fuel quality. Change may also take place in connection with changing primary and secondary fuel filters after alarm for clogged filter, see page 49.

Draining

1052819

Fuel prefilter

Drain the filter daily. Draining should also take place when draining the water trap after alarm for water in fuel, see page 49. 1 Drain the water cup of water and any other impurities by turning the valve at the bottom of the filter. Collect the water in a container. 2 Turn back the valve when only clean fuel runs out.

Removing and cleaning 1 Remove the filter cap by turning the T-handle counter-clockwise. 2 Carefully remove the filter insert with a twisting movement. 3 Clean the water cup with soapy water on a clean, soft rag or a brush. Do not use solvents or abrasive cleaners. 4 Rinse and dry the water cup thoroughly.

Installing 5 Install the new filter insert and press it down all the way to the bottom. 6 Fill with clean diesel fuel all the way up. 7 Change the gasket for the cap and the T-handle's O-ring if needed. Smear diesel on the gasket and the O-ring. Install the filter cap with the T-handle.

Breather filter, fuel system Replace the filter every 2000 hours. The filter is positioned inside the engine cover on the left side of the machine. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

1020371

Breather filter, fuel system


Engine air cleaner

179

Engine air cleaner The degree of engine wear depends largely on the cleanliness of the induction air. The air cleaner prevents dust and other impurities from entering the engine. Therefore, it is very important that the air cleaner should be checked regularly and maintained correctly.

Air cleaner

Engine air cleaner's main filter, cleaning and changing When the alarm text for clogged engine air filter is shown or every 1000 hours, the filter should be replaced or cleaned. The period of operation between filter replacements varies depending on the working environment of the machine. In certain environments the filter needs to be replaced more often. The filter can be cleaned according to instructions obtainable from an authorised dealer workshop. However, after the filter has been cleaned five times or if it is damaged, it must be replaced.

Primary filter

NOTE! Make a mark on the decal at the end of the secondary filter every time the primary filter is replaced or cleaned. In connection with replacing the filter, the cover for the air cleaner should also be cleaned as this works as a container for particles which have not been trapped in the filter. Check that all hose and pipe connections from the air cleaner to the engine induction manifold are tight. Check-tighten hose clips. If the alarm text remains after replacing the primary filter, also the secondary filter must be replaced, see page 179. Do not, under any circumstances, run the engine without a filter or with a damaged one. Always have a spare filter at hand and keep the filter well protected from dirt.

Engine air cleaner's secondary filter, changing Replace the filter every 2000 hours or when the primary filter has been replaced three times. The filter cannot be cleaned, but must be replaced. The secondary filter works as a protective filter if the primary filter is damaged. NOTE! Never remove the secondary filter unless it is to be replaced. Secondary filter

Take care of filters/oils/liquids in an environmentally safe way, see page 161.


180

Oil-bath air cleaner (optional equipment)

Oil-bath air cleaner (optional equipment) When working in a particularly dusty environment, we recommend that an oil-bath air cleaner should be installed in series with the existing dry-filter air cleaner. This will provide further safety against damage to the engine. The particle-retaining ability of the oil-bath air cleaner is between 90 and 95 %, which in practice, means that the standard dry-filter air cleaner will act as a secondary filter, with a replacement interval which is twice as long, i.e. 2000 hours

Oil-bath air cleaner, checking L66719A

Oil bath air cleaner

Check the oil level daily. Change oil and clean the lower and upper steel mesh filters if: the oil is dirty and viscous. there are sludge deposits or dry spots on the underside of the lower steel mesh filter.

Oil-bath air cleaner, cleaning Clean the steel mesh filters inserts every 2000 hours.

The oil bowl, the lower and upper steel mesh filters should be washed in diesel fuel.

Avoid using petrol (gasoline) for cleaning, as any remaining petrol can cause the engine to surge when it is started later.

Oil-bath air cleaner, changing oil

When filling or changing oil use oil with the same viscosity as in the engine.

The total oil volume is 5.5 litres (1.5 US gal).


Cooling system

181

Cooling system Coolant The cooling system is filled with Volvo Coolant VCS, which is in accordance with the highest requirements regarding anti-freeze, anti-corrosion and anti-cavitation properties. To avoid damage to the engine, is it very important that Volvo Coolant VCS is used when topping up or when changing coolant. Volvo Coolant VCS is yellow and a decal at the point of filling shows that the system is filled with this coolant (see figure). IMPORTANT! Volvo Coolant VCS must not be mixed with another coolant or corrosion protection, as this may cause engine damage. 11445056

1020820

If concentrated Volvo Coolant VCS and clean water (see page 218) is used, the table below shows the approximate amount of concentrated coolant that is required to achieve freeze protection. The amount of Volvo Coolant VCS must never be less than 40 % of the total mixture. When there is doubt as to the quality of the water, ready-mixed Volvo Coolant VCS, which contains 40 % concentrated coolant, must be used. IMPORTANT! If the ready-mixed Volvo Coolant VCS is used, it must not be mixed with any other ready-mixed coolants, as this may cause damage to the engine. Freeze protection down to

Content of concentrated coolant

25 °C (13 °F)

40% (mixture from factory)

35 °C (31 °F)

50 %

46 °C (51 °F)

60 %


Coolant, checking Check the coolant level every 50 hours. The level should stand between the Max. and Min. marks on the expansion tank.

Expansion tank


182

Cooling system Coolant, changing WARNING! Risk of scalding when opening the expansion tank's cap (radiator cap) due to high pressure in the cooling system. IMPORTANT! Change coolant every 6000 hours or at least every fourth year. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage. IMPORTANT! Volvo Coolant VCS must not be mixed with any other coolants or corrosion protection agents, as this may cause engine damage.

Draining 1 Remove the cap on the expansion tank, positioned on top of the engine hood. 2 The draining points for engine oil and coolant (A) are positioned under the machine, inside the rear left wheel.

1004312

Cap on expansion tank

3 Unscrew the protecting cover for the coolant draining point, connect the draining hose and drain into a suitable vessel. Remove the hose and re-install the protecting cover. Cooling system capacity when changing: approx. 38 litres (10.0 US gal) Take care of filters/oils/liquids in an environmentally safe way, see page 161.

Filling IMPORTANT! To avoid damage to engine and cooling system, different coolants or corrosion protection may not be mixed, see page 181.

A

Filling with coolant is done through the expansion tank. 1 The engine should not be running and the temperature control set to warm. 2 Fill with coolant to the maximum mark on the expansion tank.

1026928

Draining, coolant

NOTE! The cooling system operates at high pressure. Make sure that the cap's seals are intact and tighten the cap securely. 3 Run the engine until it is warm and top up the coolant level until all air has been removed from the system. 4 The level should be checked after the engine has been run warm and then allowed to cool. NOTE! The system can also be filled through the draining nipple. IMPORTANT! Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage.


Cooling system

183

Fan belt, checking (workshop job)

A

Check the belt tension every 500 hours.

WARNING! The engine must be stationary when checking the belt tension rotating parts can cause injuries.

Belt tension, checking and adjusting

1004314

B

B

A

The belt also drives the fuel feed pump for the fuel system. Loosen the bolts (A and B). The belt is adjusted with the aid of the oblong hole by bolt B. At correct tension, it should be possible to deflect the belt approx. 15 mm (0.6 in) applying a fairly hard pressure. Then tighten down the bolts.

Radiator, cleaning The radiator should be cleaned at regular intervals in order to safeguard the cooling of the engine. When operating under especially dusty conditions, the radiator should be checked daily.

B

D

WARNING! The engine must always be off when cleaning the radiator.

C 1020372

A B C D

Engine cover Radiator casing Cooling fan Side cover

NOTE! The radiator core may be damaged if handled carelessly. 1 Swing up the radiator casing (B). 2 Open the engine covers (A). 3 Open the side covers (D) by the cooling fan (C). 4 Blow the radiator clean with compressed air from the inside, (cooling fan side). 5 Check and clean the outside of the radiator. 6 Close all covers and lower the radiator casing.

Reversible fan, cleaning In very dirty environments it may be a good idea to clean the radiator often. If the machine is equipped with a reversible cooling fan, the fan can be made to temporarily change direction to blow the radiator clean at set intervals. To check the setting of the reversible cooling fan, see menu on the display on page 31. Setting is carried out with the keyboard under menu Engine, page 30.


184

Electrical system

Electrical system Check the travelling lights and control lamps daily.

Batteries The batteries are two 12 V batteries which are connected in series providing a system voltage of 24 V.

1003912

Battery disconnect switch The battery disconnect switch is located inside the cover on the radiator casing. If the machine is to be left unattended for some time, the battery disconnect switch should be turned off.

Battery disconnect switch

Batteries, maintenance Check the electrolyte level every 250 hours (more often at temperatures above +15 °C = +59 °F).

The level should be approx. 10 mm (0.4 in) above the cell plates.

Top up with distilled water when required.

Check that the cable terminals and pole studs are clean, well tightened and coated with petroleum jelly or similar.

The state of charge of the batteries is checked with a hydrometer. When there is a risk of frost, it is very important that the batteries do not become discharged as the electrolyte in a discharged battery is more likely to freeze and so destroy the battery. See also page 164.


Electrical system

185

Batteries, charging WARNING!

L64558A

Always remove the cell caps during rapid charging of the batteries. When a battery is being charged an explosive mixture of oxygen and hydrogen is formed. A short circuit, an open flame or a spark in the neighbourhood of the battery can cause a powerful explosion. Always switch off the charging current before the charging lead clips are disconnected. Ventilate well, especially if the battery is charged in a confined space. The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately. Wash with soap and plenty of water. If you get splashes of electrolyte in your eyes or on any other sensitive part of your body, at once rinse with plenty of water and seek medical advice immediately. 1 Connect 2 Charge 3 Operate

Electrical distribution box Relays and fuses are positioned in the electrical distribution box behind the operator seat and become accessible after the cover for the electrical distribution box has been opened. A decal on the inside of the cover shows which current consuming device is connected to the respective relay and fuse. Never install a fuse with a higher rating than that given on the decal (there is a risk of damage or fire on the circuit board). If a fault should arise in one of the relays, this can be temporarily remedied by replacing the faulty relay with another relay which has a less important function.

Welding

:

The following actions must be taken before starting electric welding on the machine or on attachments connected to the machine: 1 Turn off the battery disconnect switch. 2 Disconnect the batteries, both plus and minus terminals. 3 Unplug the electronic control units. For further information, contact a workshop authorised by Volvo CE. 4 Connect the welder's ground connection as close as possible to the welding point, and make sure that the current does not pass through a bearing. See also page 162.


186

Electrical system Alternator belt, checking (workshop job) Check the belt tension every 500 hours.

WARNING! The engine must be stationary when checking the belt tension rotating parts can cause injuries.

Checking and adjusting 1 Loosen bolts (B) and adjust with adjusting screw (A) until the correct belt tension is obtained. At correct tension, it should be possible to deflect the belt approx. 15 mm (0.6 in) applying a fairly hard pressure. 2 Then lock with bolts (B). The alternator installation is sensitive to faulty connection, therefore always follow the instructions below:

Disconnecting battery

Turn off the battery disconnect switch.

Battery and alternator cables must not be disconnected while the engine is running. This can damage the alternator.

Disconnect and insulate the battery cables before carrying out any work on the alternator equipment.

Battery connection

Turn off the battery disconnect switch.

The connecting terminals on the batteries must under no circumstances be confused. The respective pole studs have a stamped-in + or sign. If the cables are wrongly connected, the alternator rectifier is destroyed immediately.

Alternator with air filter (optional equipment) Replace the filter every 2000 hours.

1000755

Air filter, alternator



Electrical system

187

Headlamps, adjusting The headlight adjustment is of great importance in order to avoid dazzling on-coming traffic. The headlights are of the asymmetrical type, which means that one has to take extra care when adjusting. Place the machine, which must not be loaded, on level ground at right angles to a wall or similar. Adjust the upper boundary (H) of the low beams at a distance of (L) from the headlamps. Check the distance (Y) between the centres of the beams with the high beams switched on. The distance should be the same as between the headlamps on the machine.

Y

X

H

L

R L69004A

Adjusting measurements L110F/L120F L = 5000 mm (16 ft 4.8 in) H = 0.85 multiplied by (1385 mm (4 ft 6.5 in) + R) Y = 1980 mm ((6 ft 6.0 in) X = 1385 mm (4 ft 6.5 in) R = The distance from the floor / the ground to the centre of the front wheel hub


188

Electrical system Relays and fuses Relays and fuses are positioned in the electrical distribution box behind the operator seat and become accessible after the cover for the electrical distribution box has been opened. A decal on the inside of the cover shows which current consuming device is connected to the respective relay and fuse. Never install a fuse with a higher rating than that given on the decal (there is a risk of damage or fire on the circuit board). If a fault should arise in one of the relays, this can be temporarily remedied by replacing the faulty relay with another relay which has a less important function.

Bulb, changing Replacing light bulb, HID Replacement of bulbs or other work on the working lights should be carried out at a workshop authorised by Volvo CE. IMPORTANT! The bulb contains mercury. When replaced, it should therefore be taken care of according to local regulations for dangerous waste.

Working lights by cab roof, HID If the machine as an option is equipped with working lights which have a bulb of the HID type (High Intensity gas Discharge lamp), the following applies:

WARNING! The bulb stores energy after it has been turned off. Wait for at least five minutes after it has been turned off before touching the bulb.


Transmission

189

Transmission Transmission oil level, checking Check the oil level when the machine is warm every 500 hours. When checking, the machine should stand on level ground, with the gear selector in neutral position and applied parking brake. When checking the oil with the engine running and the machine at operating temperature, the level should be between the markings High and Low on the lower part of the glass. LOW HIGH

Transmission oil, changing

LOW

Change oil every 2000 hours.

WARNING! 1027005

Level sight glass, transmission oil

Take care when changing oil, as hot oil can cause burns to unprotected skin.

The oil is drained at the drain plug. Fill with oil through the filler pipe. Oil capacity when changing: approx. 38 litres (10.0 US gal) Oil quality grades, see page 215.

Take care of filters/oils/liquids in an environmentally safe way, see page 161. Filler pipe, transmission oil


190

Transmission Transmission, changing oil filter Replace the filter every 2000 hours. The oil filter is of the "spin on" type and is accessible from underneath on the left side of machine. The filter cannot be cleaned, but must be replaced.

L66462A

Oil filter, transmission

Transmission breather filter, changing Replace the filter every 2000 hours. The filter is combined with the filter for the hydraulic oil tank. The filter cannot be cleaned, but must be replaced. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

Transmission, cleaning suction filter A

Clean the filter every 2000 hours. The suction filter is located in the bottom of the transmission housing. 1 Remove the cover and clean. 2 Install a new gasket between cover and transmission housing. 3 Also change the O-ring on the suction filter's connecting pipe. 4 Fill oil. 5 Check that there are no leaks.

B 1004318

A B

Drain plug Cover, suction filter


Axles

191

Axles Axle oil, changing Change the oil every 2000 hours. A first oil change should

WARNING! Take care when changing oil, as hot oil can cause burns to unprotected skin. Front axle A Level check and filling B Draining

take place at the 1000 hour warranty inspection.

Draining Drain the oil from axle (B) and hub (C) respectively. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

A

Filling

B

Operate the machine for a few minutes after filling. Check the level again, top up if needed.

Axles, capacities L67011A

Rear axle A Level check and filling B Drain point

Oil capacity front axle when changing, 36 litres (9.5 US gal) (incl. differential carrier assembly and hubs). Oil capacity rear axle when changing, 41 litres (10.8 US gal) (incl. differential carrier assembly and hubs). Oil quality grades, see page 215.

Rear axle bearing Check the oil level every 500 hours. Change oil in the front rear axle bearing every 4000 hours. The rear rear axle bearing is maintenance-free.

C

L63534B

C

Drain point

Propeller shafts and back-up bearings, lubrication Lubricate propeller shaft and back-up bearing every 500 hours, see page 203.


192

Axles Axles, changing breather filters Front axle Replace the filter every 2000 hours. The front axle breather filter is positioned inside the front cover on the left side of the machine.

Breather filter, front axle

Rear axle Replace the filter every 2000 hours. The rear axle breather filter is positioned inside the engine cover on the right side of the machine.


1020373

Breather filter, rear axle


Brake system

193

Brake system The brake system is all hydraulic and uses the same oil tank as the working hydraulics and the steering system. Checking and changing oil, see page 200. Before opening the system or check-tightening leaking couplings and connections, the pressure in the brake system must be released. This is done by turning off the engine and pressing down the brake pedal repeatedly (3040 times).

WARNING! An accumulated pressure remains in the brake system even when the engine has been turned off. If the system is opened without first being depressurized, high-pressure oil will jet out.

Discarded accumulators should be taken care of by a workshop and "punctured".

There is a risk of explosion if an accumulator is heated.

Brakes, checking L62829D

Cap nut on wear indicator

Check brake disc wear every 1000 hours. 1 Start the engine to charge the brake system. 2 Stop the engine and apply the brake. NOTE! The brake must be applied during the entire wear check. 3 Remove the cap nut on the wear indicator and press in the pin against stop. The position of the flat face on the pin indicates how much the brake disc is worn. If the face is level with the flat face on the nipple, the brake disc is worn out and must be replaced by a workshop authorised by Volvo CE. 4 Install the cap nut on the wear indicator and carry out the same check of the other brake discs.

Brakes, air bleeding L62829C

Brake discs, checking

If bleeding of the brake system is necessary, this should be done by a workshop authorised by Volvo CE. Brake test, checking service brakes, see page 109.

Parking brake, checking

WARNING! A brake test may only be carried out in an area where there is no risk of accidents. 1 Apply the parking brake with the switch. 2 With 3rd gear engaged and engine at full speed, the machine should remain stationary.


194

Tyres

Tyres Tyres, checking air pressure WARNING! Tyres can explode when they are being inflated, which can lead to accidents. Use a self-attaching air chuck with a hose long enough to let you stand off to the side of the tyre, and as far away as possible, when inflating the tyre. Normally, follow the recommended air pressures, see page 231. Special ground conditions may require adjustment of the air pressure. Follow the tyre supplier's instructions and do not exceed the maximum permitted air pressures. The tyre pressure may have been raised before the machine was delivered from the factory. Therefore, check and adjust the tyre pressure according to recommendations, before putting the machine to work for the first time.

WARNING! Repairs or welding on a rim with an installed and inflated tyre may cause the rim to crack or the tyre to explode. Change and repair jobs on tyres and rims must be done by specially trained personnel. The instructions stated below apply to an inflated tyre where the pressure needs to be increased. If the tyre has lost all pressure, a trained service engineer should be called in. When checking the air pressure, the tyre should be cold and the machine be without a load. Ask all other persons to leave the danger area (in front of the rim). Stand by the tyre's tread. Tyre installed on a split rim may explode causing injury or in the worst case death. Use a long air hose (with a self-attaching air chuck) which allows you to stand outside the danger area. Tyres on stored wheels (spare wheels) should be kept in a lying down position and only be inflated sufficiently to keep the rim parts in position. Do not re-inflate a tyre, if the machine has been operated with a tyre pressure that has been below 80% of the lowest recommended tyre pressure according to the specifications, or if the tyre and/or rim are obviously damaged or are suspected of being damaged.

Wheel bolts, check-tightening After having changed a tyre or if the wheel has been removed and installed for any other reason, the wheel bolts must be check-tightened after eight hours of operation. Tightening torque: 600 Nm (443 lbf ft)


Cab A

195

Cab

B

Cab, cleaning and changing ventilation filter

1026286

A B

Pre filter Main filter (inside the plastic casing)

The cab ventilation filters consist of prefilter and main filter. The machine is often used in dusty conditions, and therefore it is delivered with filters that meet efficiency class F8 according to EN 779:2002. The filters reduce the risk of silicosis and also reduce particles such as quartz in fine fractions, pollen, bacteria, and mold/fungus spores. The machine is delivered with filters according to this classification, which also is recommended when changing. Contact your dealer for further information. Clogging of the filters depends entirely on the machine's operating conditions, but the filters should be checked once a week. The main filter should be replaced every 2000 hours and the prefilter every 1000 hours. NOTE! The interval between filter replacements can be increased or reduced depending on how dusty the working environment is. NOTE! The cab filters are only intended to separate particles (dust) from the air. Any dangerous gases are not trapped by the filters.

Cleaning 1 Use a respirator (face mask). 2 Open the side cover and remove the filters. 3 Shake the filters carefully without damaging them. No compressed air or vacuum-cleaners.

Carbon filter (optional equipment) The carbon filter is a main filter intended for use in conditions where there is a need to reduce odours from organic gases or gases containing sulphur. The filter meets the same particle efficiency class as the standard main filter.

Asbestos filter (optional equipment) The asbestos filter is a main filter especially intended for use in conditions where there may be asbestos dust, but of course, it is effective against all other kinds of dust when the operator needs highly filtered air in the cab. The filter meets the standards according to EN 1822:1 filter class H13. Pay attention to the national regulations regarding work in the environment in question.


196

Cab Operator seat, lubrication

B

If squeaking noises arise, the seat should be lubricated as shown below: 1 Remove bolts (A). 2 Fold up seat (B). 3 Lubricate linkage (C) on both sides with oil. 4 Lubricate spring ends (D) with grease. 5 Remove the four plastic plugs retaining the rubber bellows and push down the bellows, Lubricate linkages (E) on both sides with oil. 6 Lubricate slide rails (F) on both sides with grease.

C

D

A

L68991A

E

F

L68991B

Washer fluid reservoir The washer fluid reservoir is located in the toolbox on the machine's right side. Make sure that there is sufficient anti-freeze in the washer fluid when there is a risk of frost. Top up when necessary. Make sure that the cap on the reservoir is securely tightened and that the reservoir is clean on the inside.

1026931

Washer fluid reservoir


Air conditioning

197

Air conditioning Ask personnel at a workshop authorised by Volvo CE to check the air conditioning once a year. Rules for handling refrigerant, see page 165.

Compressor belt, checking and adjusting tension (workshop job) Check the belt tension every 500 hours.

WARNING! The engine must be stationary when checking the belt tension rotating parts can cause injuries. 1 Loosen bolts (B) and adjust with adjusting screw (A) until the correct belt tension is obtained. At correct tension, it should be possible to deflect the belt approx. 15 mm (0.6 in) applying a fairly hard pressure. 2 Then lock with bolts (B). In order to prevent leakage and to safeguard the lubrication of the seals in the air-conditioning compressor, the air conditioning should be run for at least five minutes once a month. At temperatures below freezing, 0 °C (+32 °F), the unit must be run indoors, as the power supply to the compressor lead is switched off by the thermostat whenever the evaporator temperature is below +1 °C (+34 °F). NOTE! Make sure that the exhaust gases are extracted or removed by ventilation in a suitable way.


198

Air conditioning Condenser Cleaning

A

NOTE! High-pressure wash must not be used. Clean the condenser at regular intervals as follows: 1 Open up the radiator casing. 2 Blow the condenser clean from underneath with compressed air. 3 Close the radiator casing.

1004322

A

Condenser

IMPORTANT! If the pressure in the system becomes too high because of a clogged condenser, the air conditioning will cut out. The condenser must first be cleaned before the system is restarted with the switch.

Evaporator Cleaning NOTE! High-pressure wash must not be used. Clean the evaporator at regular intervals. Simpler cleaning can be done with the evaporator in place. Use a soft brush, not compressed air. For a more thorough cleaning, the evaporator must be loosened from its mountings and cleaned from the rear. Therefore, this ought to be carried out at a workshop authorised by Volvo CE. L65987D


Bucket teeth

199

Bucket teeth WARNING! Striking metal parts with a hammer may cause metal chips to fly up towards the eyes or other body parts. Always use protective eyeglasses, hard hat, and protective gloves when working with attachments.

Special tool

Bucket teeth, changing A special tool may be ordered to facilitate replacement of teeth. The tool are available in different sizes depending on tooth size. Contact your dealer for further information.

Removing tooth 1 Lower the bucket to the ground and angle it slightly upward. 2 Clean the opening for tooth adapter locking device. 3 Drive out the lock device with a hammer and the special tool or another suitable drift. 4 Remove tooth.

Knock out the locking device

Installing tooth 1 Clean the front part of the tooth adapter and the hole for the locking device. 2 Install the tooth so that the guide lugs fit in the tooth adapter recesses.

Locking device A Steel pin B Lock retainer

3 Replace lock retainer (B) with a new part. 4 Install the locking device so that the chamfered part points downward and the lock retainer points forward. 5 Knock down the locking device with a hammer until it is level with the upper part of the tooth adapter. 6 Drive down the lock device further with a hammer and the special tool or another suitable drift until the upper part is just below the line marking in the hole. Replace the steel pin in connection with replacement of tooth adapter.

1019824

The locking device should be just below the scored line.


200

Hydraulic system

Hydraulic system The same hydraulic oil tank is used for working hydraulics, brake and steering systems. Any work on the system requires great demands on cleanliness. Even very small particles can cause damage or clog up the system. Therefore, wipe areas in question clean before any work is carried out. The pressure-limiting valves for the hydraulic system are set to the correct value at the factory. If the valves are altered by any person other than service personnel at a workshop authorised by Volvo CE, the guarantee from the manufacturer will be void.

Hydraulic oil NOTE! If the machine is provided with biologically degradable hydraulic oil, the same type of oil must be used when topping up and when changing hydraulic oil. Different types of biologically degradable hydraulic oils must not be mixed. Mineral oil must not be used together with biologically degradable hydraulic oil. When changing from mineral oil to biologically degradable hydraulic oil, contact a workshop authorised by Volvo CE.

Oil level, hydraulic oil

Hydraulic oil level, checking Check the oil level every 250 hours. The level should stand between the Max. and Min. marks on the level sight glass (positioned on the left side of the machine). NOTE! The oil level should be checked when the lifting arms are in their lowest position and with the attachment flat on the ground. Filling is done from the top of the hydraulic tank.

Hydraulic oil, changing (working hydraulics, brake system, and steering system) Change oil every 4000 hours if the system is filled with mineral hydraulic oil or Volvo Biodegradable Hydraulic Oil 46. Change oil every 2000 hours, if the system is filled with any other biologically degradable hydraulic oil. NOTE! When using attached external hydraulic equipment, e.g. road sweeper, drill, snow blower or similar, the oil should be changed at shorter intervals, i.e. every 1000 hours.

WARNING! Take care when changing oil, as hot oil can cause burns to unprotected skin.

A A B C

B

C

Breather filter Return oil filter Hydraulic oil filling point

1004323

Oil capacity of the hydraulic tank when changing: approx. 133 litres (35.1 US gal). Oil quality grades, see page 215.


Hydraulic system

201

Draining NOTE! Use the same hose as is used for draining the engine oil. Temporarily replace the rubber hose with a 3/4" inside diameter hose sufficiently long to reach the collecting vessel. The draining point is positioned behind the side plate on the left side. 1 Operate the machine until the oil reaches normal working temperature. 2 Stand the machine on level ground with the bucket (attachment) lowered to the ground. 3 Stop the engine and release the pressure in the brake system by depressing the brake pedal several times. Drain the hydraulic oil via the draining point.

Hydraulic system, draining sludge

Draining, hydraulic oil

Drain sludge and condensation water from the hydraulic oil tank via the draining point every 1000 hours.

Filling 1 Fill with oil to correct level. 2 Start the engine and operate the lifting and tilting cylinders to both end positions. 3 Top up with oil when required. Check that there are no leaks. Take care of filters/oils/liquids in an environmentally safe way, see page 161.

Hydraulic system, changing return oil filter Replace return oil filter every 2000 hours. 1 Remove the cover.

A

B

A Breather filter B Return oil filter C Hydraulic oil filler point

C

1004323

2 Lift out and take apart the filter insert. 3 Remove the filter which is of the disposable type and install a new filter. Check the seal rings when installing.

Hydraulic system, changing breather filter The filter should be replaced every 2000 hours. The filter cannot be cleaned, but must be replaced. The filter is combined with the filter for the transmission.


202

Hydraulic system Accumulators, depressurizing WARNING!

L66320A

Always depressurize the hydraulic system and turn off the electric power with the battery disconnector before starting a job. The pressure in the accumulators for brake system, Boom Suspension System and servo system is released as shown below:

Brake system 1 Stop the engine. 2 Depress the brake pedal several times (3040 times).

Boom Suspension System (BSS) If there is a need to depressurize the accumulators for the Boom Suspension System, contact a workshop authorized by Volvo CE.

Servo system 1 Stop the engine. 2 Ignition switch in position 1. 3 Move the control levers forward and backward several times.

WARNING! Discarded accumulators contain pressurized gas and may explode. Let a workshop authorized by Volvo CE handle discarded accumulators.


Lubrication

203

Lubrication Bearings, greasing The service life of bushings and pivot pins can be extended considerably, if the machine is greased regularly and in the correct way. The greasing of bearings has two main purposes: Add grease to the bearing to reduce friction between pin and bushing.

L63189A

Replace old grease that may contain dirt particles. The grease in the space inside the outer seal collects dirt and prevents dirt and also water from penetrating into the bearing. Wipe off grease nipples and grease gun before greasing, so that dirt and sand is not introduced through the grease nipples. Grease the bearing until new clean grease is forced out through the outer seal. For recommended grease, see page 217. Between 10 and 15 strokes with a normal hand-held grease gun is required to grease one of the bearings for the lifting arms.


204

Automatic greasing system

Automatic greasing system The machine may be equipped with an automatic greasing system which automatically greases many points according to a preselected lubrication cycle. The automatic greasing system should be inspected regularly and should be co-ordinated with other regular maintenance and control. Checking and adjusting grease cycles is done using the keypad and the display unit, see page 40. Check the following regularly: that there is sufficient lubricant in the reservoir. Top up as needed, see page 206. NOTE! Too low lubricant level constitutes a great risk of air entering the system (the most common cause of operating problems). that the system functions. Carry out the system test on page 208. that the lubricant reservoir is undamaged. that the connections do not leak. that the dust guards for quick-action couplings are installed and undamaged. that the lubrication lines are undamaged and well secured. that all lubrication points are lubricated (that lubricant is forced out at bearings and joints). NOTE! Remember to lubricate by hand the lubrication points which are not included in the automatic greasing system. See the ordinary lubrication chart.

1 2 3 4 5 6 7 8 9 10 11 12 13

Pump unit with automatics Battery Metering block Metering valve V-ECU Lubrication pressure sensor Main line A Main line B Ignition switch Switch Control lamp System testing button Filling point



205

6 8

4

3

L64489C

2

1 5

7

Lubrication points 1 Lifting frame

5 Propeller shafts, front and rear support bearings

2 Hydraulic attachment bracket

6 Frame joint bearings, upper and lower bearings

3 Lifting cylinder, front and rear bearings

7 Steering cylinder, front and rear bearings

4 Tilting cylinder, front and rear bearings

8 Bucket attachment, upper and lower attachments


206

Automatic greasing system Filling lubricant Lubricant must be topped up before the level falls below the minimum marking on the reservoir. On the pump unit there is a filler connection (grease nipple) to which a hand pump or an industrial pump are connected when filling. NOTE! If and industrial pump is used, the filter between connection and pump must be cleaned regularly. A partly blocked filter can easily burst, with a consequent great risk of small particles entering the lubrication system. This may in turn lead to a breakdown in the lubrication system. Proceed as follows: 1 Carefully clean the filler connection and the coupling on the filler hose.

Filler connector

2 Fill the filler hose completely full with grease before beginning to fill. This will prevent air from entering the system. 3 Remove the protective cap on the filler connection and connect the coupling to the filler connection. 4 Fill with lubricant to the maximum level on the reservoir.*) If it is hard to pump in the lubricant, either the filter behind the filler connection is blocked or there may be dirt in the filler nipple itself. Clean the filter, if required replace the nipple and try again. 5 Re-install the protective cap. 6 Keep the lubrication pump in a dust-free place, so that it will not be exposed to dirt. *) If the reservoir is filled above the maximum level, the surplus lubricant will be drained through the ventilation hole on the left side of the reservoir. Any air under the plate in the reservoir is also drained through the ventilation hole.



207

Recommended lubricants The system requires that the lubricant is clean and possible to pump at the prevailing temperature. Therefore use lubricant of a recommended NLGI class. A lower NLGI class grease, may reduce the lubrication effect with increased wear as a consequence.

Do not mix different types of lubricants. When changing, all lubricant must be changed, not only in the reservoir.

There must be no additives of graphite or Teflon in the lubricant.

The use of molybdenum disulphide (MoS2) is only permitted if: the lubricant is of a very high quality and does not contain more than 5 % MoS2. the lubrication system is regularly checked to provide reliable operation. the main lines are flushed through at least once a year.

Recommended lubricants Lowest temperature

Highest temperature

Lubricant type, NLGI

Above 25 °C (13 °F)

80°C (176 °F)

2

Below 25 °C (13 °F)

0 °C (32 °F)

0/1

Below 25 °C (13 °F)

+80 °C (176 °F)

Synthetic 2

Below 25 °C (13 °F)

0 °C (32 °F)

Synthetic 0 / 1

NOTE! Special tools are required for fault tracing, adjusting and repairing the control unit. Therefore, contact qualified service personnel when required.

Changing greasing interval If the preselected greasing interval does not suit the operating and loading conditions to which the machine is exposed, the interval can be changed using the keypad and the display, see page 29. 1 Turn the ignition key to position 1 (running position). 2 Choose "Service" with the keypad. 3 Select "Central lubrication" with the arrow keys and press SELECT. 4 Select "Interval" with the arrow keys and press SELECT. 5 Select the greasing interval you want to change to with the arrow keys and press SELECT. 6 Wait 45 seconds before turning the start key to 0 (selected interval on the display may return to earlier interval, but the change will take place after 45 seconds). NOTE! If the ignition key is turned to position 0 within 45 seconds, the latest selected lubrication cycle will be erased. Therefore, wait for at least 45 seconds after setting before turning the start key to position 0. 7 Turn the start key to position 0 and wait until the display shuts down. 8 Turn the start key to position 1 (operating pos.) and check that the correct greasing interval is shown on the display. To change greasing interval again, the start key must be turned to position 0. When the display has shut down, turn the start key to position 1 again, now a new greasing interval can be chosen.


208

Automatic greasing system System test In order to check the function of the greasing system, or to initiate an extra lubrication cycle after for example the machine has been washed, a system test can be carried out. The test button, which is used to begin a system test, is positioned at the front on the pump. A test cycle can only be carried out when the pump is between two ordinary lubrication cycles (not during an ongoing lubrication cycle). Single test lubrication cycle The pump only carries out one lubrication cycle via one main line. May be used after a wash in order to obtain an extra lubrication cycle. 1 Turn the ignition key to position 1 (running position). 2 Press in the test button for 26 s. 3 The lubrication cycle starts. 4 The test cycle is ended automatically.

Test button

If the test lubrication cycle has been used to obtain an extra lubrication cycle after a wash, the test button should be pressed once more to lubricate the other main line. Continuous test lubrication cycle The pump carries out an unlimited number of lubrication cycles, i.e. it continuously pumps out lubricant alternately via the two main lines. This is used for bleeding the system of air. 1 Turn the ignition key to position 1 (running position). 2 Press the test button for more than 6 s. 3 The lubrication cycle starts. 4 End the test cycle by turning the start key to position 0. The test cycle does not end automatically.

Bleeding the system

A B

The pump must not be activated for longer than five minutes. 1 Make sure that the lubricant reservoir has been filled up to the max. mark. 2 Remove the plugs in metering block (C) which is furthest away from pump unit (D). 3 Turn the ignition key to position 1 (running position).

C

A

B

4 Press the test button for more than six seconds, which will initiate a continuous test cycle. 5 When lubricant, free from air, emerges from one of main lines (B), the air bleeding is completed in that main line.

D

6 Turn the ignition key to the "0" position and install plug (A). 7 Follow points 36 in order to bleed the other main line. 8 Test the system using the method Single test lubrication cycle, see page 207. L68946B

Cleaning with high-pressure wash Normally water cannot penetrate into the system. However, during a high-pressure wash the risk increases and the pump unit should be protected, as water, which has entered the system, does not disappear by itself, but could instead cause operating problems. After a high-pressure wash a Single test lubrication cycle should be carried out to obtain extra lubrication.


Lubrication and service chart

209

Lubrication and service chart Other service and maintenance jobs not included in the service and lubrication chart requires trained service personnel or special equipment. Contact a workshop authorized by Volvo CE for learn more about these.

Symbol key The following standard symbols are used in the service and lubrication chart.

Lubrication

Engine L66544A

Transmission

Grease nipple

L66542A

1027023

Hydraulic system

Oil/liquid L66627A

L66543A

Brake system

L66637A

L66625A

Axles

Filter

Air filter L66626A

Fuel system

Level check

L66546A

L66636A

Battery

Belt tension L66639A

L66633A

Coolant L66629A

Control lamps L66638A

Draining Air conditioning L66632A

L66640A


210


Lubrication and service chart Checks, oil changes and lubrication Intervals: Daily, 10, 50, 250, and 500 hours (symbol key, see previous page)

1

12 500h 250h 50h 10h

11

12

2

7

3 4

4

2

5 6 10

7 3

2 1

9

4 3

7

8

10h 50h 250h 500h 1000h

.

2000h

4000h

6000h

1030486



Item

Page

211

Measure DAILY (every 10 hours)

1

184

Check function of control lamps

180

Check oil-bath air cleaner oil level (optional equipment) Check travel lights, working lights, reversing alarm EVERY 50 HOURS After carrying out Daily service

4

173

Check engine oil level

12

181

Check coolant level

194

Check tyres (air pressure and damage) 5)

203

Lubricate the lifting frame lower bucket pins 1)

2

EVERY 250 HOURS After carrying out Daily and 50 hour services 3

200

Check hydraulic system oil level

6

177

Drain the fuel system water trap

7

184

Check battery electrolyte level Check for any leaks

2

203

Lubricate lifting frame 3)

8

203

Lubricate the frame joint upper bearing 3)

8

203

Lubricate the steering cylinder bearings 3)

178

Change fuel prefilter EVERY 500 HOURS After carrying out Daily, 50, and 250 hour services

4

173

Change engine oil and replace oil filter 2)

5

176

Replace fuel filters

11

186 183 197

Check belt tension, alternator (workshop job) Check belt tension, coolant pump, and fuel feed pump (workshop job) Check belt tension, compressor (workshop job)

10

189

Check transmission oil level

9

191

Lubricate propeller shafts and support bearing 4)

1) 2) 3) 4)

During difficult operating conditions these should be lubricated daily. For conditions which have to be met, if the interval is to apply, see page 173. In aggressive/corrosive environment lubrication should be carried out every 50 hours. In aggressive/corrosive environment lubrication of the universal joints should be carried out every 50 hours. Splined joints should only be lubricated when necessary. 5) If the machine is used for handling sharp rocks, a check should be carried out daily.


212


Lubrication and service chart Checks, oil changes and lubrication Intervals: Daily, 1000, 2000, 4000, and 6000 hours. (For symbol key, see page 209)

26

20

19

16

23 6000h 4000h 2000h 1000h

16 27 18

31

18 21 21

15

22

25 24

17 32 1000h

30

2000h

F

29

R

4000h

32

6000h

1030487

28

33

29

30



Ite m

Page

213

Measure EVERY 1000 HOURS After carrying out Daily, 50, 250, and 500 hour services

17

201

Drain sludge and condensation water from the hydraulic system

21

179

Replace air cleaner primary filter

16

195

Replace cab ventilation filter (prefilter) 1)

28

203

Lubricate lower bearing on frame joint

15

203

Lubricate cab door hinges 4)

32

193

Checking service brakes

33

193

Checking parking brake Workshop jobs (should be carried out by an authorised workshop)

30

193

Checking brake disc wear EVERY 2000 HOURS After carrying out Daily, 50, 250, 500, and 1000 hour services

29

191

Change oil in front and rear axles

25

189

Change transmission oil and clean suction strainer

23

190

Replace transmission breather filter

24

190

Replace transmission oil filter

20

201

Replace hydraulic system return oil filter

19

201

Replace hydraulic system breather filter

16

195

Replace cab ventilation filter (main filter) 1)

21

179

Replace air cleaner secondary filter

18

192

Replace front and rear axle breather filters

22

178

Replace the fuel system breather filter

31

Checking freezing point of the coolant 186

Replace alternator air filter (optional equipment) Workshop jobs (should be carried out by an authorised workshop) Check valve clearance, engine EVERY 4000 HOURS After carrying out Daily, 50, 250, 500, 1000 and 2000 hour services

26

200

Change hydraulic system oil 2) EVERY 6000 HOURS After carrying out Daily, 50, 250, 500, 1000, 2000 and 4000 hour services

27

182

Change coolant 3)

1) Replace the cab filter more often when required 2) If the system is filled with mineral hydraulic oil or Volvo Biodegradable Hydraulic Oil 46, the oil should be changed every 4000 hours (In case of other biologically degradable hydraulic oil, the oil should be changed every 2000 hours). 3) Change coolant every 6000 hours or at least every fourth year. 4) Lubricate more often when required. Machines with automatic greasing, see page 204.


214

Specifications

Recommended lubricants

215

Specifications Recommended lubricants For questions about oils, lubricants and extreme outdoor temperatures, contact your dealer for information. Oil grade ENGINE

Recommended viscosity at varying ambient temperatures

Volvo Ultra Diesel Engine Oil or Volvo Super Diesel Engine Oil or VDS-3 or VDS-2 + ACEA-E7 or VDS-2 + API CI-4 or VDS-2 or VDS + ACEA-E3 or ACEA: E7, E4 or API: CI-4, CH-4, CG-4 For recommended change intervals according to the oil's grade and sulphur content in the fuel, see page 216.

AXLES HUB REDUCTION GEARS

Volvo Super Wet Brake Transaxle Oil Volvo WB 102 1)

WB102 1053112

TRANSMISSION

Volvo Automatic Transmission Fluid AT102 2) or Volvo Automatic Transmission Fluid Volvo Transmission Oil 97341

Volvo Automatic Transmission Fluid AT102 / Volvo Automatic Transmission Fluid

1053113

HYDRAULIC SYSTEM

Volvo Super Hydraulic Oil Swedish norm SS 15 54 34

V46/AV 46 V68/AV 68 ISO VG 46 HV

Cooling system

1) 97304 2) 97342

Available as an alternative there is also Volvo Biodegradable Hydraulic Oil 46. For further information contact your local Volvo Service. Volvo Coolant VCS See page 181.

ISO VG 68 HV

1015382

Specifications

216


Engine oil Follow recommended change intervals according to the oil's grade and sulphur content in the fuel. Sulphur content of the fuel Oil grade

< 0.3 %

0.30.5 %

> 0.5 %

Oil change interval Volvo Ultra Diesel Engine Oil Volvo Super Diesel Engine Oil VDS-3

500 hours

250 hours

125 hours

250 hours

125 hours

75 hours

125 hours

75 hours

50 hours

VDS-2 plus ACEA-E7 VDS-2 plus API CI-4 VDS-2 VDS plus ACEA-E3 ACEA: E7, E4 API: CI-4, CH-4, CG-4

Coolant Only use Volvo Coolant VCS when topping up or changing coolant. To avoid damage to engine and cooling system, different coolants or corrosion protection must not be mixed. When using concentrated Volvo Coolant VCS and clean water, the mixture should contain 4060 % concentrated coolant and 6040 % clean water. The amount of concentrated coolant must never be less than 40 % of the total mixture, see table below. Freeze protection down to

Mixed-in amount of concentrated coolant

25 °C (13 °F)

40 %

35 °C (31 °F)

50 %

46 °C (51 °F)

60 %

The concentrated coolant must not be mixed with water that contains a high degree of lime (hard water), salt or metals. Clean water for the cooling system must also meet the following requirements:

Description

Value

Total number of solid particles

< 340 ppm

Total hardness

< 9.5 ° dH

Chloride

< 40 ppm

Sulphate

< 100 ppm

pH value

5.59

Silica

< 20 mg SiO2/litre

Iron

< 0.10 mg Fe/litre

Manganese

< 0.05 mg Mn/litre

Electrical conductivity

< 500 μS/cm

Organic content, COD-Mn

< 15 mg/litre

When there is doubt as to the quality of the water, ready-mixed Volvo Coolant VCS, which contains 40 % concentrated coolant, must be used. Do not mix with other ready-mixed coolants, as this may cause engine damage.

Specifications


217

Fuel Quality requirements: The fuel should at least meet the legal requirements, and national and international standards for marketed fuels, for example: EN590 (with nationally adapted temperature requirements), ASTM D 975 No. 1D and 2D, JIS KK 2204. Sulphur content: According to current legal requirements (the sulphur content must however not exceed 0.3 percent by weight), see also page 173. Bio-diesel fuel Vegetable oils and / or esters, also called bio-diesel, (e.g. rape-seed methyl ester RME fuel), which are offered on certain markets both as pure products and as mixed into the diesel fuel. Volvo CE accepts a maximum intermix of 7% bio-diesel fuel in the diesel fuel, ready mixed from the oil companies. A higher intermix than 7% of bio-diesel fuel may cause: Increased emission by nitrogen oxide, (thereby not meeting legal requirements) The short service life of motor and injection system Increased fuel consumption Altered engine output Shortening the engine oil change interval to a half Shortened service life of rubber materials in the fuel system Less good cold handling properties of the fuel Limit storage time for the fuel, which may cause clogging up of the fuel system if the machine is laid up for a longer period Warranty condition The warranty does not cover damage caused be an intermix of more than 7% of bio-diesel fuel.

Lubrication grease Volvo Super Grease Lithium EP2. Or corresponding grease on lithium base with EP additives and consistency NLGI class 2. If the machine is provided with automatic greasing system, other recommended lubricants apply. Rear axle bearings Front rear axle bearing: Axle oil according to Recommended Lubricants, see page 215. Rear rear axle bearing:* Rubens HT2 (Q8) Chevron Ultra Duty No. 2 Texaco Starplex HD2 Almagard 3752 *Rear rear axle bearing is maintenance-free, and only greased in connection with a service.

Specifications

218

Change volumes

Change volumes Capacities

When changing

Engine oil, incl. filter

21 litres (5.5 US gal)

Transmission incl. filter


Front axle incl. hub reduction gear


Rear axle incl. hub reduction gear


Hydraulic system Hydraulic oil tank

215 litres (56.8 US gal) 133 litres (35.1 US gal)

Fuel tank (available) Cooling system Oil-bath air cleaner (optional equipment)

Total

269 litres (71.0 US gal) 38 litres (10.0 US gal)

40 litres (10.6 US gal) 9.1 litres (2.4 US gal)

Specifications

Interval between changes

219

Interval between changes Oil and fluid changes

Hours

Engine

500*

Coolant

6000**

Transmission, at the same time clean suction strainer

2000

Front and rear axles

2000***/4000****

Hydraulic system (working hydraulics, brake system and steering system)

2000/4000*****

*) Regarding conditions required if the interval between engine oil changes is to apply, see page 128. **) Change coolant every 6000 hours or at least every fourth year. ***) First change should take place after 1000 hours. ****) If separate axle oil cooling (optional equipment) is installed, the interval is 4000 hours. First change should take place after 1000 hours. *****) If the system is filled with mineral hydraulic oil or Volvo Biodegradable Hydraulic Oil 46, the interval is 4000 hours If another biologically degradable hydraulic oil is used, the interval is 2000 hours.

Filter changes

Hours

Engine, oil filters

500*

Engine, air cleaner (primary filter)

1000

Engine, air cleaner (secondary filter)

2000

Engine, coolant filter

1000

Fuel prefilter

250

Fuel filters, prefilter / water trap

500**

Fuel system, breather filter

2000

Oil-bath precleaner, cleaning filter insert (optional equipment)

2000

Transmission, oil filter

2000

Transmission, breather filter

2000

Axle oil cooling filter (optional equipment)

4000

Drive axles, breather filter

2000

Cab, ventilation filters

2000***

Hydraulic system, return oil filter

2000

Hydraulic system, breather filter

2000

*) Regarding conditions required if the interval between engine oil changes is to apply, see page 173. **) Or when replacing the engine oil filter, which may mean a shorter interval. ***) In case of environment containing asbestos the filter should be replaced every 1000 hours.

Specifications

220

Engine

Engine L110F Designation

Volvo D7E LBE3

Max. output according to ISO 9249, SAE J1349

169 kW (230 hp) at 1700 rpm (28.3 r/s)

Max. torque according to ISO 9249, SAE J1349

1059 Nm (781 lbf ft) at 1500 rpm (25.0 r/s)

Number of cylinders

6

Cylinder bore

108 mm (4.252 in)

Stroke

130 mm (5.118 in)

Cylinder capacity

7.1 litres (433 in3)

Compression ratio

18.1:1

Valve clearance

Method with angular tightening is required

Idling speed, low

13 ± 0.8 r/s (780 ± 50rpm)

Idling speed, high

37.5 ± 0.6 r/s (2250 ± 35rpm)

Air cleaner

Air cleaning in 3 steps Precleaner main filter secondary filter

Lubrication system Oil pressure when operating

400500 kPa (45 bar) (3280 psi)

Oil pressure, low idling min.

60 kPa (0.6 bar) (87 psi)

Fuel system Common rail Feed pressure

600 kPa (6.0 bar) (87 psi)

Cold-starting device

Preheating element in inlet manifold

Intercooler

Air/air

Cooling system Type

Closed system

Thermostat begins to open at

83 °C (181 °F)

Thermostat fully open at

95 °C (203 °F)

Specifications

Engine

221

L120F Designation

Volvo D7E LAE3

Max. output according to ISO 9249, SAE J1349

179 kW (243 hp) at 1700 rpm (28.3 r/s)

Max. torque according to ISO 9249, SAE J1349

1059 Nm (781 lbf ft) at 1500 rpm (25.0 r/s)

Number of cylinders

6

Cylinder bore

108 mm (4.252 in)

Stroke

130 mm (5.118 in)

Cylinder capacity

7.1 litres (433 in3)

Compression ratio

18.1:1

Valve clearance

Method with angular tightening is required

Idling speed, low

13 ± 0.8 r/s (780 ± 50rpm)

Idling speed, high

37.5 ± 0.6 r/s (2250 ± 35rpm)

Air cleaner

Air cleaning in 3 steps Precleaner main filter secondary filter

Lubrication system Oil pressure when operating

400500 kPa (45 bar) (3280 psi)

Oil pressure, low idling min.

60 kPa (0.6 bar)

Fuel system Common rail Feed pressure

600 kPa (6.0 bar) (87 psi)

Cold-starting device

Preheating element in inlet manifold

Intercooler

Air/air

Cooling system Type

Closed system

Thermostat begins to open at

83 °C (181 °F)

Thermostat fully open at

95 °C (203 °F)

Specifications

222

Electrical system

Electrical system System voltage

24 V

Batteries

2 (connected in series)

Battery voltage

12 V

Battery capacity

2 x 140 Ah

Alternator

2280 W / 80 A

Starter motor output

5.5 kW (7.5 hp)

Battery electrolyte density kg/dm3 Fully charged battery

1.2751.285

The battery should be recharged at a density of

1.250

Bulbs

Watt

Socket

Travel lights, low beams

70

PX 26D (H7)

Travel lights, high beams

70

PK 22s (H3)

Parking lights, front

4

BA 9s

Parking lights, rear

10

BA 15s

Tail lights

10

BA 15s

Stop lights

21

BA 15s

Direction indicators, front

21

BA 15s

Direction indicators, rear

21

BA 15s

Cab light

10, 21

BA 15s

Working lights, front halogen (optional)

70

PK 22s (H3)

Working lights, rear halogen (optional)

70

PK 22s (H3)

Guide light in switches

LED

Specifications

Electrical system

223

Relays

RE8701

RE3102

DI08

DI06 DI22

DA

DB

DI07

DI23

DI21

DI10

RE2301

DI17 R02

RE3601

R09

RE9110

DC

DI20

DD

DI09 DI18

R01

FU 01 02 03 04

05 06 07 08 09

10 11 12 13 14

15 16 17 18

DI19

19 20 21 22

FUSE TEST

DI14

R15

RE03

DI15

RE04

RE07

RE09

RE08

RE11

RE10

RE12 DI05

RE06

RE05

DI12

RE02

RE01

DI13

RF1

C01

30K

32 33 34 35 36

R10

R08

R05 R06

DE

DI04 DI02

P1 R04

37 38 39 40 41

DF

DI11 RE18

42 43 44 45 46

DG

47 48 49 50 51

DI16

27 28 29 30 31

R07 R03

FU 23 24 25 26

RE17

RE16

RE15

RE14

R14

RE13

DI03

DI01

R13

DH

1027076

RE

FUNCTION

RE

FUNCTION

01

Bucket positioner

13

Voltage supply E-ECU, V-ECU, V2-ECU

02

Reversing alarm

14

Voltage supply ECC

03

Working lights, front

15

Windscreen wiper

04

Working lights, rear

16

15A feed

05

Boom kick-out

17

15A feed

06

Starter relay

18

15EA feed

07

Working lights cab front

08

Boom Suspension System BSS

09

Rear window wiper

8701

Water pump interval heating

10

Stop lights

9101

Adjustable flow for 3rd hydraulic function

11

Working lights radiator casing

RF 1

Flasher relay

12

30 feed controlled by I-ECU Holding voltage RE 13

Specifications

224

Electrical system

1027077

RE2501, RE6401 Relays positioned outside the electrical distribution box

RE

FUNCTION

RE

FUNCTION

2501

Preheating

6401

Secondary steering

Specifications

Electrical system

225

Fuses Fuses FU

A

FUNCTION

FU

A

FUNCTION

01

5

Stop lights

31

5

Preheating relay, RE2501

02

32

10

boom Suspension System, attachment lock, detent function 3rd hydraulic function

03

15

Working lights cab, front

33

10

Working hydraulics

04

5

Voltage supply to RE14

34

10

Windscreen wiper, windscreen washer, headlight flasher

05

5

Instrument lighting, parking light front left, side light front left, tail light right

35

10

Rear window wiper, rear window washer, level monitor washer fluid

06

5

Parking light front right, side light front right, tail light left, number plate lighting

36

5

Battery charging

07

5

Low beam, left

37

5

Hazard flashers

08

5

Low beam, right

38

5

Electrically heated fuel filter, working lights, double working lights cab, working lights automatic reversing light

09

5

Reversing warning unit

39

10

Horn, kick-down, rear vision camera, electrically heated rear view mirrors, electrically adjustable rear view mirrors

10

5

High beam, right

41

10

Seat with air suspension, heated seat, position sensor operator seat

11

5

High beam, left

42

5

Mode selector, differential lock, fully automatic downshifting, gear selector control on control lever carrier, comfort drive control, Boom Suspension System activation / function selection

12

5

15RA feed to voltage converter

43

10

Automatic greasing

13

15

Working lights forward, attachments

45

5

Gear selector control, steering column

14

5

Direction indicator

48

5

Parking Brake

15

15

Working lights rear, working lights automatic reversing light

49

5

Secondary steering

16

15

Working lights radiator casing

50

5

Voltage supply VCADS Pro service socket

17

10

Voltage supply I-ECU, holding voltage RE13

51

5

Ignition switch dependent voltage supply, IECU, V-ECU, V2-ECU, ECC

18

10

Power socket 24 V

61

15

Electrically heated fuel filter

19

15

Travel lights

62

5

Rear vision camera

20

10

Ignition switch voltage supply

63

5

Rear vision camera, activated when reversing

21

10

Rotating warning beacon, interior lighting

64

22

5

Voltage supply to RE12

65

23

5

Starter motor

66

15

Radio

24

15

Voltage supply E-ECU

25

15

Voltage supply V-ECU

70

125

Main fuse

26

15

Voltage supply V2-ECU

71

125

Secondary steering pump

27

20

Cab fan

72

125

Preheating

28

10

AC compressor, water pump interval heating

74

10

Voltage converter

29

5

ECC, air conditioning

30

5

EGR valve

Specifications

226

Electrical system

DA

DI23

DB

DI07

DI17 R02

DI06 DI22

DI21

DI10

DI08

R09

FU61

DC

DI20

DD

DI09 DI18

R01

FU 01 02 03 04

05 06 07 08 09

10 11 12 13 14

15 16 17 18

DI19

19 20 21 22

FUSE TEST

DI14

R15

RE03

DI15

RE04

RE07

RE08

RE09

RE11

RE10

RE12 DI05

RE06

RE05

DI12

RE02

RE01

DI13

RF1

C01

30K

32 33 34 35 36

R10

R08

DE

DI04 DI02

R05 R06

P1 R04

DF

37 38 39 40 41

DI11

42 43 44 45 46

47 48 49 50 51

DG

DI16

27 28 29 30 31

RE18

R07 R03

FU 23 24 25 26

RE17

RE16

RE15

RE14

R14

RE13

DI03

DI01

R13

DH

1027078

FU74

1027079

FU72 FU71 FU70

Specifications

Transmission

227

Transmission L110F Transmission Type

Full power shift transmission

Make

Volvo

Designation

HTE204

Torque converter

Single stage

Torque multiplication

2.69:1

Number of gears

4 forward, 4 reverse

Gear-shifting system

Electro-hydraulic with APS (Automatic Power Shift)

Speed range (tyres 20.5R25L2)

1st gear

07.0 km/h (04.3 mph)

2nd gear

013.0 km/h (08.1 mph)

3rd gear

024.4 km/h (015.2 mph)

4th gear

037.0 km/h (023.0 mph)

L120F Transmission Type

Full power shift transmission

Make

Volvo

Designation

HTE205

Torque converter

Single stage

Torque multiplication

2.85 : 1

Number of gears

4 forward, 4 reverse

Gear-shifting system

Electro-hydraulic with APS (Automatic Power Shift)

Speed range (tyres 20.5R25L2)

1st gear

07.0 km/h (04.3 mph)

2nd gear

013.0 km/h (08.1 mph)

3rd gear

024.4 km/h (015.2 mph)

4th gear

037.0 km/h (023.0 mph)

Specifications

228

Axles

Axles L110F Type

Fully floating drive shafts with hub reductions of the planetary gear type

Front axle, make

Volvo

Designation

AWB31

Rear axle, make

Volvo

Designation

AWB30

Differential lock

On front axle

Type

Dog clutch 100%

Operation, differential lock

Hydraulic via servo pressure

L120F Type

Fully floating drive shafts with hub reductions of the planetary gear type

Front axle, make

Volvo

Designation

AWB31

Rear axle, make

Volvo

Designation

AWB30

Differential lock

On front axle

Type

Dog clutch 100%

Operation, differential lock

Hydraulic via servo pressure

Specifications

Brake system

Brake system L110F Brakes Service brakes, type

Dual circuit, all-hydraulic, wet disc brake

Number of discs per wheel

1

Accumulator capacity

1 litre (61 in3), 3 pcs.

Parking brake Type

Electrically operated hydraulic disc brake

Control pressure

1216 MPa (120160 bar) (17402321 psi)

L120F Brakes Service brakes, type

Dual circuit, all-hydraulic, wet disc brake

Number of discs per wheel

1

Accumulator capacity

1 litre (61 in3), 3 pcs.

Parking brake Type

Electrically operated hydraulic disc brake

Control pressure

1216 MPa (120160 bar) (17402321 psi)

229

Specifications

230

Steering system

Steering system Type

Load-sensing, hydrostatic

Number of steering wheel revolutions, total

4.0 revolutions

Steering arc

±40°

Steering pump

in common with the working hydraulics

Oil pump Type

Axial piston pump, variable displacement

Working pressure, high idling speed

21.0 ± 0.3 MPa (210 ± 3 bar)

Shock valve opening pressure at 10 litres (2.6 US gal) per minute

2729 MPa (270290 bar) (39164206 psi)

Specifications

Tyre sizes and air pressures

231

Tyre sizes and air pressures L110F If other tyres are used for than those stated, the tyre manufacturer should be contacted regarding information about the correct tyre pressure. All tyres in the tables below are not available on all markets. Contact your dealer for further information. Tyres

Material handling loading work 10 km/ h (6.2 mph)

Material handling Loading/Carrying 25 km/h (15.5 mph)

Timber handling 25 km/h (15.5 mph)

Front

Front

Front

Rear

Rear

Rear

Goodyear 23.5R25 GP-2B

kPa psi

375 54

225 33

375 54

225 33

425 62

275 40


kPa psi

375 54

225 33

375 54

225 33

425 62

275 40

Goodyear 23.5R25 RL-2+

kPa psi

375 54

225 33

375 54

225 33

425 62

275 40

Goodyear 23.5R25 TL-3A+

kPa psi

375 54

225 33

375 54

225 33

425 62

275 40

Goodyear 23.5R25 RL-5K

kPa psi

375 54

225 33

375 54

225 33

Not recommende d

Not recommended

Goodyear 23.5R25 HRL

kPa psi

325 47

200 29

325 47

200 29

Not recommended

Not recommended

Goodyear 750/65R25 GP-3D

kPa psi

350 51

250 36

350 51

250 36

400 58

300 44

Michelin 23.5R25 XHA

kPa psi

275 40

200 29

275 40

200 29

325 47

250 36

Michelin 23.5R25 XMINE D2

kPa psi

275 40

200 29

275 40

200 29

Not recommended

Not recommended

Bridgestone 23.5R25 VJT

kPa psi

400 58

250 36

400 58

250 36

450 65

350 51

Bridgestone 23.5R25 VSDL

kPa psi

400 58

250 36

400 58

250 36

Not recommended

Not recommended

Michelin 750/65R25 XLD

kPa psi

250 36

200 29

250 36

200 29

300 44

250 36

The recommended tyre pressures are based on the rated load for each handling case. In case of heavier loads, especially during timber handling or loading-carrying operations, a higher tyre pressure is required. Contact the tyre manufacturer for information about which air pressure is the correct one for the load to be handled and transported over a particular distance. If L4 or L5 tyres are used for loading-carrying operations, due attention must be paid to the transporting distances. Radial tyres are to be preferred for loading-carrying operations, as the build-up of heat is less in this type of tyre.

Specifications

232

Tyre sizes and air pressures

L120F If other tyres are used for than those stated, the tyre manufacturer should be contacted regarding information about the correct tyre pressure. All tyres in the tables below are not available on all markets. Contact your dealer for further information. Tyres

Material handling loading work 10 km/ h (6.2 mph)

Material handling Loading/Carrying 25 km/h (15.5 mph)

Timber handling 25 km/h (15.5 mph)

Front

Front

Front

Rear

Rear

Rear


kPa psi

400 58

250 36

400 58

250 36

425 62

300 44


kPa psi

400 58

250 36

400 58

250 36

425 62

300 44

Goodyear 23.5R25 RL-2+

kPa psi

400 58

250 36

400 58

250 36

425 62

300 44

Goodyear 23.5R25 TL-3A+

kPa psi

400 58

250 36

400 58

250 36

425 62

300 44

Goodyear 23.5R25 RL-5K

kPa psi

400 58

250 36

400 58

250 36

Not recommended

Not recommended

Goodyear 23.5R25 HRL

kPa psi

350 51

200 29

350 51

200 29

Not recommended

Not recommended

Goodyear 750/65R25 GP-3D

kPa psi

400 58

300 44

400 58

300 44

425 62

300 44

Michelin 23.5R25 XHA

kPa psi

325 47

200 29

325 47

200 29

375 54

250 36

Michelin 23.5R25 XMINE D2

kPa psi

325 47

200 29

325 47

200 29

Not recommended

Not recommended

Bridgestone 23.5R25 VJT

kPa psi

400 58

250 36

400 58

250 36

450 65

350 51

Bridgestone 23.5R25 VSDL

kPa psi

400 58

250 36

400 58

250 36

Not recommended

Not recommended

Michelin 750/65R25 XLD

kPa psi

350 51

250 36

350 51

250 36

400 58

300 44

The recommended tyre pressures are based on the rated load for each handling case. In case of heavier loads, especially during timber handling or loading-carrying operations, a higher tyre pressure is required. Contact the tyre manufacturer for information about which air pressure is the correct one for the load to be handled and transported over a particular distance. If L4 or L5 tyres are used for loading-carrying operations, due attention must be paid to the transporting distances. Radial tyres are to be preferred for loading-carrying operations, as the build-up of heat is less in this type of tyre.

Specifications

Wheel nuts, tightening torques

Wheel nuts, tightening torques Wheel bolts Tightening torque

600 ±50 Nm (443 ±37 lbf ft)

233

Specifications

234

Cab

Cab General The cab is fitted on rubber elements, is insulated and has a flat floor with rubber mat. Tested and approved as a protective cab and meets standards according to ISO/DIS 3471-1:2004 and SAE 1040-MAY 94 (ROPS), ISO/DIS 3449-2004 (FOPS) and ISO 6055-1997 (protective roof for high-lifting rider trucks). Cab interior fittings and upholstery

Fire retardant (fire resistant) measured according to ISO 37951989

Number of emergency exits

2 (the door and the right side window)

Heating and ventilation The basic version of the loader is provided with a heating and ventilation system with defrosting for all windows and the best possible air distribution (10 outlets). Air conditioning is available as optional extra.

Operator seat This machine is equipped with an operator seat, which meets the criteria of EN ISO 7096. Height adjustment (rapid adjustment)

100 mm (4 in)

Longitudinal adjustment

160 mm (6.3 in)

Adjustment for driver weight

40130 kg (88287 lb)/ 40160 kg (88353 lb) (HD-seat (optional equipment)

Adjustment of back-rest, (adjustable backrest inclination)

12°

Upholstery

Fire resistant

Lap type seat belt with reel

Yes

Specifications

Cab

235

Hand-arm vibrations Emission of hand-arm vibration during real operating conditions at its intended use is less than 2.5 m/s2 RMS (root mean square) acceleration according to ISO 8041.

Whole-body vibrations Emission of Whole-Body Vibration during real operating conditions at its intended use is according to the table below. Typical operating conditions

Vibration emission value aw,eqx (m/s² RMS)

Vibration emission value aw,eqy (m/s² RMS)

Vibration emission value aw,eqz (m/s² RMS)

Loading and carrying work

0.6

0.6

0.5

Mining application

0.8

0.7

0.8

Transporting operation

0.5

0.7

0.5

V-shaped loading and carrying work

0.7

0.6

0.5

The following vibration directions are defined: x = longitudinally y = lateral z = vertical NOTE! These whole-body vibration emission values were determined at particular operating and terrain conditions and is therefore not representative for all the various conditions in accordance with the intended use of the machine and should not alone be used to determine the whole-body vibration exposure to the operator using the machine. For this purpose, the information in ISO/TR 25398 is recommended. To ensure that the whole-body vibration emission during machine use is kept to a minimum, see page 126.

Sound information, L110F Sound pressure level (LpA) at operator position 68 dB (A) (Measurement according to ISO 6396) Sound power level (LWA) around the machine (Measurement according to 2000/14/EC with applicable appendices and measuring method according to ISO 6395)

106 dB (A)

Sound information, L120F Sound pressure level (LpA) at operator position 68 dB (A) (Measurement according to ISO 6396) Sound power level (LWA) around the machine (Measurement according to 2000/14/EC with applicable appendices and measuring method according to ISO 6395)

106 dB (A)

NOTE! Uncertainties in given noise values (e.g. uncertainty in production and measuring instruments) are calculated in accordance with ISO 6395:2008 for the sound power level around the machine and ISO 6396:2008 for the sound pressure level at operator position.

Specifications

236

Hydraulic system

Hydraulic system L110F Type

Load-sensing, (closed centre)

Hydraulic oil pump, type


Pump 1 Function

Working hydraulics

Displacement

80 cm3 (4.9 in3)

Flow at 32 r/s (1900 rpm) and 10 MPa (100 bar) pressure

145 litres (38.3 US gal) per minute


23.6 ± 0.5 MPa (236 ± 5 bar)

Pump 2 Function

Working hydraulics, steering system, brake system and servo system

Displacement

60 cm3 (3.7 in3)

Flow at 32 r/s (1920 rpm) and 10 MPa (100 bar) (1450 psi) pressure



24.0 ± 0.5 MPa (240 ± 5 bar)

Pump 3 Function

Cooling fan pump, brake system, pilot valve

Displacement

18 cm3 (1.1 in3)




21 ± 0.5 MPa (210 ± 5 bar)

Specifications

Hydraulic system

237

L120F Type

Load-sensing, (closed centre)

Hydraulic oil pump, type


Pump 1 Function

Working hydraulics

Displacement

80 cm3 (4.9 in3)




25.0 ± 0.5 MPa (250 ± 5 bar)

Pump 2 Function

Working hydraulics, steering system, brake system and servo system

Displacement

60 cm3 (3.7 in3)




26.0 ± 0.5 MPa (260 ± 5 bar)

Pump 3 Function

Cooling fan pump, brake system, pilot valve

Displacement

18 cm3 (1.1 in3)




21 ± 0.5 MPa (210 ± 5 bar)

Specifications

238

Dimensions

Dimensions L110F Specifications and dimensions comply in applicable parts with ISO 7131:1997, SAE J732 JUN92, ISO 7546 1983, SAE J742 FEB85, SAE J818 MAY87, ISO 14397:2002 Part 1 & 2. The data apply to a machine with 23.5 R25* L3 tyres and 3.1 m3 (4.1 yd3) bucket (direct-mounted).

L64136A

L64050A

Standard boom (lifting arms)


Extended boom

A

*

P***

50°

B

7000 mm (22' 11.6'')

B

6470 mm (21' 2.7'')

R

41°

J

4220 mm (13' 10.1'')

C

3200 mm (10' 6.0'')

R1**

46°

K

4530 mm (14' 10.3'')

D

440 mm (1' 5.3'')

S

66°

R

42°

E

*

T

96 mm (0' 3.8'')

S

64°

F

3360 mm (3' 0.3'')

U

470 mm (1' 6.5'')

T

105 mm (0' 4.1'')

G

2132 mm (6' 11.9'')

V

*

Z

3800 mm (12' 5.6'')

H

*

X

2070 mm (6' 9.5'')

J

3700 mm (12' 1.7'')

Y

2670 mm (8' 9.1'')

K

4020 mm (13' 2.3'')

Z

3290 mm (10' 9.5'')

L

*

a2

5730 mm (18' 9.6'')

M

*

a3

3060 mm (10' 0.5'')

N

*

a4

±40°

O

55°

*) See table on the next page **) Carrying position SAE ***) P-max. 50° The difference between standard boom and long boom is shown here with the same size bucket. Note that the version with long boom is intended to be used with a material with a lower density.

Specifications

Dimensions

239

L120F Specifications and dimensions comply in applicable parts with ISO 7131:1997, SAE J732 JUN92, ISO 7546: 1983, SAE J742 FEB85, SAE J818 MAY87, ISO 14397:2002 Part 1 & 2. The data apply to a machine with 23.5 R25* L3 tyres and 3.1 m3 (4.1 yd3) bucket (direct-mounted).

L64136A

L64050A



Extended boom

A

*

P***

49°

B

7060 mm (23' 2.0'')

B

6580 mm (21' 7.1'')

R

42°

J

4290 mm (14' 0.9'')

C

3200 mm (10' 6.0'')

R1**

47°

K

4610 mm (15' 1.5'')

D

420 mm (1' 4.5'')

S

67°

R

43°

E

*

T

96 mm (0' 3.8'')

S

64°

F

3370 mm (11' 0.7'')

U

510 mm (1 ft 8.1 in)

T

145 mm (0' 5.7'')

G

2133 mm (7' 0.0'')

V

*

Z

3700 mm (12' 1.7'')

H

*

X

2070 mm (6' 9.5'')

J

3780 mm (12' 4.8'')

Y

2670 mm (8' 9.1'')

K

4090 mm (13' 5.0'')

Z

3330 mm (10' 11.1'')

L

*

a2

5730 mm (18' 9.6'')

M

*

a3

3060 mm (10' 0.5'')

N

*

a4

±40°

O

54°

*) See table on the next page **) Carrying position SAE ***) P-max. 49° The difference between standard boom and long boom is shown here with the same size bucket. Note that the version with long boom is intended to be used with a material with a lower density.

Specifications

240

Machine, volumes

Machine, volumes L110F The maximum weight of the machine (incl. equipment and attachment) is 23000 kg (50706 lb). Current machine weight depends on the equipment, see table (last line). Tyres 23.5 R25 L3

Rock & gravel handling*

Light material

Edge savers

Teeth & wear segments

Edge savers

Standard buckets

Edge savers

Edge savers

Edge savers

Long boom

Teeth

Teeth

Capacity, heaped ISO/ SAE

2.8 m3 (3.7 yd3)

3.0 m3 (3.9 yd3)

3.1 m3 3.1 m3 (4.1 3.4 m3 (4.4 3.4 m3 (4.4 (4.1 yd3) yd3) yd3) yd3)

2.7 m3 (3.5 yd3)

5.5 m3 (7.2 yd3)

9.5 m3 (12.4 yd3)

Capacity filled to 110 %

3.1 m3 (4.1 yd3)

3.3 m3 (4.3 yd3)

3.4 m3 3.4 m3 (4.4 3.7 m3 (4.8 3.7 m3 (4.8 (4.4 yd3) yd3) yd3) yd3)

3.0 m3 (3.9 yd3)

6.1 m3 (8.0 yd3)

10.5 m3 (13.7 yd3)

Static tipping load, straight machine

13440 kg (29639 lb)

12650 kg (27888 lb)

13120 kg (28925 lb)

12410 kg (27359 lb)

12260 kg (27929 lb)

13040 kg (28748 lb)

13330 kg (29388 lb)

11560 kg (25485 lb)

11650 kg (25684 lb)

2550 kg ( 5622 lb)

Static tipping load, turned 35°

12000 kg (26455 lb)

11260 kg (24824 lb)

11690 kg (25772 lb)

11020 kg (24295 lb)

10880 kg (23986 lb)

11600 kg (25573 lb)

11850 kg (26125 lb)

10200 kg (22487 lb)

10250 kg (22597 lb)

2320 kg ( 5115 lb)

Static tipping load, fully turned machine ***)

11570 kg (25507 lb)

10840 kg (23898 lb)

11270 kg (24846 lb)

10600 kg (23369 lb)

10470 kg (23082 lb)

11170 kg (24626 lb)

11410 kg (25155 lb)

9790 kg (21583 lb)

9840 kg (21693 lb)

2250 kg ( 4960 lb)

Break-out force

166.7 kN (37476 lbf)

146.8 kN 156.7 kN 139.3 kN 132.8 kN 153.5 kN (33002 lbf) (35228 lbf) (31316 lbf) (29855 lbf) (34508 lbf)

129.9 kN (29203 lbf)

105.0 kN (23605 lbf)

91.6 kN (20593 lbf)

+17 kN (+3822 lbf)

A

8070 mm (26' 5.7'')

8240 mm (27' 0.4'')

7890 mm (25' 10.6'')

8060 mm (26' 5.3'')

8130 mm (26' 8.1'')

7920 mm (25' 11.8'')

8310 mm (27' 3.2'')

8530 mm (27' 11.8'')

8820 mm (28' 11.2'')

+500 mm (+1' 7.7'')

E

1320 mm (4' 4.0'')

1470 mm (4' 9.9'')

1160 mm (3' 9.7'')

1310 mm (4' 3.6'')

1380 mm (4' 6.3'')

1190 mm (3' 10.9'')

1510 mm (4' 11.4'')

1730 mm (5' 8.1'')

1990 mm (6' 6.3'')

+/-0 mm

H**)

2740 mm (8' 11.9'')

2630 mm (8' 7.5'')

2860 mm (9' 3.6'')

2750 mm (9' 0.3'')

2700 mm (8' 10.3'')

2840 mm (9' 3.8'')

2610 mm (8' 6.8'')

2390 mm (7' 10.1'')

2190 mm (7' 2.2'')

+520 mm (1' 8.5'')

L

5490 mm (18' 0.1'')

5600 mm (18' 4.5'')

5480 mm (17' 11.7'')

5600 mm (18' 4.5'')

5660 mm (18' 6.8'')

5610 mm (18' 4.9'')

5550 mm (18' 2.5'')

5820 mm (19' 1.1'')

5980 mm (19' 7.4'')

+510 mm (+1' 8.1'')

M**)

1230 mm (4' 0.4'')

1350 mm (4' 5.1'')

1110 mm (3' 7.7'')

1230 mm (4' 0.4'')

1280 mm (4' 2.4'')

1130 mm (3' 8.5'')

1400 mm (4' 7.1'')

1520 mm (4' 11.8'')

1730 mm (5' 8.1'')

30 mm (0' 1.2'')

N**)

1730 mm (5' 8.1'')

1780 mm (5' 10.1'')

1680 mm (5' 6.1'')

1740 mm (5' 8.5'')

1760 mm (5' 9.3'')

1690 mm (5' 6.5'')

1810 mm (5' 11.3'')

1780 mm (5' 10.1'')

1790 mm (5' 10.5'')

+430 mm (+1' 4.9'')

V

2880 mm (9' 5.4'')

2880 mm (9' 5.4'')

3000 mm (9' 10.1'')

2880 mm (9' 5.4'')

2880 mm (9' 5.4'')

3000 mm (9' 10.1'')

2880 mm (9' 5.4'')

3000 mm (9' 10.1'')

3400 mm (11' 1.9'')

-

a1

12680 mm (41' 7.2'')

12770 mm 12700 mm (41' 10.8'') (41' 8.0'')

12670 mm (41' 6.8'')

12710 mm (41' 8.4'')

12720 mm (41' 8.8'')

12830 mm (42' 1.1'')

13060 mm (42' 10.2'')

13600 mm (44' 7.4'')

-

Machine weight

18150 kg (40014 lb)

18430 kg (40631 lb)

18540 kg (40874 lb)

18610 kg (41028 lb)

18430 kg (40631 lb)

19330 kg (42615 lb)

18950 kg (41778 lb)

19170 kg (42263 lb)

+310 kg (+683 lb)

18300 kg (40345 lb)

*) With L5 tyres. **) Measurement to point of bucket tooth or edge saver. Dumping height to edge of bucket (acc. to SAE) + approx. 200 mm (8 in). Measurement at a dumping angle of 45°. (Spade-nose bucket 42°.) ***) When the machine is used with a bucket, a working load of 50% of the tipping load for a fully steered machine is permissible. Depending on application and/or machine size the manufacturer often recommends a utilisation lower than 50%.

Specifications

Machine, volumes

241

L120F The maximum weight of the machine (incl. equipment and attachment) is 24000 kg (52911 lb) Current machine weight depends on the equipment, see table (last line). Tyres 23.5 R25 L3

Standard buckets

Teeth

Edge savers

Light material

Edge savers

Teeth & wear segments

Edge savers

Long boom

Teeth

Edge savers

Capacity, heaped ISO/ SAE

3.0 m3 (3.9 yd3)

3.1 m3 (4.1 yd3)

3.3 m3 3.4 m3 (4.4 3.4 m3 (4.4 3.6 m3 (4.7 (4.3 yd3) yd3) yd3) yd3)

3.0 m3 (3.9 yd3)

5.5 m3 (7.2 yd3)

9.5 m3 (12.4 yd3)

Capacity filled to 110 %

3.3 m3 (4.3 yd3)

3.4 m3 (4.4 yd3)

3.6 m3 3.7 m3 (4.8 3.7 m3 (4.8 4.0 m3 (5.2 (4.7 yd3) yd3) yd3) yd3)

3.3 m3 (4.3 yd3)

6.1 m3 (8.0 yd3)

10.5 m3 (8.4 yd3)

Static tipping load, straight machine

14540 kg (32055 lb)

13580 kg (29939 lb)

13590 kg (29960 lb)

14240 kg (31394 lb)

13910 kg (30666 lb)

13340 kg (29410 lb)

14500 kg (31967 lb)

12700 kg (27999 lb)

12840 kg (28307 lb)

2630 kg (5798 lb)

Static tipping load, turned 35°

12920 kg (28484 lb)

12010 kg (26477 lb)

12030 kg (26522 lb)

12620 kg (27822 lb)

12310 kg (27139 lb)

11780 kg (25970 lb)

12860 kg (28351 lb)

11180 kg (24648 lb)

11270 kg (24846 lb)

2390 kg (5269 lb)

Static tipping load, fully turned machine ***)

12440 kg (27425 lb)

11550 kg (25463 lb)

11570 kg (25507 lb)

12140 kg (26764 lb)

11830 kg (26081 lb)

11330 kg (24978 lb)

12370 kg (27271 lb)

10730 kg (23656 lb)

10810 kg (23831 lb)

2320 kg (5115 lb)

Break-out force

170.1 kN (38240 lbf)

148.5 kN 148.8 kN 164.0 kN 151.0 kN 138.0 kN (33384 lbf) (33451 lbf) (36869 lbf) (33946 lbf) (31024 lbf)

138.6 kN (31159 lbf)

112.0 kN (25179 lbf)

97.8 kN (21986 lbf)

+6 kN (+1349 lbf)

A

8200 mm (26' 10.8'')

8150 mm (26' 8.9'')

8380 mm (27' 5.9'')

8020 mm (26' 3.7'')

8130 mm (26' 8.1'')

8270 mm (27' 1.6'')

8390 mm (27' 6.3'')

8610 mm (28' 3.0'')

8920 mm (29' 3.2'')

+500 mm (+1' 7.7'')

E

1370 mm (4' 5.9'')

1330 mm (4' 4.4'')

1530 mm (5' 0.2'')

1200 mm (3' 11.2'')

1300 mm (4' 3.2'')

1430 mm (4' 8.3'')

1520 mm (4' 11.8'')

1740 mm (5' 8.5'')

2010 mm (6' 7.1'')

+30 mm (+1.18 in)

H**)

2800 mm (9' 2.2'')

2820 mm (2' 5.9'')

2680 mm (9' 11.3'')

2910 mm (9' 6.6'')

2840 mm (9' 3.8'')

2740 mm (8' 11.9'')

2690 mm (8' 9.9'')

2470 mm (8' 1.2'')

2260 mm (7' 5.0'')

+510 mm (+1' 8.1'')

L

5610 mm (18' 4.9'')

5670 mm (18' 7.2'')

5730 mm (18' 9.6'')

5690 mm (18' 8.0'')

5750 mm (18' 10.4'')

5780 mm (18' 11.6'')

5690 mm (18' 8.0'')

5900 mm (19' 4.3'')

6060 mm (19' 10.6'')

+520 mm (1' 8.5'')

M**)

1330 mm (4' 4.4'')

1270 mm (4' 2.0'')

1460 mm (4' 9.5'')

1170 mm (3' 10.1'')

1250 mm (4' 5.2'')

1350 mm (4' 5.1'')

1440 mm (4' 8.7'')

1560 mm (5' 1.4'')

1760 mm (5' 9.3'')

30 mm ( 0' 1.2'')

N**)

1880 mm (6' 2.0'')

1830 mm (6' 0.0'')

1930 mm (6' 4.0'')

1780 mm (5' 10.1'')

1820 mm (5' 11.7'')

1860 mm (6' 1.2'')

1920 mm (6' 3.6'')

1880 mm (6' 2.0'')

1900 mm (6' 2.8'')

+430 mm (+1' 4.9'')

V

2880 mm (9' 5.4'')

2880 mm (9' 5.4'')

2880 mm (9' 5.4'')

3000 mm (9' 10.1'')

3000 mm (9' 10.1'')

2880 mm (9' 5.4'')

2880 mm (9' 5.4'')

3000 mm (9' 10.1'')

3400 mm (11' 1.9'')

-

a1

12780 mm (41' 11.1'')

12740 mm 12880 mm (41' 10.6'') (42' 3.1'')

12780 mm (41' 11.1'')

12830 mm (42' 1.1'')

12800 mm (41' 11.9'')

12890 mm (42' 3.5'')

13120 mm (43' 0.5'')

13660 mm (44' 9.8'')

-

Machine weight

18980 kg (41844 lb)

19310 kg (42571 lb)

19200 kg (42329 lb)

19380 kg (42726 lb)

19430 kg (42836 lb)

20010 kg (44114 lb)

19630 kg (43277 lb)

19950 kg (43982 lb)

+190 kg (+419 lb)

19270 kg (42483 lb)

Edge savers

Rock & gravel handling*

*) With L5 tyres. **) Measurement to point of bucket tooth or edge saver. Dumping height to edge of bucket (acc. to SAE) + approx. 200 mm (8 in). Measurement at a dumping angle of 45°. (Spade-nose bucket 42°.) *) Measurement to tip of bucket tooth or edge savers. Dumping height to edge of bucket (acc. to SAE) + approx. 200 mm (8 in). Measurement at a dumping angle of 45°. (Spade-nose bucket 42°.) ***) When the machine is used with a bucket, a working load of 50% of the tipping load for a fully steered machine is permissible. Depending on application and/or machine size the manufacturer often recommends a utilisation lower than 50%.

Specifications

242 Combination table, interchangeable equipment (attachments) machine model

Combination table, interchangeable equipment (attachments) machine model The table shows attachment in the category interchangeable equipment *)(attachments that can be changed by the operator) and for which machines these attachments are approved.

Model / Type number

Attachment, type

Attachment, model

Page

Bucket with clamping arm

REF H TB CA 5.2 m3 3000 mm 83364

137

High-tipping light material bucket High-tipping light material bucket High-tipping light material bucket High-tipping light material bucket High-tipping light material bucket High-tipping light material bucket Pallet forks, sideshift version

HIT H BOE 7.0 m3 3000 mm **)

82041

138

HIT H BOE 4.5 m3 3000 mm, side-mounted cylinders HIT H BOE 5.5 m3 3000 mm, side-mounted cylinders HIT H BOE 5.0 m3 3000 mm

83209

Historical Machine authorizamodel tion

138

L110F L120F L110F L120F L110F

L110E L120E L110E L120E

84233

138

L120F

L120E

82043

138

HIT H BOE 9.5 m3 3400 mm***) 82045

138

84231

138

L110E L120D/E L110E L120D/E L110E

83772

149

83773

149

Pallet forks, combi forks

HIT H BOE 5.0 m3 3000 mm, side-mounted cylinders Sideshift pallet forks 1500 mm FFPSS Sideshift pallet forks 2000 mm FFPSS Combi forks 1.6 m2 COF

Log grapple, unloading

UNLGR H 1.8 m2 1634 mm

80834

142

Log grapple, unloading


80831

142

Log grapple, sorting


80835

142

Log grapple, sorting


80832

142

Log grapple, general purpose UNLGR H 1.3 m2 1200 mm

82340

142

Log grapple, general purpose UNLGR H 1.3 m2 1635 mm

82339

142

L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F L110F L120F

Pallet forks, sideshift version

148

High-Lift grapple

SWC GR 1.5 m2

82131

145

High-Lift grapple

SWC GR 1.8 m2

82132

145

High-Lift grapple

SWC GR 2.0 m2

82133

145

Log grapple, tropical


82695

142

Material handling arm

MHA H HYDR

82137

150

L110E L120E L110E L120E L110E L120E L110E L120D/E L110E L120D/E L110E L120D/E L110E L120D/E L110E L120D/E L110E L120D/E L110E L120D/E L110E L120D/E L110E L120D/E L110E L120D/E L110E L120D/E

*) "interchangeable equipment" (attachments that can be changed by operator) means that the attachment requires the combination hydraulic attachment lock ("hook-on") and quick-couplings for optional hydraulics (3rd and 4th hydraulic function). **) Requires installation of two optional highly placed, front-mounted mirrors (optional equipment) ***) Requires camera.

Specifications

Pallet forks

243

Pallet forks L110F Pallet fork (for attachment bracket) Attachment

Bracket-mounted

Order No.

93688

Tyres

23.5R25

F

E

D

L68186A

A B

C

A

870 mm (2' 10.3'')

C

20 mm (0' 0.8'')

E

3780 mm (12' 4.8'')

B

1650 mm (5' 5.0'')

D

1830 mm (6' 0.0'')

F

770 mm (2' 6.3'')

Loading table for pallet fork

Rated operating load capacity (rated work load) at different load centre distances Ground

Tyres

500 mm (19.7 in)

600 mm (23.6 in)

700 mm (27.6 in)

800 mm (31.5 in)

900 mm (35.4 in)

1200 mm (47.2 in)

Rough terrain

23.5R25

5350 kg (11795 lb)

5150 kg (11354 lb)

5000 kg (11023 lb)

4850 kg (10692 lb)

4700 kg (10362 lb)

4300 kg (9480 lb) *

Even and hard

23.5R25

7050 kg (15543 lb)

6800 kg (14991 lb)

6600 kg (14550 lb)

6400 kg * (14110 lb) *

5700 kg * (12566 lb) *

4300 kg (9480 lb) *

The maximum permissible load according o the table is reduced if the attachments are fitted with additional equipment. For more information, contact your dealer who has access to the attachment catalogue. *) Is limited by the attachment. (max. load per tine, 4300 kg (9480 lb) at a distance to centre of gravity of 600 mm (23.6 in))

Specifications

244

Pallet forks

L120F Pallet fork (with attachment bracket) Attachment

Bracket-mounted

Order No.

93688

Tyres

23.5R25

F

E

D

L68186A

A B

C

A

966 mm (3' 2.0'')

C

29 mm (0' 1.1'')

E

3847 mm (12' 7.5'')

B

1723 mm (5' 7.8'')

D

1836 mm (6' 0.3'')

F

814 mm (2' 8.0'')

Loading table for pallet fork

Rated operating load capacity (rated work load) at different load centre distances Ground

Tyres

500 mm (19.7 in)

600 mm (23.6 in)

700 mm (27.6 in)

800 mm (31.5 in)

900 mm (35.4 in)

1200 mm (47.2 in)

Rough terrain

23.5R25

5890 kg (12985 lb)

5670 kg (12500 lb)

5530 kg (12192 lb)

5360 kg (11817 lb)

5210 kg (11486 lb)

4300 kg (9480 lb) *

Even and hard

23.5R25

7780 kg (17152 lb)

7500 kg (16535 lb)

7310 kg (16116 lb)

6450 kg (14220 lb)*

5730 kg (12632 lb) *

4300 kg (9480 lb) *

The maximum permissible load according o the table is reduced if the attachments are fitted with additional equipment. For more information, contact your dealer who has access to the attachment catalogue. *) Is limited by the attachment. (max. load per tine, 4300 kg (9480 lb) at a distance to centre of gravity of 600 mm (23.6 in))

Specifications

Log grapples

Log grapples L110F Timber grapple (for attachment bracket) Attachment

Bracket-mounted

Tyres

750/65 R25

A

2.4 m2 (2.9 yd2)

A

20° 45°

I H K

20°

J D

B

F

E C L G M

L67074A

B

3470 mm (1' 4.6'')

F

1520 mm (4' 11.8'')

J

2790 mm (9' 1.8'')

C

1840 mm (6' 0.4")

G

2720 mm (8' 11.1'')

K

2990 mm (9' 9.7'')

D

2840 mm (9' 3.8'')

H

4580 mm (15' 0.3'')

L

2060 mm (6' 9.1'')

E

1460 mm (4' 9.5'')

I

6620 mm (24' 8.6'')

M

8760 mm (28' 8.9'')

245

Specifications

246

Log grapples

L120F Timber grapple (for attachment bracket) Attachment

Bracket-mounted

Order No.

80832

Tyres

750/65 R25

A

20° 45°

I H K

20°

J D

B

F

E C L G M

L67074A

A

2.4 m2 (2.9 yd2)

B

3550 mm (11' 7.9'')

F

1530 mm (5' 0.2'')

J

2790 mm (9' 1.8'')

C

1880 mm (6' 2.0'')

G

2790 mm (9' 1.8'')

K

2990 mm (9' 9.7'')

D

2920 mm (9' 7.0")

H

4660 mm (15' 3.5'')

L

2150 mm (7' 0.6'')

E

1500 mm (4' 11.1'')

I

6690 mm (21' 11.4'')

M

8850 mm (29' 0.4'')

Specifications


Material handling arm L110F Attachment

Bracket-mounted

Order No.

92008

Tyres

23.5R25

Weight

500 kg (1103 lb)

D E F

S R Q

A

G

B

C

H

P

I L68188A

M N O J K L

D

2740 mm (8' 11.9'')

J

1310 mm (4' 3.6'')

P

1620 mm (5' 3.8'')

E

2120 mm (6' 11.5'')

K

1880 mm (6' 2.0'')

Q

5350 mm (17' 6.6'')

F

1500 mm (4' 11.1'')

L

2450 mm (8' 0.5'')

R

6310 mm (20' 8.4'')

G

3220 mm (10' 6.8'')

M

1900 mm (6' 2.8'')

S

7250 mm (23' 9.4'')

H

4350 mm (14' 3.3'')

N

2970 mm (9' 8.9'')

I

5490 mm (18' 0.1'')

O

3950 mm (12' 11.5'')

Loading table for material handling arm Mechanical 92008 Arm extension Retracted (A)

3300 kg (7275 lb)

Halfway extended (B)

2570 kg (5666 lb)

Fully extended (C)

2100 kg (4630 lb)

Hydraulically folding 82137 Retracted (A)

2480 kg (5467 lb)

Extended (C)

2080 kg (4586 lb)

247

Specifications

248


L120F Attachment

Bracket-mounted

Order No.

92008

Tyres

23.5R25

Weight

500 kg (1103 lb) D E F

S

R Q

A

G

B

C

H

P

I L68188A

M N O J

K L

D

2853 mm (9' 4.3'')

J

1363 mm (4' 5.7'')

P

1624 mm (5' 3.9'')

E

2209 mm (7' 3.0'')

K

1907 mm (6' 3.1'')

Q

5408 mm (17' 8.9'')

F

1565 mm (5' 1.6'')

L

2452 mm (8' 0.5'')

R

6341 mm (20' 9.6'')

G

3298 mm (10' 9.8'')

M

2023 mm (6' 7.6'')

S

7274 mm (23' 10.4'')

H

4432 mm (14' 6.5'')

N

3017 mm (9' 10.8'')

I

5565 mm (18' 3.1'')

O

4011 mm (13' 1.9'')

Loading table for material handling arm Mechanical 92008 Arm extension

Distance to load *)

Without counterweight

Retracted (A)

4104 mm (13' 5.6'')

3640 kg (8025 lb)

Halfway extended (B)

5237 mm (17' 2.2'')

2830 kg (6239 lb)

Fully extended (C)

6370 mm (20' 10.8'')

2330 kg (5137 lb)

Retracted

5382 mm (17' 7.9'')

2740 kg (6041 lb)

Extended

6381 mm (20' 11.2'')

2300 kg (5071 lb)

Hydraulically folding 82137

*) From wheel centre to lifting hook

Specifications

Service journal

Service journal Type of service

Service 100 hours Date

Hours

Date

Hours

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Signature and stamp


Type of service

Service 3000 hours

Signature and stamp


Type of service

Service 2500 hours

Signature and stamp


Type of service

Service 2000 hours

Signature and stamp

Warranty Inspection Service and maintenance

Type of service

Service 1500 hours

Signature and stamp


Type of service


Warranty Inspection

Type of service

Service 500 hours

Signature and stamp


Signature and stamp

249

Specifications

250



Hours

Date

Hours

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Signature and stamp


Type of service

Service 6500 hours

Signature and stamp


Type of service

Service 6000 hours

Signature and stamp


Type of service

Service 5500 hours

Signature and stamp


Type of service

Service 5000 hours

Signature and stamp


Type of service



Type of service

Service 4000 hours

Signature and stamp


Signature and stamp

Specifications



Hours

Date

Hours

Hours

Date

Hours

Date

Hours

Date

Hours

Date

Hours

Signature and stamp


Type of service

Service 10000 hours

Signature and stamp


Type of service

Service 9500 hours

Signature and stamp


Type of service

Service 9000 hours

Signature and stamp


Type of service

Service 8500 hours

Signature and stamp


Type of service



Type of service

Service 7500 hours

Signature and stamp


Signature and stamp

251

Specifications

252

Alphabetical index

253

Alphabetical index Accidents .......................................................................96 Accumulators, depressurizing ......................................202 Actions before operating ..............................................100 Actions before transporting machine ...........................117 Adjusting lift height .........................................................79 Adjusting tilting rearwards ..............................................79 Air conditioning ............................................................197 Alarm texts .....................................................................45 Alternator belt, checking (workshop job) ......................186 Alternator with air filter (optional equipment)................186 Anti-theft system ............................................................55 Arrival and Delivery Inspection.....................................169 Attachment brackets ....................................................133 Attachments .................................................................132 Auto engine shut-off (optional equipment) .....................93 Automatic greasing system ..........................................204 Automatic shifting (APS) ..............................................104 Axle oil, changing .........................................................191 Axles ....................................................................191, 228 Axles, changing breather filters....................................192 Batteries .......................................................................184 Batteries, charging .......................................................185 Batteries, maintenance ................................................184 Battery disconnect switch ............................................184 Bearings, greasing .......................................................203 Before service read ......................................................160 Boom kick-out and bucket positioner (Electric servo) ....79 Boom kick-out ................................................................78 Brake system ...................................................6, 193, 229 Brake test .....................................................................109 Brakes, checking..........................................................193 Braking .........................................................................109 Breather filter, fuel system ...........................................178 Bucket operation ..........................................................136 Bucket positioner ...........................................................78 Bucket teeth .................................................................199 Bucket teeth, changing ................................................199 Bucket with clamping arm (optional equipment) ..........137 Buckets ........................................................................136 Bulb, changing .............................................................188 Cab ..................................................................6, 195, 234 Cab, cleaning and changing ventilation filter ...............195 CareTrack (optional equipment).......................................8 CE-marking, EMC-directive............................................11 Change volumes ..........................................................218 Choosing bucket ..........................................................136 Cleaning the machine ..................................................170 Climate control system.............................................65, 86 Combi forks (optional equipment) ................................148 Combination table, interchangeable equipment (attachments) machine model...................................242 Communication equipment, installation .........................14 Compressor belt, checking and adjusting tension (workshop job) .................................................197 Condenser ...................................................................198 Control panel (optional equipment) ................................67 Controls..........................................................................69 Coolant.................................................................181, 216 Coolant, changing ........................................................182 Coolant, checking ........................................................181 Cooling system ............................................................181 Delivery Instructions.....................................................169 Depressurizing, 3rd and 4th hydraulic function ............135 Dimensions ..................................................................238 Display ...........................................................................29 Dumping load ...............................................................141 Economical operation ..................................................125 Electrical distribution box .............................................185 Electrical system ..............................................6, 184, 222 Engine air cleaner ........................................................179

Engine air cleaner's main filter, cleaning and changing179 Engine braking / downshifting...................................... 105 Engine braking/downshifting, electric servo (optional equipment) .................................................... 106 Engine oil filters, replacing........................................... 174 Engine oil ..................................................................... 216 Engine oil, changing .................................................... 173 Engine oil, checking..................................................... 173 Engine protection - Software ......................................... 93 Engine.............................................................. 5, 173, 220 Environmental requirements............................................ 5 Equipment........................................................................ 7 Evaporator ................................................................... 198 Excavating ................................................................... 139 Fan belt, checking (workshop job) ............................... 183 Fire protection.............................................................. 162 Fire suppression system (optional equipment) ................ 8 FOPS and ROPS............................................................. 7 Foreword.......................................................................... 1 Fuel filling point............................................................ 175 Fuel filter, replacing ..................................................... 176 Fuel prefilter, changing (optional equipment) .............. 178 Fuel system ................................................................. 175 Fuel system, air bleeding............................................. 175 Fuel.............................................................................. 217 Function check............................................................... 67 Fuses ........................................................................... 225 Gear shifting ................................................................ 103 Gravel and heap loading.............................................. 139 Handling hazardous materials ..................................... 164 Headlamps, adjusting .................................................. 187 High-Lift grapple (optional equipment)......................... 145 High-tip bucket (optional equipment) ........................... 138 Hydraulic function, 3rd and 4th .................................... 135 Hydraulic oil level, checking......................................... 200 Hydraulic oil ................................................................. 200 Hydraulic oil, changing................................................. 200 Hydraulic system ............................................. 7, 200, 236 Hydraulic system, changing breather filter................... 201 Hydraulic system, changing return oil filter .................. 201 Hydraulically powered, rotating attachments ............... 153 Identification numbers...................................................... 2 Information and warning plates / decals ........................ 16 Information..................................................................... 31 Instrument panel, cab post ............................................ 56 Instrument panel, front................................................... 24 Instrument panel, overhead ........................................... 65 Instrument panels .......................................................... 23 Intended use .................................................................... 5 Interval between changes............................................ 219 Keypad for display ......................................................... 30 Kick-down function....................................................... 105 Kick-down function, electric servo (optional equipment) .................................................... 106 Lashing of machine...................................................... 123 Levelling....................................................................... 141 Lifting objects............................................................... 154 Lifting the machine....................................................... 123 Loading vehicle with timber grapples........................... 143 Loading ........................................................................ 151 Log grapples (optional equipment) ...................... 142, 245 Lubrication and service chart............... 169, 209, 210, 212 Lubrication grease ....................................................... 217 Lubrication ................................................................... 203 Machine operator safety ................................................ 97 Machine, volumes........................................................ 240 Manual gear shifting .................................................... 103 Material handling arm (optional equipment) ........ 150, 247 Oil-bath air cleaner (optional equipment)..................... 180 Oil-bath air cleaner, changing oil ................................. 180 Oil-bath air cleaner, checking ...................................... 180 Oil-bath air cleaner, cleaning ....................................... 180

Alphabetical index

254 Operating (working) on a public road .............................98 Operating information ....................................................29 Operating instructions ....................................................93 Operating techniques ...................................................125 Operating with a load ...................................................152 Operating with material handling arm ..........................151 Operating with pallet forks ...........................................147 Operating with whole trunks.........................................144 Operator comfort ............................................................83 Operator duties ..............................................................96 Operator seat, lubrication.............................................196 Operator's seat...............................................................83 Other controls ................................................................69 Overhead power lines for high voltage ........................128 Paint finish maintenance ..............................................170 Pallet forks (optional equipment) .................................146 Pallet forks ...................................................................243 Parking brake, mechanical release ..............................116 Parking .........................................................................112 Positioning of transporting vehicle ...............................141 Power transmission..........................................................6 Presentation .....................................................................5 Product plates ................................................................15 Propeller shafts and back-up bearings, lubrication ......191 Radiator, cleaning ........................................................183 Rear cab wall .................................................................66 Rear vision system, screen, black/white (optional equipment) ......................................................91 Rear vision system, screen, colour (optional equipment) ......................................................90 Recommended lubricants ............................................215 Recovering/towing .......................................................114 Relays and fuses .........................................................188 Relays ..........................................................................223 Return-to-Dig .................................................................79 Reversible fan, cleaning...............................................183 Rock loading ................................................................140 Rotating attachments ...................................................153 Running-in instructions ..................................................93 Safety regulations ............................................................1 Safety rules in case of fire..............................................99 Safety rules when operating ..........................................96 Safety when servicing ..................................................159 Seat belt .........................................................................85 Service and maintenance ............................................169 Service journal .....................................................169, 249 Service points ..............................................................172 Service position............................................................159 Service programme......................................................169 Settings ..........................................................................42 Sideshift forks (optional equipment).............................149 Signalling diagram .......................................................156 Specifications ...............................................................215 Starting engine in cold weather....................................102 Starting engine .............................................................101 Starting with booster batteries .....................................102 Steering system .......................................................6, 230 Steering........................................................................107 Stopping machine ........................................................111 Symbol key ..................................................................209 Table of contents .............................................................3 The USA Federal Clean Air Act .....................................20 Touch-up painting ........................................................170 Transmission breather filter, changing .........................190 Transmission oil level, checking...................................189 Transmission oil, changing ..........................................189 Transmission........................................................189, 227 Transmission, changing oil filter...................................190 Transmission, cleaning suction filter ............................190 Transporting load (loading carrying) .........................140 Transporting machine ..................................................117 Travelling on public road ................................................98

Turbocharger ............................................................... 101 Tyre sizes and air pressures........................................ 231 Tyres............................................................................ 194 Underground cables and pipelines .............................. 129 Visibility.......................................................................... 94 Washer fluid reservoir.................................................. 196 Water trap .................................................................... 177 Welding........................................................................ 185 What to do if the machine gets stuck........................... 113 Wheel bolts, check-tightening...................................... 194 Wheel nuts, tightening torques .................................... 233 Whole-body vibrations ................................................. 126 Working in the cold ...................................................... 131 Working in water .......................................................... 131 Working on a grade ..................................................... 130 Working with log grapples............................................ 143 Working within dangerous areas ................................. 128

Ref.No. VOE21B1003320 Volvo, Eskilstuna

English CST

L120F

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