L45F/L50F 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 service and maintenance. Keep the manual in the cab so that it is always at hand. Replace it immediately, 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 both machine models, L45F and L50F, 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 make these changes without committing ourselves to introducing 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 maintenance without prior notice.
Other controls
Safety regulations
Operating techniques
Instrument panels
Operating instructions
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.
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!
Safety when servicing
Service and maintenance
Specifications
Alphabetical index
Ref no: VOE21A1004613 The original language is English Printed in Sweden 2008.11 Copyright Š 2008, Volvo Construction Equipment Customer Support. All rights reserved.
Foreword
2
Identification number
Identification number In order to avoid queries when ordering spare parts or in case of enquiries by phone or in writing please make a note of the machine data on the page below.
Manufacturer:
Volvo Compact Equipment GmbH & Co.KG D-54329 Konz-Kรถnen โ ข Max-Planck-Str. 1 Germany
Model/Type: Product identification number: Year of manufacture:
Please send comments about the Operator's Manual to om@volvo.com
Table of contents
3
Table of contents Foreword....................................................................1 Identification number .............................................................. 2
Presentation ..............................................................5 Communication equipment, installation............................................................................... 8 Machine view.......................................................................... 9 CE marking, EMC directive .................................................. 10 Product plates....................................................................... 11 Information and warning decals............................................ 12 USA federal clean air act...................................................... 15
Instrument panels ...................................................17 Instrument panel, front.......................................................... 18 Ceiling panel......................................................................... 20 Cab post panel ..................................................................... 21 Rear cab wall........................................................................ 25 Centre instrument ................................................................. 26 Display unit ........................................................................... 30 Alarm texts............................................................................ 42 Anti-theft device (optional equipment) .................................. 47
Other controls .........................................................49 Controls ................................................................................ 49 Operator’s comfort................................................................ 59 Climate control system ......................................................... 62
Operating instructions ...........................................67 Safety rules when operating ................................................. 68 Measures before operating................................................... 71 Starting ................................................................................. 72 Gear shifting ......................................................................... 75 Differential lock ..................................................................... 76 Braking ................................................................................. 77 Stopping ............................................................................... 78 Parking ................................................................................. 79 Measures when getting stuck ............................................... 80 Recovering and towing ......................................................... 81 Transporting machine........................................................... 83
Operating techniques .............................................85 Whole-body vibrations .......................................................... 86 Working within dangerous areas .......................................... 88 Attachments.......................................................................... 92 Connecting and disconnecting attachments......................... 93 Attachment brackets............................................................. 94 Loading................................................................................. 96 Boom suspension system (BSS) .......................................... 97 Buckets................................................................................. 98 Timber grapples (optional equipment)................................ 106 Special hydraulics............................................................... 107 Pallet forks.......................................................................... 109 Material handling arm ......................................................... 112 Road sweeping (optional equipment) ................................. 115 Lifting objects...................................................................... 116 Signalling diagram .............................................................. 117
Table of contents
4 Safety when servicing ..........................................119 Service position .................................................................. 119 Before service read ............................................................ 120 Fire prevention.................................................................... 122 Handling hazardous materials ............................................ 124 Service and maintenance ................................................... 127 Service points ..................................................................... 129 Engine ................................................................................ 130 Fuel system ........................................................................ 134 Engine air cleaner............................................................... 138 Cooling system ................................................................... 140 Electrical system................................................................. 145 Axles................................................................................... 149 Brake system...................................................................... 151 Tyres................................................................................... 152 Cab ..................................................................................... 153 Windscreen washer system................................................ 154 Air conditioning (optional equipment) ................................. 155 Bucket teeth, replacing (Volvo tooth system) ..................... 158 Hydraulic system ................................................................ 159 Accumulators, releasing pressure ...................................... 162 Greasing ............................................................................. 163 Lubrication and service chart.............................................. 166 Automatic greasing system (optional equipment)............... 170
Specifications........................................................177 Recommended lubricants................................................... 177 Coolant ............................................................................... 179 Service capacities and change intervals ............................ 180 Engine ................................................................................ 181 Electrical system................................................................. 183 Transmission ...................................................................... 188 Brake system and steering system..................................... 189 Tyre sizes and pressures ................................................... 190 Cab ..................................................................................... 191 Hydraulic system ................................................................ 193 Dimensions and performance values ................................. 194 Service history .................................................................... 200
Alphabetical index ................................................203
Presentation
5
Presentation
1041516
Intended use The machine is intended to be used under normal conditions for the applications described in the Operator's Manual. If it is used for other purposes or in potentially dangerous environments, for example explosive atmospheres, flammable environments or areas with dust containing asbestos, special safety regulations are to be followed and the machine to be equipped for such use. Contact the manufacturer/dealer for further information. The machine is designed for a maximum machine weight (incl. equipment and attachments) of 9500 kg (20944 lb) for L45F and 10300 kg (22707 lb) for L50F. 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 Be conscious of the environment while operating and maintaining the machine. Always follow national environmental legislation applying to all handling of the machine.
Engine Volvo D5D is a four cylinder four-stroke water-cooled low-emission engine with direct fuel injection. The engine of the L45F is turbocharged without intercooler. The engine of the L50F is turbocharged with intercooler.
Electrical system The battery disconnect switch is located behind the upper step of the cab entrance. The machine has three 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. The V-ECU (for the machine) receives signals from sensors on the machine and these are sent to the IECU. The T-ECU controls the transmission.
Transmission The machine has an infinitely variable hydrostatic transmission with automotive drive control. Maximum rim pull is available in all speed ranges. The inching-brake pedal provides hydrostatic braking with precise control of travel speed. All wheel drive with planetary axles. Rear axle with self-lubricated oscillating. Differential lock with 100 % dog clutch system in both axles.
Presentation
6 Brake system Inching-brake valve for hydrostatic braking via transmission and subsequent hydraulic operation of the service brakes. Single circuit all-hydraulic brake system for rear axle. Service brakes: Inboard wet disc brakes on rear axle. Front axle braking via propeller shaft. Parking brake: Mechanically operated dry disc brake on input shaft of front axle.
Steering system Articulated frame steering with dampened end stops. Hydrostatic load-sensing steering system with two double-acting steering cylinders.
Frame Articulating frame concept with oscillating rear axle suspension. Front and rear frame designed for maximum ground clearance with robust articulation joint bearings.
Cab The cab features full instrumentation and has a heating and ventilation system with defrosting for all windows. Air conditioning is available as an option.
FOPS and ROPS The cab and cab support are approved as a protective cab according to FOPS and ROPS standards. FOPS is an abbreviation of Falling Object Protective Structure (roof protection) and ROPS is an abbreviation of Roll Over Protective Structure (roll over protection). If any part of the cab’s protective structure is affected by plastic deformation or rupture, the cab shall be immediately replaced. 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, through 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 aware of these regulations.
Hydraulic system Demand controlled Load-sensing hydraulic system. Work hydraulic system with a servo-controlled main control valve. The oil in the work hydraulic system is supplied in proportion to the position of the control levers. If the hydraulic control levers are in neutral position, consequently no oil is supplied by the variable displacement work hydraulic pump. The steering system has priority supply from another pump, which also supplies the brake charging valve and the fan motor. The combined suction and return flow filter serves the hydrostatic transmission pump. The filter element can be changed without having to empty the oil tank. Thermostatically controlled oil flow to the integrated hydraulic oil cooler.
Presentation
7 Equipment Volvo CE supplies a range of after-market kits and options. Contact a Volvo CE dealer for further details.
Anti-theft device (optional equipment) An installed anti-theft device makes it more difficult to steal the machine. Volvo CE supplies anti-theft devices as optional equipment. If your machine is not yet equipped with one, check the possibilities of having such a device installed by your dealer.
Modifications of machine Modifications to this machine including the use of unauthorised attachments, accessories, assemblies or parts may affect the integrity of the machine and/or the ability of the machine to perform as designed. Persons or organisations making unapproved modifications assume all liability arising from or related to the modification, including any adverse affect on the machine. No modifications of any kind should be made to this product unless the specific modification has been officially approved in writing by Volvo Construction Equipment. Volvo Construction Equipment reserves the right to reject any and all warranty claims which arise from or are related to unauthorised modifications. Modifications are officially approved if at least one of the following conditions is met: 1 The attachment, accessory, assembly or part is manufactured or distributed by Volvo Construction Equipment and installed in a factory approved manner as described in the publications available from Volvo Construction Equipment; or 2 The modification has been approved in writing by the Product Line Engineering Department of Volvo Construction Equipment.
Logged machine data This machine is equipped with software systems, which records various information about the machine and this information is transferred from the machine to Volvo and used by Volvo and its authorized workshops in the product development process and for possible malfunction detection. Questions regarding this information can be directed to your dealer.
CareTrack (optional equipment) The machine can be dealer equipped with CareTrack, a telematics system developed by Volvo Construction Equipment. The system collects machine data which can be wirelessly transferred to a computer. The data shows machine position and operating hours. It also offers geo- and time-fences, plus service reminders. For further information, contact a Volvo CE dealer.
Presentation
8
Communication equipment, installation
Communication equipment, installation IMPORTANT! All installation of optional electronic communication equipment must be performed by trained professionals and in accordance with the Volvo CE instructions.
Protection against electromagnetic interference This machine has been tested in accordance with EU directive 89/ 336/EEC governing electromagnetic interference. It is therefore very important that all non-approved electronic accessories, such as communication equipment, should be tested before installation and use, since they can cause interference to the electronic systems of the machine.
Mobile telephones To obtain the best functionality, mobile telephones should be permanently installed in the electrical system of the machine, with a permanent aerial fixed on the cab and installed as advised by the manufacturer. If a portable mobile telephone is used, note that it can constantly transmit information to its base station, even when the telephone is not used. For this reason, it should not be placed beside electronic equipment in the machine, such as directly on a control panel etc.
Guide-lines The guide-lines given below must be followed during installation: Q
The aerial placement must be chosen to give good adaptation to the surroundings.
Q
The down lead from the aerial must be of the coaxial type. Make sure that the cable is undamaged, that the sheath and braid are not split at the ends, the braid covers the connector ferrules and has good galvanic contact with them.
Q
The mating surface between the aerial mounting bracket and the bodywork must be clean metal surfaces, with all dirt and oxide removed. Protect the mating surfaces against corrosion after installation, to maintain good galvanic contact.
Q
Remember to keep interfering cables and those which may suffer from interference apart. Interfering cables are the power supply cables and the aerial to the communication equipment. Cables which may suffer from interference are cables to and from electronic units on the machine. Install cable harnesses as close to grounded plate surfaces as possible, as these have a screening effect.
Presentation
Machine view
9
Machine view Machine description The terms left-hand and right-hand, when used in this manual, indicate the sides of the machine as seen from the operator seat facing the front of the machine.
12 1 4 2
6
3
4 5
12
7
10 9
11
8
1040804
1
Tilt linkage
7
Bucket
2
Tilt cylinder
8
Lifting arms
3
Lift cylinder
9
Battery box
4
Front lights with direction indicators
10
Cab filter cover
5
Steps, lower step with flexible suspension
11
Rear lights with direction indicators and back-up lights
6
Engine hood
12
Working lights, front and rear
Presentation
10
CE marking, EMC directive
CE marking, EMC directive CE marking (Declaration of Conformity) (Only applies to machines marketed within the EU/EEA.) This machine is CE marked. This means that when delivered the machine meets the applicable "Essential Health and Safety Requirements", which are given in the EU Machinery Safety Directive, 98/37/EC. 1000808
Any person carrying out changes that affect the safety of the machine, is also responsible for the same. As proof that the requirements are met, the machine is supplied with an EU Declaration of Conformity, issued by Volvo CE for each separate 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. The person carrying out such action is also responsible for the action which, in some cases, may require a new CE marking and the issue of a new EU Declaration of Conformity.
EU EMC Directive 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", 89/ 336/EEC, 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 which meets the requirements should be CE marked. 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.
Presentation
Product plates
11
Product plates With the aid of the product plates, shown below, it is possible to identify the machine and its components. The Product Identification Number, PIN, indicates the model designation, engine code and serial number of the machine. Make a note on page 2 of the identification numbers. When ordering spare parts, and in all telephone enquiries or correspondence the PIN must always be quoted.
7
9
8
6 1 5 2/3/4/7
1041517
1
PIN product plate The plate is located on the right-hand side of the front frame and shows machine type, manufacturer's name and address, machine PIN (Product Identification Number) for the complete machine.
6
Cab The plate is located behind the filter cover (on the right-hand side). It shows the manufacturer's name and address, product number, machine model designation, max. machine weight, cab serial number and ROPS/FOPS certificate number.
2
Additional type plate (EU/EEA only) The plate is located on the right-hand side of the front frame and shows machine weight, engine power, year of manufacture and the CE mark.
7
Engine identification plate (North America only) The plate is located on the top of the engine. The EPA plate is located on the right-hand side of the front frame, near to the PIN product plate.
3
Additional type plate (Germany only) The plate is located on the right-hand side of the front frame and shows the machine type, machine PIN (Product Identification Number), permissible axle loads and year of manufacture.
8
Front axle The manufacturer's name and address with product and serial numbers.
4
Additional type plate (Italy only) The plate is located on the right-hand side of the front frame and shows the machine type, EU approval number, permissible axle loads and data for trailer brake (if applicable).
9
Rear axle The manufacturer's name and address with product and serial numbers.
5
Primary marking Machine PIN stamped-in on the right-hand side of the front frame.
10
Transmission The manufacturer's name and address with product and serial numbers.
Presentation
12
Information and warning decals
Information and warning decals The operator should know and pay attention to the information and warning decals which are positioned on the machine. All decals are not installed on all machines, as they are market and machine dependent. The decals must be kept free from dirt, so that they can be read and understood. If they have been lost or no longer are legible, they must be replaced immediately. The part number (order number) is given on the respective decal and in the Parts Catalogue. NOTE! On the machine, the text WARNING! is given on the warning decals for North America only.
12 23 11
16 1 9
21 10
22 5 6 18
10
2 3 15
9
17
4
4 24 14 13 10 9 8 25 19 7
20
32
10
21
1040957
Presentation
2
WARNING! First read the Operator's Manual.
1040934
13
WARNING! Safety alert symbol: Danger area in the immediate vicinity of the machine.
3
WARNING! Crushing articulation area. Stay a safe distance from the machine.
1040935
1
1040933
1040932
Information and warning decals
11026729
1014833
WARNING! Hot surfaces and rotating parts.
5
Battery disconnect switch
8
Hydraulic oil filling point
6
WARNING! Before welding - read the Operator’s Manual.
9
Point for lifting
4948103
4
M300008A
1040940
11 Lever functions for loader, hydraulic and transmission control.
11445056
1020820
1040941
13 WARNING! Hot coolant
14 Use Volvo coolant VCS only
12 Emergency exit
4948092
L67533A
10 Attaching point for tie-down
1026932
L67542A
Fuel filling point
1040939
7
L67543A
11055037
1040938
D
15 WARNING! System under pressure
Presentation
14
Information and warning decals
1040944 1040943
1040942
20 WARNING! Before connecting jump leads - read the Operator's Manual.
21 WARNING! Do not walk under raised lifting arms. Stay a safe distance from the machine.
1040945
19 Electrical sockets on right side of cab.
1000h
1500h
2000h
18 Electrical sockets on left side of cab.
1040947
17 Fuses and relays in engine compartment.
1040946
16 Fuses and relays in cab.
6000h
500h 250h 125h 50h 10h
6
14/ 16
4
1
7
2 1
9
NOTICE: R134a AC-SYSTEM
1
5
SYSTEM DESIGNED ACC. TO SAE J639 MAR99
3
CAUTION: SYSTEM ONLY TO BE SERVICED BY VOLVO CE QUALIFIED PERSONNEL. SEE VOLVO CE SERVICE INSTRUCTION.
2
AIR COND. CHARGED WITH 1,85 Kg ± 5g R134a
13
Volvo Construction Equipment
10
500h
11
1
11
12
22 Lubrication and service chart
1040951
25 20 km/h (Germany only)
1040949
50h 250h
1041559
8
10h 125h
1040950
23 Sound power level outside the machine.
24 Refrigerant R134a (optional with AC)
Presentation
USA federal clean air act
15
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 C.F.R.Section 89.1003(a)(3)(i), reads as follows: The following act 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 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 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 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 your nearest Volvo Construction Equipment Regional office for assistance.
Normal Non-Road Engine Use The Maintenance Instructions are based on the assumption that this conventional machine will be used as designated in the Operator’s Instruction Manual and operated only with the specified fuel and lubrication oils.
Non-Road Engine Maintenance The non-road engine is of conventional design and any local dealer may perform the necessary non-road engine emission control maintenance 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 and receipts should be transferred to each subsequent purchaser of the non-road engine.
Presentation
16
USA federal clean air act Service Performed By Your Local Dealer Your local dealer is best qualified to give you good, dependable service since he has trained service technicians and is equipped with genuine original manufacturer´s parts and special tools, as well as 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. This will aid your local dealer in efforts to decrease service time on your machine.
Preventative 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 receive 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 °F (0 °C), the use of lighter distillate or higher cetane level fuel are recommended. (Final boiling point max. 660 °F (349 °C) and a 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 should meet ASTM designation: D 975 No. 1D (C-B) or No. 2D (TT); with a cetane level above 42 and sulfur content not exceeding 0.05 percent by weight. Check for fuel leaks (while the engine is running at fast idle): Q
Visually check unions and hose connections.
Check the conditions of the fuel hoses for: Q
Ageing
Q
Cracks
Q
Blisters
Q
Scuffing
Check the condition of the fuel tank: Q
Drain water condensation.
Q
Check for cracks.
Q
Check for leaks.
Q
Check the mounting.
Check the turbocharger: Q
Visually check for leaks in the intake hoses and exhaust pipe of the turbocharger.
Instrument panels
17
Instrument panels WARNING! Do not operate the machine until you know the function and position of the instruments and operating controls. Carefully read through this Operator’s Manual, your safety is involved!
Keep the manual in the cab so that it is always at hand.
2 1 3
4
1041271
1
Instrument panel, front (centre instrument, switches and keypad for display unit)
2
Ceiling panel (e.g. for optional radio)
3
Cab post panel (switches and ignition switch)
4
Rear cab wall (power socket 24 V, hour recorder and electrical distribution box with fuses and relays)
Instrument panels
18
Instrument panel, front
Instrument panel, front 4
1
3
2
1
Hazard flashers
2
Keypad for display unit
3
Separate attachment locking
4
Centre instrument
5
Reserve
6
Reserve
5 6
1041274
1 Hazard flashers Two- position switch. – Upper end of switch pressed in = On, all direction indicators on the machine will flash in time with the lamp in the switch together with the control lamp for the direction indicators. The hazard flashers can be used even with ignition switch in off position. – Lower end of switch pressed = Off 1020381
Hazard flashers
2 Keypad for display unit For information about keypad, see page 31.
1026099
Keypad for display unit
Instrument panels
Instrument panel, front
19
3 Separate attachment locking This switch must be applied for safety reasons when the attachment locking shall be unlocked. Spring-return switch. – Upper end of switch pressed in = Ready for Unlocking. 1043875
Separate attachment locking
A question regarding whether a check, that the attachment is locked, has been carried out will be shown on the display unit. Make sure the attachment is locked and acknowledge by pressing the SELECT key on the keypad. WARNING
11 111 506
L67523A
WARNING!
Check that the attachment is securely locked
Always check that the attachment is properly secured to the attachment bracket by pressing the front part of the attachment against the ground. For information about attaching and disconnecting attachments, see page 94.
4 Centre instrument For information about the centre instrument, see page 26. 0 km/h N
5 Reserve
700 rpm
1027057
Centre instrument
6 Reserve
Instrument panels
20
Ceiling panel
Ceiling panel For optional equipment, e.g. radio.
1041275
Interior lighting The lamp for interior lighting is located in the ceiling above the operator seat.
1033941
Interior lighting
Instrument panels
Cab post panel
21
Cab post panel 1
Head lights
2
Rotating warning beacon (optional equipment)
3
Ignition switch
4
Front working lights
15
5
Rear working lights
14
6
Working hydraulic / Control lever lockout
13
7
Wiper and washer, rear window
8
Bucket positioner
9
Boom kick-out (optional equipment)
12 11 10
10 Function selector, Boom suspension system (BSS) (optional equipment) 11 Water pump for road sweeper (optional equipment)
9 8 7 6 5 4 3
2 1 1041279
12 Back-up alarm (optional equipment) 13 Lifting fork operation / Hose rupture protection (optional equipment) 14 Electrically heated rear view mirrors (optional equipment) 15 Reserve
Instrument panels
22
Cab post panel 1 Head lights Three-position switch: – Upper end of switch pressed in = Travelling lights switched on. – Switch in centre position = Parking and Instrument lighting switched on. – Lower end of switch pressed in = Lights switched off. 1017895
2 Rotating warning beacon (optional equipment) Two-position switch: – Upper end of switch pressed in = Rotating warning beacon switched on. – Lower end of switch pressed in = Rotating warning beacon switched off. Control lamp on the front instrument panel indicates that the rotating warning beacon is connected.
1020409
3 Ignition switch The ignition switch has 4 positions: 0 R 1 2
Switched off (key-turn engine stop) Radio position Running position Engine starting position
1026348
4 Front working lights Two-position switch:
1020403
– Upper end of switch pressed in = Front working lights switched on. – Lower end of switch pressed in = Front working lights switched off. Control lamp on the front instrument panel indicates that the working lights are switched on.
5 Rear working lights Two-position switch: – Upper end of switch pressed in = Rear working lights switched on. – Lower end of switch pressed in = Rear working lights switched off. 1020404
NOTE! Working lights should be off when travelling on public roads.
Instrument panels
Cab post panel
23
6 Working hydraulic / Control lever lockout The control lever lockout is used in order to avoid involuntary actuation of the control levers, for example when servicing or transporting the machine. Two-position switch: 1041280
– Upper end of switch pressed in = Hydraulic function of control levers unlocked. – Lower end of switch pressed in = Hydraulic function of control levers locked.
7 Wiper and washer, rear window NOTE! For wiping, the front wiper must be switched on. Washing and post-wiping is possible without having the front wiper switched on. Three-position switch: 1020411
– Upper end of switch pressed in (spring return) = Washing and the wiper makes a few strokes. – Switch in centre position = Rear window wiper operates in intervals. When the front wiper is on at the same time as the reverse gear is engaged, the rear wiper will be on continuously. – Lower end of switch pressed in = Wiper and washer turned off. For the washer reservoir, see page 154.
8 Bucket positioner Two-position switch: – Upper end of switch pressed in = Adjusting tilt position / bucket positioner activated. – Lower end of switch pressed in = Detent function for tilt position / bucket positioner deactivated. 1020399
9 Boom kick-out (optional equipment) Three-position switch:
1020398
– Upper end of switch pressed in = Adjusting lift height position / boom kick-out activated. – Switch in centre position = Detent function for lifting position activated. – Lower end of switch pressed in = Detent function for lifting position deactivated / boom kick-out deactivated.
Instrument panels
24
Cab post panel 10 Function selector, Boom suspension system (BSS) (optional equipment) When starting the engine, the function reverts to the previously preselected position. Two-position switch: 1041546
– Upper end of switch pressed in = Speed-dependent BSS selected. The BSS is engaged equal and above 6 km/h. When speed drops below 6 km/h, the BSS function will be disengaged. – Lower end of switch pressed in = BSS deactivated. For further instructions, see page 97.
11 Water pump for road sweeper (optional equipment) Two-position switch: – Upper end of switch pressed in = Water pump activated. – Lower end of switch pressed in = Water pump deactivated. 1041281
12 Back-up alarm (optional equipment) Two-position switch: – Upper end of switch pressed in = Back-up alarm enabled. – Lower end of switch pressed in = Back-up alarm disabled.
1041282
13 Lifting fork operation / Hose rupture protection (optional equipment) Two-position switch: – Upper end of switch pressed in = Lifting fork operation enabled. – Lower end of switch pressed in = Lifting fork operation disabled. 1041283
14 Electrically heated rear view mirrors (optional equipment) Two-position switch: – Upper end of switch pressed in = Electrical heating activated. – Lower end of switch pressed in = Electrical heating deactivated.
1020410
15 Reserve
Instrument panels
Rear cab wall
25
Rear cab wall 2
1
3
1041284
Rear cab wall
1
Power socket 24V
2
Hour recorder
3
Compartment for fuses and relays (behind the service cover)
4
Service plug (marked VP) (behind the service cover)
Fuse test In the compartment for fuses and relays it is possible to test the fuses.
FUSE TEST
On the circuit board there is mark FUSE TEST. 1027074
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.
Instrument panels
26
Centre instrument
Centre instrument On the display unit are shown current operating information, vehicle messages and alarm texts. With the aid of the keypad 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 two seconds, the pointers in the gauges then move to indicate the correct value for fuel level and temperature. If the machine is equipped with anti-theft device, the display unit will show a request for the code to be entered, see page 47. After the correct code has been entered, the test programme will start.
1
4
5
6
2
3
9
7 8
10
11
12
13 14
0 km/h N
700 rpm
15 Central warning lamps 1
Central warning (red)
2
Central warning (amber)
3
Information symbol (green)
Warning and control lamps 4
High beams (blue)
5
Rotating warning beacon (amber)
6
Working lights (amber)
7
Applied parking brake (red)
8
Battery charging (red)
9
Direction indicator, left (green)
10
Direction indicator, right (green)
11
Display unit
12
Activated Boom Suspension System (green)
13
Engaged differential lock (green)
14
Not used
Gauges 15
Fuel level
16
Transmission oil temperature / Hydraulic oil temperature
17
Coolant temperature
16
17
1027056
Instrument panels
Centre instrument
27
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 three seconds on the display unit. The buzzer sounds four times. 1027075
4 High beams The lamp is alight when the high beams are switched on. 1021106
5 Rotating warning beacon The lamp lights when the rotating warning beacon is switched on. 1021108
6 Working lights The lamp lights when the working lights are switched on. 1021107
7 Applied parking brake The lamp is alight when the parking brake is applied. 1021109
The buzzer sounds and alarm text is shown on the display unit, if a directional gear is selected.
Instrument panels
28
Centre instrument 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 lamp flashes when the left direction indicators are on. Uneven flashing pulses indicate a faulty bulb, which then should be replaced.
1020767
10 Right direction indicators The lamp flashes when the right direction indicators are on. Uneven flashing pulses indicate a faulty bulb, which then should be replaced.
1020768
11 Display unit
0 km/h
In addition to alarm texts the display unit also shows starting sequence, operating information and settings.
700 rpm
N
1026319
12 Activated Boom Suspension System (BSS) The lamp is activated differently depending on the state: 1021111
– Flashing in safety state – Lighting in active state
13 Engaged differential lock The lamp lights when the lock is engaged. 1021112
14 Not used
Instrument panels
Centre instrument
29
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. Capacity, fuel tank:150 litres (39.6 US gal)
1021185
16 Transmission oil temperature / Hydraulic oil temperature If the gauge indicates into the red sector, the warning lamp to the right of the gauge lights up. Stop the machine and investigate the cause. The buzzer sounds if a directional gear is selected and alarm text is shown on the display unit. 1021186
17 Coolant temperature If the gauge indicates into the red sector, the warning lamp to the right of the gauge lights up. 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 if a directional gear is selected and alarm text is shown on the display unit. 1021187
Instrument panels
30
Display unit
Display unit On the display unit are shown, current operating information, vehicle messages and alarm texts. With the aid of the keypad 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 two seconds, the pointers in the gauges then move to indicate the correct value for fuel level and temperature. If the machine is equipped with anti-theft device, the display unit will show a request for the code to be entered, see page 47. After the correct code has been entered, the test programme will start.
Operating Information display screen
XX
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.
yyy
zzz zzz
vvv rpm
ww
ss
There are two different arrangements of the Operating Information screen, Operating Information screens 1 and 2. Use ARROW UP/ DOWN to select Operating Information screen 1 or 2. If any information is missing or fails to occur, – – – will be shown. 1041463
Operating Information screen 1
Travelling Speed
yyy
km/h/mph Selected gear N/F1/F2//R1/R2
XX yyy zzz zzz
xx
zzz zzz
vvv rpm
1026137
Operating Information screen 2
Shows if another gear selector control has been selected
vvv
Engine rpm
ww
Time, 12/24, AM/PM
ss
Temperature, C/F
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. Not used
Instrument panels
Display unit
31
Keypad for display unit With the aid of the keypad 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 messages
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
32
Display unit Information Information about the machine status is obtainable by pressing the respective function key on the keypad. 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 keypad. 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
Engine rpm rpm
Shows current engine speed.
Oil pressure Shows oil pressure, normal or low. 102799
Low
Air filter Normal
Shows whether the air filter is normal or when clogged, a text message is shown.
Instrument panels
Display unit
33
Selected key
Engine
The hydraulic oil temperature must exceed 0 °C (+32 °F) to make it possible to reverse the cooling fan.
Rev. 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.
Rev. cooling fan Short
Shows that reversing is selected and the selected interval. Shows the duration of the interval in minutes.
Interval
To select a new interval, press SELECT, use the arrow keys to make required selection, then press SELECT.
Rev. cooling fan mode Short Long Manual OFF
For manual reversing make a new selection as above and select Manual.
Manual Interval
Move down one step with the arrow key. Press SELECT. The cooling fan reverses. Reversing ceases automatically.
Rev. cooling fan
To revert to the "Operating Information" screen, press the ESC key. Selected key
Transmission Oil temperature Shows oil temperature, normal or high. 102799
High
Instrument panels
34
Display unit Selected key
Hydraulics Oil temperature Shows oil temperature, normal or high.
102799
High
Oil filter Shows oil filter, normal.
Normal
Selected key
Axles / Brakes Brake pressure Shows brake pressure, normal or low. 102799
Low
Selected key
Electrical system Voltage Shows system voltage, low, normal, high. 102799
Low
High
Instrument panels
Display unit
Selected key
Vehicle information Operational Data
To see operational data, press the SELECT key.
Shows operational data since previous setting to zero.
Vehicle information Operational Data Reset
Reset
Set operational data to zero with SELECT
Off Time
h
Distance
km
Cycles
Operating time in hours Travelling distance in km/mile Number of cycles
Reset
Reset Off To return to previous menu press ESC.
For information move downward with the arrow key.
Vehicle information
Operational Data Model Tires Machine hours
h
See previous screen
Lxxxx
Machine designation
mm h
Time
xx:xx
Date
xxxxxxxx
HW/SW
Tire size Total operating time of machine Real time Current date Only accessible for service personnel
To return to previous menu press ESC.
35
Instrument panels
36
Display unit Selected key
Vehicle messages Message is available for retrieval
Selected key
Service Next service
Select but with arrow key, press SELECT
Central lubrication Test
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
Yes
To confirm service, press SELECT
No
To go back and make a new selection, press ESC To go back to Operating Information screen, press ESC twice
Instrument panels
Display unit
37
Service Central lubrication Interval
Selected menu
Light
Level
Normal
Shows the selected interval. To make a new selection, press SELECT. The screen shows an example Shows that there is sufficient lubricant in the reservoir
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
Light Normal
Select interval by moving up or down with the arrow keys.
Heavy 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
Testing warning and control lamps in the centre instrument
Sound test
Off
Testing the warning buzzer in the centre instrument Select Off or On with SELECT To return, press ESC To go back to Operating Information screen, press ESC twice
Instrument panels
38
Display unit Selected key
SETUP Settings
Shows previous setting. Select row by moving up or down with the arrow keys.
Operation Parameters
Shows Operation Parameters (depending on machine model and equipment)
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 %
Selected key
SETUP Settings
Shows previous setting. Select row by moving up or down with the arrow keys.
Operation Parameters
Selected menu
Auto Engine Off
Shows Auto Engine Off. On or Off. (When "Auto Engine Off" is installed)
Anti-Theft Time
Shows Anti-Theft Time. (When "Antitheft" is installed)
Change Code
Shows Change Code. (When "Antitheft" is installed)
Instrument panels
Display unit
39
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 keypad. 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 keypad. 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
40
Display unit 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
41 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. Inverted / Normal 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: – Normal – Inverted
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
42
Alarm texts
Alarm texts 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. 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 a the alarm is shown certain number of times.
Miscellaneous Information
Information
Go to Service mode
Exit Service mode
Enter Anti Theft Code
Instrument panels
Alarm texts
43
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. – Rectify or contact a workshop authorised by Volvo CE for information.
Warning
Warning
Stop vehicle
Stop vehicle Turn Off Engine
These two warning 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
Low engine oil pressure
Coolant level low* *) The level is checked continuously during operation.
Brakes Warning
Warning
Low brake pressure
Steering system Warning
Warning
Low steer pressure*
*) Applies only to machines equipped with secondary steering.
Hydraulics Warning
Warning High hydraulic oil temperature
Attachment lock open
Low steer pressure*
Instrument panels
44
Alarm texts 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
Cooling fan reversal failure
Cooling fan system failure
Fuel level sensor
Clogged air filter engine
Fuel level low
Preheating failure
High temp. starter motor Wait 5 min. before start
High coolant temperature engine
Automatic Engine shutdown
Low engine coolant level Check at next stop
Electrical system Check
Check
High system voltage
Low system voltage
HVAC failure
Transmission Check
Check
Transmission failure
Gear sel. F/N/R failure Check at next stop
Instrument panels
Alarm texts Axles Check
Check
Diff. lock failure
Steering system Check
Check
Secondary steer failure
Secondary steer pump failure
Steering system failure
Hydraulics Check
Check
Check attachment lock and confirm*
Attachment lock
BSS Failure
Hydraulic oil filter clogged
Temperature sensor hydraulics
*) Confirm with SELECT
45
Instrument panels
46
Alarm texts Miscellaneous Check
Check
ECU network Communication Interrupt
ECU network Reduced Communication**
HVAC failure
Central lubrication failure
Lubricant level low Check at next stop
Rear wiper failure
Wiper failure
Residual time XXX h Next service YYYY h*
Parameter failure
’Limp Home’ safety related failure
Ambient temperature sensor
Back-up alarm 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 gear. Only Operating Information and Alarms are available on the display unit. **) Contact a workshop authorised by Volvo CE for information.
Instrument panels
Anti-theft device (optional equipment)
47
Anti-theft device (optional equipment) The anti-theft device prevents theft of the machine as: – the engine does not start – the gear selector does not work 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 Press SELECT to enable code entering.
****
4 Enter the four-digit code on the keypad. – 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. – If the code has failed 5 times, the antitheft system displays a recovery code (5 digits). Via this recovery code Volvo CE can provide a new 4 digit antitheft code.
1026099
Q
The engine can be restarted within a predetermined time after it was stopped without having to enter the code. The predetermined time is set 60 seconds, but can be adjusted from 0 - 60 minutes via the menu "Setting \ Operational parameters".
Instrument panels
48
Other controls
Controls
49
Other controls Controls 8
3 1 4 5
2 6 10 11 9 12
7
1040953
1
Control lever (travelling direction selection, gear selection, differential lock and loader functions)
2
Control lever for attachment locking and special hydraulics
3
Multi functional lever (light switch / direction indicators / warning horn / windscreen wiper/washer system)
4
Inching-brake pedal, left side
5
Inching-brake pedal, right side
6
Drive pedal
7
Parking brake lever
8
Steering wheel, adjusting
9
Climate control system
10
Hand throttle control (optional equipment)
11
Hand-inching control (optional equipment)
12
12 V socket (optional equipment)
Other controls
50
Controls 1 Control lever
H
F
Travelling direction selection Forward: Roll the left control knob fully forward (F). Rearward: Roll the left control knob fully backwards (R). NOTE! The display unit on the centre instrument will display the selected travelling direction (F = Forward or R = Rearward), when the parking brake not operated and the parking brake lever fully released downwards and the respective control lamp is out.
N R
L
Neutral: Press button (N) to go to neutral position. NOTE! The display unit on the central instrument will display N = Neutral gear. Gear selection Higher gear: Roll the right control knob fully forward (H). Lower gear: Roll the right control knob fully backwards (L). NOTE! The display unit on the central instrument will display the selected gear. 1041254
C
B
A
IMPORTANT! Always make sure that the parking brake is fully released and that the respective control lamp is out.
Loader functions Neutral position, not activated (spring-centred) A Lowering B Floating position (with detent function) C Tilting backwards (with detent function)
E
D Tilting forward
D
E Lifting (with detent function)
1041265
Other controls
Controls
51
Differential lock function – Pressing and keeping the button (arrow) depressed, engages the differential lock on the front- and rear axle. IMPORTANT! When releasing the button, the differential locks may eventually not disengage immediately (due to the friction on the contact forces caused by the differential torques). Then, interrupt the drive and do some steering operations so that the differential torque is reduced and the differential locks on front and rear axle disengage. IMPORTANT! The differential lock should only be used when operating on slippery ground. When operating on firm ground, particularly when turning, the differential lock must be disengaged. IMPORTANT! If the machine has become stuck and one of the wheels is spinning, the wheel must be stopped before engaging the differential lock. Otherwise the drive axle system may be damaged. 1041266
2 Control lever for attachment locking and special hydraulics Function
S T
1041270
Neutral position, not activated (spring-centred) S Unlocking T Locking (with detent function)
Other controls
52
Controls 3 Multi functional lever Direction indicator, warning horn – – – M300029A
Lever forward = Left hand direction indicator Lever backward = Right hand direction indicator Button depressed = Horn
Headlights –
Lift the lever towards the steering wheel = High / low beams
Windscreen washer system –
Push the ring towards the steering wheel = Windscreen washer system
Windscreen wiper (turning of lever) – – – –
Position = Interval wiper Position 0 = Neutral Position I = Windscreen wiper, normal speed Position II = Windscreen wiper, fast
4 Inching-brake pedal, left side The inch-braking pedal enables matching of the travel speed of the wheel loader to the current travel situation, irrespective of the drive pedal position. Actuating the inch-brake pedal while the drive pedal is fully kicked down (highest possible lifting speed of the bucket) reduces the travel speed to a minimum (approaching a truck).
5 Inching brake pedal, right side Identical function as left-hand pedal - for safety only.
6 Drive pedal With the drive pedal the travel speed is controlled via the engine speed.
7 Parking brake lever
1021109
With the parking brake lever the dry disc brake on the front axle is operated via a Bowden cable. The control light is activated when the parking brake lever operated and has left its bottom position. When a gear has been selected the operation of the parking brake lever will cause the transmission to neutral gear.
Other controls
Controls
53
8 Steering wheel, adjusting
A
Adjusting the steering wheel inclination – Press locking lever (A) down and adjust the steering wheel inclination. Adjusting the steering wheel height – Pull locking lever (A) up and adjust the height of the steering wheel. IMPORTANT! After adjusting, check that all control levers have sufficient clearance when operated. 1041285
A
Locking lever
9 Climate control system For information about the climate control system, see page 62.
1041293
10 Hand-inching control (optional equipment) The hand-inching control (a turning knob) offers the possibility to match the travel speed of the machine to the application, independently from the position of the drive pedal. The turning knob is located behind the control lever for lifting arms and bucket. – Turn the hand-inching control counter-clockwise to the stop (open = no drive). – Adjust the engine speed with the drive pedal or the hand throttle control to the required speed. – Select the directional gear (Forward / Rearward). – Turn the hand-inching control clockwise (close), until the desired travel speed is reached. NOTE! During normal operation of the machine the handinching control must be completely closed (turned clockwise to the stop)!
Other controls
54
Controls 11 Hand throttle control (optional equipment)
A
Setting of hand throttle control (A) 1 Operate the drive pedal until the desired engine speed is reached. 2 Set hand throttle control (A) by pressing the push button (on top of the control knob) and pulling the control knob upwards to the stop. Now the drive pedal position is limited upwards. Deactivating hand throttle control (A) Q Press the drive pedal slightly, then press the push button on top of the knob and push the control knob completely down. NOTE! The machine can be stopped with the inching brake pedal, independently from the setting of the rotary inching valve.
WARNING! 1041549
When travelling on public roads, the hand throttle control must be deactivated.
Hand throttle control (optional equipment)
12 V
1020413
12 12 V socket (optional equipment)
Other controls
Controls
55
Lifting fork operation / Hose rupture protection (optional equipment) The Lifting fork operation / Hose rupture protection is a safety system, which prevents against uncontrolled lowering of the lifting frame in case of a hose rupture during lifting work (loading fork loading hook operation). – Upper end of switch pressed in = Lifting fork operation / Hose rupture protection enabled. – Lower end of switch pressed in = Lifting fork operation / Hose rupture protection disabled. IMPORTANT! After the engine has been shut down, "Lowering or Tilting forward" of the lifting fork is only possible in this switch position (disabled). 1041283
WARNING! Before starting maintenance or repair work, the attachment must be lowered flat to the ground and the hydraulic system must be depressurized, i.e. the lower end of the switch must be pressed in. The engine is shut down (ignition switch in position I) and the lever for the working hydraulics must be shifted several times out of neutral position to the positions "Up Down" - "Tipping back Tipping". Work in hydraulic systems must only be performed by authorized personnel.
Other controls
56
Controls Bucket positioner The machine is equipped with a bucket positioner, which automatically adjusts the tilting position according to the adjusted loading position after the bucket has been dumped. Activate the function with the switch, see page 23. For activation after dumping the control lever must be fully moved to the left side (tilting backwards) so that the lever will be kept in this position by the detent.
1020399
C
B
A
When the bucket has reached the pre-adjusted position, the detent will be released automatically and thereby the tilting backwards function will be stopped. The control lever returns to neutral position. NOTE! At every time the movement of the tilting backwards function can be stopped by pushing the control lever out of the detent position.
E
D
1041265
A
The bucket positioner is adjustable with the sensor on the tilt cylinder. IMPORTANT! The distance (A) between the sensors and the actuating part of the machine should be 3–5 mm (0.12– 0.20 in). See the adjacent figure.
L41037A
Bucket positioner switchable In some applications it is not desirable to have the attachment tilted backwards automatically. Therefore the bucket positioner function can be deactivated with the switch. Deactivate the function with the switch, see page 23. 1020399
Other controls
Controls
57
Boom kick-out (optional equipment) Activate the function with the switch, see page 23. The boom kick-out automatically adjusts the lifting position according to the adjusted lifting height. For activation after lowering the control lever must be fully moved to the rear (lifting) so that the lever will be kept in this position by the detent. When the lifting arms have reached the pre-adjusted position, the detent will be released automatically and thereby the lifting function will be stopped. The control lever returns to neutral position.
1020398
C
B
A
NOTE! At every time the movement of the lifting arms can be stopped by pushing the control lever out of the detent position. Neutral position, not activated (spring-centred) A Lowering
E
D
B Floating position (with detent function) C Tilting backwards (with detent function) D Tilting forward E Lifting (with detent function)
1041265
A
The boom kick-out is adjustable with the sensor on the left side of the front frame. IMPORTANT! The distance (A) between the sensors and the actuating part of the machine should be 3–5 mm (0.12– 0.20 in). See the adjacent figure.
L41037A
In some applications it is not desirable to have the lifting arms lifted automatically. Therefore the boom kick-out function can be deactivated. Deactivate the function with the switch, see page 23.
1020398
Other controls
58
Controls Back-up alarm (optional equipment) The back-up alarm is used to warn people in the immediate vicinity of the machine when the machine is reversing or when the "rearwards" direction is selected. – Select the Rearward gear. The back-up warning signal should be activated immediately. NOTE! The back-up alarm remains active until the Rearward gear is changed to Forward or to Neutral gear.
Back-up alarm switchable (optional equipment) If sounding the back-up alarm horn is not permitted or not desired, e.g. on public roads or inside buildings, the back-up alarm can be disabled with the switch, see page 24.
1041282
Other controls
Operator’s comfort
59
Operator’s comfort Operator seat 1
+70 kg
1 2
2
The operator seat meets the criteria of EN ISO 7096. Briefly, this means that the seat is designed to minimise whole-body vibrations during machine operation. The amount of vibration 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 weight and height of the operator. – Keep the ground on the work site in good condition. – Choose the appropriate operating technique and speed for the existing circumstances.
WARNING! Do not adjust the operator seat while the machine is moving.
3
4
5
6
A correctly adjusted operator seat enhances the operator comfort and safety. An incorrectly adjusted seat may lead to injuries. The adjustments that could be made are: 1 Weight adjustment: Turn the lever until your weight is shown in the indicator. NOTE! Do not sit in the seat while adjusting. 2 Height adjustment: Raise the operator seat to the required height until it audibly latches into place. When the seat is raised above the highest setting (endstop) it drops back down to the lowest position. 3 Seat pan angle adjustment: Pull the left handle upwards and push down or pull up the front part of the seat pan to adjust for desired angle. 4 Seat depth adjustment: Pull the right handle upwards and move the seat cushion forward or backwards to desired position. 5 Longitudinal (leg room) with control carrier: Lift the lock handle and use the control carrier to adjust for desired position. 6 Longitudinal (leg room) without control carrier: Lift the lock handle and move the seat forward or backwards to desired position. NOTE! After longitudinal adjustment, the lock handle must latch with an audible click. Then, it should not be possible to move the operator seat. 7 Backrest adjustment: Pull up the lock catch and move the backrest to the desired position. Then release the lock catch. NOTE! The backrest is spring-loaded to forward direction when the lock catch is pulled upwards.
7
8
1040926
NOTE! It should not be able to move the backrest when the lock catch has been released. 8 Armrest adjustment: Operate the turning knob (arrow) according to the desired position. The armrests can be folded up if required.
Other controls
60
Operator’s comfort Air suspended seat (optional equipment) 1
The adjustments are carried out in the same way as for the mechanical seat (see previous page), except for the weight and height adjustment. 1 Weight adjustment: Push in or pull out lever (1) until indicator (2) shows green marking. 2 Height adjustment: Push down or pull up lever (1) fully to adjust the height. NOTE! The green marking must be shown in indicator (2)
2
IMPORTANT! Do not operate the function more than 60 seconds to avoid damage. 9 Lumbar support (optional equipment): Turn the adjustment knob to adjust for lumbar support. 10 Seat heater (optional equipment): – 0 = seat heater OFF
9
– 1 = seat heater ON 11 Fore/aft isolator (optional equipment): This function should be activated under certain driving conditions for the operator seat to better absorb shock impacts in the driving direction. – 1 = activated – 2 = deactivated
0 1
10
11
1040927
NOTE! After choosing position 1, push back the operator seat fully until the lock handle laches with an audible click. NOTE! It should not be able to move the seat when the lock handle has latched.
Other controls
Operator’s comfort
61
Seat belt WARNING! A seat belt that is damaged or has been stretched in an accident must be replaced immediately. The seat belt complements the cab or canopy safety structure and must be used to protect the operator from being thrown out of the cab in case the machine should roll over. A fastened seat belt also aids the operator in maintaining control of the machine in case of violent swaying or other machine movements. Q
The seat belt and its assemblies should be inspected regularly. Replace the complete seat belt assembly immediately if damage such as worn or damaged hardware, nicked or frayed strap, buckle or retractor malfunction, or loose stitching is found.
Q
Replace the seat belt if the machine has been involved in an accident where the belt has taken excessive strain to cause deformation.
Q
Replace the seat belt every third year regardless of its condition.
Q
Modifications on the seat belt or its mountings must never be made.
Q
The seat belt is intended for one adult person only.
Q
Keep the seat belt rolled-up when not in use.
Q
When washing, use a mild soap solution. Allow the seat belt to dry while it is fully pulled out, before rolling it up. Make sure the seat belt is installed in a correct way.
Other controls
62
Climate control system
Climate control system
1
1
2
4
3
1041291
1 Air nozzles, front 2 Climate control system 3 Air nozzles, rear 4 Temperature sensor for cab climate 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
Climate control system
2
3
4
63
5
26 24 22
1
20 18
1020417
1 Air conditioning 2 Not used 3 Fan control 4 Temperature control 5 Air distribution control
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. 1
1026312
Air conditioning
If the control lamp starts to flash, the air conditioning has become turned off. The cause may be clogged condenser, see page 144. NOTE! (The switch is installed on machines without this optional equipment, but is then without any function.)
2 Not used 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
Fan control
4 Temperature control
26
Position upward = max. heating, red marking.
24
Position left = selection of required temperature.
22
Position downward = max. cooling, blue marking.
20 18
4
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.
1026310
Temperature control
Other controls
64
Climate control system 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
Air distribution control
B A
C A B C
Position right = defroster, ventilation nozzles at the windows open and directed towards the windows.
Ventilation nozzles Open the ventilation nozzles and adjust the direction of the air to obtain the best possible air distribution.
L68569A
Open Closed Air flow direction
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 153.
Other controls
Climate control system
65
How to achieve ... ... comfortable working temperature: Q
All nozzles fully open.
Q
During warm outdoor climate – air conditioning switched on.
Q
Fan control in position AUT.
Q
Temperature control set to required temperature.
Q
Air distribution control in position AUT.
... demisting all windows: Q
The front nozzles directed towards the windscreen.
Q
Floor nozzles under instrument panel closed.
Q
The rear nozzles should be directed towards the rear window / side window.
Q
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
66
Operating instructions
67
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 eight hours operation, see page 152.
Auto engine shutoff (optional equipment) Engine shutoff takes place after a predetermined time. The time is set to 5 minutes. The conditions required for engine shutoff to take place are that: – 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. The count-down for the engine shutoff can then be interrupted by actuating the accelerator pedal, hand throttle or gear selector control. When automatic engine shutoff has taken place: – The ignition key remains in position 1, running position. – Lights or other connected current consuming devices remain connected.
Operating instructions
68
Safety rules when operating
Safety rules when operating Operator obligations WARNING! The operator of, and the management for a construction machine are responsible for the working area of the machine and must turn away any person who is not authorised to be there when the machine is operating. The operator must keep a good lookout forward, rearward and to both sides to avoid the risk of running into persons or objects.
Q
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.
Q
The machine operator must be thoroughly familiar with how to operate and maintain the machine and should preferably undergo required training on the machine.
Q
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.
Q
The machine operator must be thoroughly rested and must never operate the machine under the influence of alcohol, medicine or other drugs.
Q
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. Q
The danger area is the area around the machine and at least 7 m (23 ft) beyond the maximum reach of the attachments.
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.
Accidents Q
Accidents and other incidents should be reported to the site management immediately.
Q
If possible leave the machine in position.
Q
Only take necessary action so as to reduce the effect of damage, especially personal injuries. Avoid action which may make an investigation more difficult.
Q
Wait for further instructions from the site management.
Operating instructions
Safety rules when operating
69
Machine operator safety Q
The machine must be operational, i.e. faults which can cause accidents must be rectified.
Q
Suitable clothing for safe handling and a hard hat should be worn.
Q
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 fitted according to the instructions of the manufacturer, see page 8.
Q
Always sit in the operator seat when starting the engine/machine.
Q
Keep your hands away from areas where there is a risk of crushing, e.g. covers, door and window.
Q
Always use the lap type seat belt.
Q
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!
Q
The door should be closed:
Q
Check that the attachment is properly attached and locked.
Q
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 your speed.
WARNING! It is forbidden to sit or stand in an unsuitable place on the machine, i.e. on the attachment (bucket, fork, platform etc.) or any other mounted equipment, so that the operator cannot handle the machine in a safe way.
Q
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!
Q
The cab is also designed to meet the requirements for falling objects, the weight of which agrees with testing methods according to "FOPS".
Q
The cab has one emergency exit, the rear window, which can be broken with an emergency hammer.
Q
Only stand on surfaces which have slip protection.
Q
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.
Operating instructions
70
Safety rules when operating Travelling and operating (working) on a 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.
L66358A
SMV plate
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 0.6–1.8 m (2–6 ft) above the ground, measured from the lower edge of the plate.
Travelling on public road Q
The attachment should be empty, lowered to the carry position (30 cm (12 inches)) and tilted fully backward. If a machine, equipped with a material handling arm, is transport-driven, a red flag should be attached to the front end of the arm.
Q
Lock the control levers with the switch for control lever lockout.
Q
All working lamps and any rotating warning beacon should be switched off.
Q
Attachments and buckets which obscure the vision must not be used.
Q
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.
Q
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.
IMPORTANT! Follow national and state regulations.
Operating (working) on a public road Q
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.
Q
When moving a machine with a suspended load, special attention must be observed. When required, a signal man must be used.
Q
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 operating (working) on or by the side of the roadway. – also follow national or state regulations.
Operating instructions
Measures before operating
71
Measures before operating 1 Carry out daily service, see page 166. (Make sure that the freezing point of the coolant is sufficiently low in cold weather and that the lubricating oil is intended for winter use.) 2 Clean/scrape the windows. 3 Check that there are no faulty/loose parts or leaks which can cause damage. 4 Check that the battery disconnect switch is switched on. 5 Check that the frame joint lock has been disconnected. 6 Check that the wheels are not blocked. 7 Check that the covers on the machine are attached, closed and secured and that the engine hood is closed. 8 Check that there are no persons in the vicinity of the machine, see page 68. 9 Adjust the operator seat (see page 59) and the steering wheel (see page 53). 10 Fasten the lap-type seat belt. 11 Check that there is sufficient fuel in the tank. After operating Q
Fill the fuel tank, as this will counteract the formation of condensation water.
Operating instructions
72
Starting
Starting WARNING! The engine must only be started with the ignition switch in the cab. If the machine is equipped with anti-theft device, see page 47. 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 4–5 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 oil
Exhaust
Q
lubrication and cooling is safeguarded by – not racing the engine immediately after it has been started.
A
D
– allow the engine to run at low idling for at least 30 seconds before it is turned off.
C
– 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.
B Q
engine oil is changed and oil filters are replaced at prescribed intervals.
Q
the air cleaner is serviced regularly and that the exhaust system and lubricating oil lines do not leak.
L67289A
A B C D
Exhaust inlet To exhaust system Air inlet Compressed air
In case jarring noises can be heard, or if the turbocharger vibrates, it must be reconditioned or replaced immediately. Only workshops authorized by Volvo CE should carry out work on the turbocharger.
Operating instructions
Starting
73
Starting engine in cold weather The preheating function is controlled by the V-ECU. 1 Turn the ignition key to running position (1). 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 30. 4 When the symbol is extinguished, the engine can be started by turning the ignition key to starting position (2).
WARNING! Starting gas (ether etc.) must not be used at the same time as the preheating element.
Q
Leave the engine running at low idling for 30 seconds so that the oil in the engine, transmission and hydraulic system has warmed up and become sufficiently fluid to provide proper lubrication.
Q
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.
Operating instructions
74
Starting Starting with booster batteries WARNING!
B B
A A
The batteries could explode due to the current surge if a fully charged battery is connected to a completely discharged battery. Since the batteries contain sulphuric acid, this could result in personal injuries.
Check that the booster batteries or any other power source has the same voltage as the ordinary batteries. Proceed as follows: 1 Move the gear selector to neutral.
D
2 Apply the parking brake.
C 1041518
(Principle diagram) A Booster batteries B Ordinary batteries C Cylinder block D Starter motor
3 Connect one of the jump leads from (+) on the booster battery, to (+) on the battery, which is connected nearest to the starter motor. 4 Connect the other jump lead from (–) on the booster battery, to for example the lifting eye on the cylinder head. 5 Make sure that the battery disconnect switch is switched on. 6 Start the engine from the cab with the ignition key.
WARNING! Do not under any circumstances disconnect the cables to the ordinary batteries on the machine! 7 Leave the batteries connected for 5–10 minutes after starting the engine. 8 If the ordinary batteries are greatly discharged, it may happen that the alternator does not provide any charging current. Therefore, switch on a number of devices, which consume a lot of current, in order to initiate the charging, e.g. travel lights, working lights and preheating. 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 from (+) 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.
Operating instructions
Gear shifting
F
75
Gear shifting
H
Travelling direction selection Forward: Roll the left control knob fully forward (F). Rearward: Roll the left control knob fully backwards (R). NOTE! The display unit on the centre instrument will display the selected travelling directional (F = Forward or R = Rearward), when the parking brake is not operated and the parking brake lever is fully released downwards.
N R
L
Neutral: Press button (N) to go to neutral position. NOTE! The display unit on the central instrument will display N = Neutral gear. Gear selection Higher gear: Roll the right control knob fully forward (H). Lower gear: Roll the right control knob fully backwards (L). NOTE! The display unit on the central instrument will display the selected gear.
1041254
IMPORTANT! Always make sure that the parking brake is fully released and that the respective control lamp is out. NOTE! 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.
Operating instructions
76
Differential lock
Differential lock To improve the traction of the machine on soft and slippery soil, the differential lock, which works on all four wheels, can be engaged by depressing and holding the push button (arrow) depressed. IMPORTANT! The differential lock must only be engaged when the machine is standing. Make sure, that under no circumstances, the differential lock is activated when the wheels are turning with different speeds. When the differential lock is engaged control light (13) lights up, see page 28. If only one wheel of an axle turns although the differential lock switch is depressed, interrupt the drive and operate the steering to help the dog clutch to engage. The differential lock may be disengaged while driving. IMPORTANT! When cornering on hard ground the differential lock must be switched off.
1041266
IMPORTANT! The differential lock should only be used when operating on slippery ground. When operating on firm ground, particularly when turning, the differential lock must be disengaged. IMPORTANT! If the machine has become stuck and one of the wheels is spinning, the wheel must be stopped before engaging the differential lock. Otherwise the drive axle system may be damaged. NOTE! If there is risk of getting stuck, engage the differential lock before the machine has got stuck. For further information on the differential lock, see page 51.
Operating instructions
Braking
77
Braking Brake smoothly. This is particularly important when operating with a load and on slippery ground. IMPORTANT! Do not apply the parking brake while the machine is moving. The parking brake should only be used when the machine has been stopped or as an emergency brake. NOTE! When the parking brake is operated the transmission will be forced into Neutral gear.
Operating instructions
78
Stopping
Stopping 1 Lower the engine speed. 2 Apply the brakes and when the machine is stationary, press button (N) to go to neutral position. 3 Lower the attachment to the ground. 4 Apply the parking brake after the machine has come to a complete standstill. IMPORTANT! To ensure lubrication and cooling of the turbocharger, run the engine at idling speed for at least 30 seconds before it is turned off. 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 off the engine with the ignition key, so that the control lamps go out and the engine stops.
WARNING! Always use the three-point approach to access or leave the cab, i.e. two hands and one foot or one hand and both feet. Use stepping surfaces and handholds. Always face the machine when entering or stepping down from the machine. Do not jump off! 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.
L64417A
Operating instructions
Parking
79
Parking
L68292A
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 to the ground. 2 Check that all switches and controls are in the "off" position or in neutral. 3 Apply the parking brake after the machine has come to a complete standstill. 4 Remove the key. 5 Turn off the current supply with the battery disconnect switch, if the machine is to be left unattended for some time. 6 Lock all covers, windows, engine hood 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 IMPORTANT! If the machine is not going to be used every day, all cylinders should be protected against corrosion. 1 Carry out the measures as described above. Remember that the ground on which the machine is to stand may shift depending on the weather. Therefore take suitable action. 2 Wash the machine and touch up any damaged paint finish to avoid rusting. 3 Rust-proof exposed components, lubricate the machine thoroughly and grease all unpainted surfaces like cylinder rods etc. 4 Check the tyre pressure and protect the tyres against strong sunlight. 5 Fill the fuel tank and the hydraulic oil tank to the max. marks. 6 Cover the exhaust pipe (for outdoors parking). 7 Make sure that the freezing point of the coolant is sufficiently low (in cold weather).
Check after long-term parking All oil and fluid levels. Q Tension of all belts. Q Air pressure Q Air cleaner NOTE! If a preservative has been used on the machine to prepare it for long term storage, follow the manufacturer’s instructions for any necessary safety precautions and the method of removal. Q
Operating instructions
80
Measures when getting stuck
Measures when getting stuck 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 (like a duck's waddle). 1041563
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 next page. 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.
Operating instructions
Recovering and towing
81
Recovering and towing WARNING! Before taking any action for towing or recovering, the parking brake must be applied and the wheels must be blocked to prevent the machine from starting to roll. Work with extreme care when towing/recovering in order to avoid personal injuries and, at worst, fatalities.
Measures Q
If possible, the engine should be running to make the brakes and steering operational.
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.
A
L67530A
Recovering eyes (one per side)
11 026 730
A
Attaching point for lashing
1041554
Q
When recovering rearwards, use recovering eyes (A) (accessible from behind the rear wheels).
Q
When recovering forwards, use the eyes by the front axle attachment intended for lashing the machine.
Q
To avoid oblique loading, pull the machine straight rearwards/ forwards. Try to distribute the load by connecting to both eyes.
Operating instructions
82
Recovering and towing Towing
Connected to eyes by front axle attachment
The towing vehicle or machine must weigh at least as much as the machine to be towed and must have sufficient engine power and braking capacity to pull and brake both machines in any up or down hills. Q Before towing select neutral gear. Q Before towing the machine, the high-pressure relief valves A and B must be relieved by taking the following steps: 1 Remove plastic caps from A and B. 2 Loosen the counter-nut while maintaining the position of the adjusting screw. 3 Turn the adjusting screw counter-clockwise by exactly two turns. Then tighten the counter-nut while maintaining the position of the adjusting screw. Q Do not tow further than absolutely necessary as otherwise the transmission may be damaged. Q Towing should be limited to a speed of max. 2 km/h (1.25 mph) and a towing distance of 1 km (0.625 mile). NOTE! For longer distances the machine must be transported with a transport vehicle or trailer. Q
Connect in a corresponding way as when recovering.
NOTE! It is not possible to start the engine by towing. Follow national regulations where required.
B A A B
1041557
High-pressure relief valve High-pressure relief valve
After towing IMPORTANT! The high pressure relief valves must be adjusted to the original setting. Before the towbar or wire rope is removed, the following safety measures should be taken: 1 If possible place the machine on level ground. 2 Apply the parking brake or block the wheels to prevent the machine from rolling. 3 Reset the high-pressure relief valves A and B to the original setting by taking the following steps: 1 Loosen the counter-nut while maintaining the position of the adjusting screw. 2 Turn the adjusting screw clockwise by exactly two turns. Then tighten the counter-nut while maintaining the position of the adjusting screw. Tightening torque for the counter-nuts: max. 30 Âą5 Nm (22 Âą4 lb ft). 3 Put back the plastic caps onto A and B. In most cases the plastic caps need to be renewed.
Towing device on counterweight WARNING! The towing pin on the counterweight must not be used to tow a trailer.
1041550
Towing device on counterweight
Maximum temporary force on the towing device (towbar) on the counterweight including attachment bracket must not exceed a horizontal force of 50 kN (11220 lbf) and a vertical force of 10 kN (2240 lbf).
Operating instructions
Transporting machine
83
Transporting machine
C
WARNING!
A
A B C
B
B
A
1041294
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.
Tying down machine
B A
Q
Block the wheels (B).
Q
Tie down (lash) the machine using attaching points (A) intended for this purpose, so that it cannot tip or begin to roll.
On another vehicle Q
– Use intended attaching points for lifting, see next page.
1041551
Storage position for lock bolt (A) and locking pin (B).
A B
1041552
Frame joint lock A Lock bolt B Locking pin
If the machine is lifted up onto another vehicle, the frame joint must be locked. – Lock the frame joint with lock bolt (A) and locking pin (B).
Q
If the machine is driven up onto another vehicle, the frame joint must not be locked.
Q
Tie down (lash) the machine.
Operating instructions
84
Transporting machine Lifting machine Q
2m
Across ramp Q
6,5 m
First check that the ramp is amply wide enough and has the required strength and that it will not be displaced.
L6751
4A
4 8 98 4
95
5m
Lift the machine by the therefore intended lifting eyes (see figure) and lock the frame joint.
In elevator or other narrow space 1 Reverse the machine in. 2 Apply the parking brake and stop the engine before starting the elevator.
1041520
Attaching points when lifting
Also follow national or state regulations.
Operating techniques
85
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. The machine is equipped with load-sensing hydraulics, which means that the oil in the system is supplied proportionally according to the position (deflection) of the control levers. If the control levers are in neutral position, consequently no oil is supplied from the pumps. To utilise the system in the best way and at the lowest fuel consumption, the engine speed should be kept low during all operations. 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. Torque Nm
Power kW 80
500 P
70
450
60
400 T
50
350
40
300
30
250
20
200
10
150
0 1000
1200
1400
1600
1800
100 2200 rpm
2000
L45F
1041523 Torque Nm
Power kW 100
600
90
550 P
80
500
70
450 T
60
400
50
350
40
300
30
250
20 800
L50F
1000
1200
1400
1600
1800
2000
200 2200 rpm
1041524
Economical engine speed (grey area) — Power (P) .... Torque (T)
Operating techniques
86
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.
Guidelines for reducing vibration levels on earthmoving machines Q Q
Use the proper type and size of machine, with optional equipment and attachments for the application. Keep the terrain and haul roads in good condition. – Remove any large rocks or obstacles. – Fill any ditches and holes. – Provide equipment and schedule time to maintain terrain conditions.
Q
Adjust the machine speed and travel path to minimize the vibration level. – Drive around obstacles and rough terrain conditions. – Reduce the speed when it is necessary to go over rough terrain.
Q
Maintain machines according to the manufacturer's recommendations. – Tire pressures. – Brake and steering systems. – Controls, hydraulic system and linkages.
Q
Keep the seat maintained and adjusted. – Adjust the seat and suspension for the weight and size of the operator. – Inspect and maintain the seat suspension and adjustment mechanisms. – Use the seat belt and adjust it correctly.
Q
Steer, brake, accelerate, shift gears, and move the attachments smoothly.
Q
Minimize vibrations for long work cycle or long distance travelling. – Use Boom Suspension System if available. – If no Boom Suspension System is available, reduce speed to prevent bouncing. – Transport machines when there are long distances between worksites.
Operating techniques
Whole-body vibrations
87
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 cab or access system. – Minimize repeated handling and lifting of loads. – Maintain reasonable weight and physical condition.
Operating techniques
88
Working within dangerous areas
Working within dangerous areas Q
Observe great care at marked danger areas.
Q
Do not operate too close to the edge of a quay, ramp, etc.
Q
Move slowly when working in confined spaces and check that here is sufficient room for machine and load.
Q
When working under ground, special equipment, e.g. certified engine is required within the EU and in EES countries. Talk to your dealer.
Q
When working in low light conditions, e.g. buildings and tunnels, use head light.
Q
Do not operate the machine when visibility is poor such as a heavy fog, snow or rain.
Q
When working in an area which is contaminated or dangerous to one’s health, the machine must be especially equipped for this purpose. Talk to your dealer. Check also local regulations before entering the area.
High voltage overhead power line Voltage
Min. distance to power line
0–1 KV
2 m (7 ft)
1–55 KV
4 m (13 ft)
55–500 KV
6 m (20 ft)
WARNING! Make sure that the machine does not come into contact with power lines while the power is switched on. Injuries will arise if part of your body should come into contact with a machine which is conducting electrical power. High voltage is lethal and the current sufficiently strong to destroy both machine and attachments. Your life is in danger if you come into contact with or close to high voltage power lines. Always contact the power company responsible before beginning any work near high voltage power lines. Go through the special instructions issued by the power company for work/presence near the power lines. Regard all power lines as if they were live even if they are supposed to be without current. Working when the machine or its load at any time is closer than the minimum safety distance to a power line, is taking a very serious risk. Q
Remember that the voltage of the power line determines the safety distance. Electrical flash-over may occur and damage machine and operator at fairly great distances from the power line.
Q
Find out what action to take if a person has been exposed to an electric shock.
IMPORTANT! Also when transporting the machine, take overhead power lines into consideration. IMPORTANT! There can be a visual distortion through roof window. Real distance should be reconsidered.
Operating techniques
Working within dangerous areas
89
Overhead railway power lines
WARNING! Bear in mind that the power line over the adjacent track may be live. Loading and unloading is only permissible between the boundary signs. The signs may be mounted directly on the power line or on special posts. Q
Contact authorised railway personnel to obtain permission to load or unload.
Q
After any breaks in the work, always contact the railway personnel again.
Underground cables and pipes Make sure that authorities or companies responsible for cables and pipes have been contacted and that their instructions are followed. Also check which rules apply to ground personnel regarding exposing cables and pipes. Normally only the service companies' own personnel may expose and arrange provisional suspension of cables. Make use of a signal man when you cannot see the actual point where you are working or when the position of the pipe or cable is critical, see page 117. The position of the pipe or cable may deviate from the drawing or distances may be incorrectly determined. Regard all electrical cables as live.
Working where there is risk of landslip Always check ground conditions before beginning to work. If the ground is soft, great care must be taken when positioning the machine. Thawing of frozen ground, rain, traffic, piling and blasting are factors which increase the risk of landslip. The risk also increases on sloping ground. Q
Do not operate too close to the edge of a steep slope or road bank. Take care when working in a place where the machine may tip.
Q
Take care when working on river banks or in other similar places where the ground is soft. There is a risk that the machine, because of its own weight and own vibrations, may sink and this could lead to accidents.
Q
Keep in mind that the ground conditions may have changed after heavy rain. Therefore, be careful when restarting work. This is particularly important when working near the edge of ditches, road verges or similar, as the ground may easily give way after it has been raining.
Operating techniques
90
Working within dangerous areas Working on slopes IMPORTANT! In order not to jeopardize the lubrication of the engine, it must not be inclined more than 35 degrees in either direction. However, note that the machine can perhaps not manage to work at this angle. It may cause the machine to become unstable or unbalanced, depending on the load. Q
Be careful when opening or closing the doors on a slope, operational force may be changed rapidly. Make sure to keep the doors closed.
Q
Do not descend backward on a slope.
Q
Operate the travel function slowly when approaching or descending a slope.
Q
Do not change direction or travel a cross on a slope. Change direction on level ground, if necessary first come down to level ground and make a detour.
Q
If the machine slides, immediately lower the bucket to the ground. The machine can turn over due to unbalance.
Q
While travelling on a slope, raise the bucket 20–30 cm from the ground.
Q
If the engine shuts down on a slope, lower the attachment to the ground.
Working in water Do not exceed the maximum permitted water depth, reaching the lower foot step. IMPORTANT! Check the water depth before taking the machine into the water.
Operating techniques
Working within dangerous areas
91
Working in cold weather WARNING! In very low temperatures the hydraulic system of the machine will response slowly. Therefore, take care before the system has reached operating temperature, so that accidents are avoided. Read the advice for starting, see page 72. The windows must be free from ice and snow before putting the machine to work. Q
Watch out for ice on the machine causing slippery conditions. Step only onto anti-slip surfaces.
Q
Use an ice scraper on a long handle or a ladder when removing ice from the windows.
Q
Warm up the systems carefully and avoid high engine speed.
WARNING! Avoid contact between unprotected skin and very cold metal objects, as the skin may freeze to the metal.
WARNING! Disconnect the electrical engine heater before servicing the machine. There may be risk of burns and electrical shock.
Operating techniques
92
Attachments
Attachments Using the correct attachment for a particular job is a deciding factor for the capacity of the machine. The machine has either permanently mounted attachment or attachment mounted in a attachment bracket which allows rapid changes of attachment. When selecting a working attachment, observe the recommendations of the Volvo CE working attachment catalogue. The EU Machine Safety Directive is stated on the product plate of the machine by way of the CE symbol. This identification therefore also covers the attachment which are designed and marked by Volvo CE, as they are an integrated part of the machine and adapted to the machine. We will only assume reliability for machines which are operated with the attachments, equipment and spare parts specified by us. Attachments manufactured by other companies must be approved by Volvo CE for the specific machine, have a CE marking and be delivered with a Declaration of Conformity as well as operating instructions.
WARNING! Never use any attachment, unless you have checked that it is securely fastened and that the attachment including hydraulic hoses, hose connections and other components is free of damage. Your safety is concerned!
Operating techniques
Connecting and disconnecting attachments
93
Connecting and disconnecting attachments 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.
Q
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! 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. 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.
1041561
Operating techniques
94
Attachment brackets
Attachment brackets Separate attachment locking Connecting 1 Release the locking pins by first pressing the upper end of the switch (see page 19) and then push control lever 2 forward in order to retract the locking pins.
1043875
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.
Attachment locking
3 Raise the lifting arms until the attachment is lifted off the ground. 4 For locking the attachment, the switch must not be pressed in any longer. Lock the attachment by pulling control lever 2 rearward in order to move the locking pins out into locking position (locking pins protruding approx. 10 mm (0.4 in).
N R
1
2
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.
WARNING!
1041423
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 a workshop authorized by Volvo CE.
Disconnecting 1 The attachment should be in a level position just above the ground. 2 Release the locking pins by first pressing the upper end of the switch (see page 19) and then push control lever 2 forward in order to retract the locking pins. 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.
Operating techniques
Attachment brackets
95
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 backwards until level and lock with the locking pins of the attachment bracket
Pressure release 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.
N R
1
2 Ignition switch in position 1.
2
3 Move control lever (2) forward and rearward several times (approx. 5 seconds in each direction). 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.
1041423
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.
Operating techniques
96
Loading
Loading C
B
A
Loader functions Neutral position, not activated (spring-centred) A Lowering B Floating position (with detent function) C Tilting backwards (with detent function)
E
D Tilting forward
D
E Lifting (with detent function) Q
For loading, the blocking of the working hydraulics must be deactivated.
Q
To pick up solid, cohesive materials it is recommended to operate the lever (1) alternately several times quickly from from tilting forward to tilting backwards when entering into the material. This eases entering of the bucket into the material.
Q
During the transport of the picked up material the bucket should not be higher than 0.5 m (20 in) above the ground.
Q
You should never drive longer distances with a high raised loaded bucket.
Q
When lever (1) is in "float position", the bucket rests on the ground "without force" and can be used e.g. to level the tracks when reversing.
1041265
WARNING! For road travel and maintenance work the working hydraulics must be blocked against unintended actuation. – For information about bucket positioner, see page 56. – For information about boom kick-out, see page 57.
Operating techniques
Boom suspension system (BSS)
97
Boom suspension system (BSS) (optional equipment) The Boom suspension system (BSS) works only after reaching 6 km/h. When speed drops below 6 km/h, the BSS function will be disengaged. This function can only be pre-selected when the engine is running. 1 Lower bucket or other attachment flat on the ground. 2 Upper end of switch pressed in = Speed-dependent BSS selected. The BSS control lamp on the centre instrument starts blinking (BSS safety state). 1041546
3 Lift the attachment up from the ground by approx. 0.5 m (20 in). The BSS control lamp on the centre instrument extinguishes (BSS idle state). 4 After reaching a travel speed of 6 km/h (4 mph) the BSS is activated. The BSS control lamp on the centre instrument lights up continuously (BSS active state). 5 When the attachment is lowered (almost to the ground) or the travel speed drops below 6 km/h (4 mph) the BSS changes back to idle state. 6 The BSS is switched off by pressing the lower end of the switch or by turning off the engine.
WARNING! Before starting maintenance or repair work, park the machine on level ground, rest the working equipment flat on the ground and relieve the pressure in the hydraulic system. Shut down the engine and actuate the lever for working hydraulics several times from neutral to tilting forward and backwards. NOTE! The Boom suspension system must not be activated while travelling. For precise work with working attachments the Boom suspension system must be disabled.
Operating techniques
98
Buckets
Buckets WARNING! The bucket must not be used for transporting or lifting people – as this might lead to accidents. 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 Q
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.
Q
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.
Bucket operation To obtain efficient and safe operation it is important to bear the following points in mind: Q
Select the correct bucket.
Q
Level the ground at the work site as far as possible and make sure the ground is firm.
Q
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.
Q
Work with a straight machine against the material to obtain the greatest penetrating ability. This also contributes to reduced tyre wear.
Operating techniques
Buckets
99
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. 2 Enter the material. 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.
WARNING! Pay attention to the risk of falling material. Falling material can cause severe accidents if due care is not taken.
Excavating Q
When excavating and surface stripping, start by angling the bucket 2–3° downward.
Q
Operate in 1st gear and at low engine speed. Gradually increase the engine speed at the same time as you raise the bucket slightly.
Q
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 1
BSS:
Not activated
Operating techniques
100
Buckets Transporting load (loading – carrying) Q
The bucket should be fully tilted backward and kept in the carrying position 30–40 cm (12–16 in) above the ground.
Q
Keep the transporting road even and free from stones and other objects. There is always spillage from a too full bucket.
Q
Even out the road on the way back if necessary.
Suitable maximum speed:
Approx. 15 km/h (9.3 mph)
NOTE! Remember that the stability of a heavily loaded machine changes when it is steered.
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 operation 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. Q
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.
Q
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.
Q
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 Q
The positioning of the hauler (transporting vehicle) is of great importance for making the loading operation efficient.
Q
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 Q
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.
Q
To finish off the levelling operation, keep the edge of the bucket slightly downward and reverse while pressing the bucket lightly against the ground.
Suitable bucket:
Straight without teeth (alt. levelling bucket)
BSS:
Not activated
Operating techniques
Buckets A
101
Multi-purpose bucket (optional equipment)
B
The multi-purpose (4-in-1) bucket is most suitable for all different types of earth moving operations as well as for levelling, scraping and gripping. A Loading B Scraping C Levelling D Gripping
C
D – The front flap is operated via control lever (2).
M300098A
N R
1
2
1041423
NOTE! When levelling in rearward gear, the front bucket flap must only be partly opened, so that any obstructions, such as rocks or tree trunks do not damage or distort the front flap. The travel speed must be matched to the condition of the road. Q
Material which is trapped between locking cylinder and rear clam must be immediately removed, as otherwise the piston rod of the cylinder may be damaged or bent.
Q
Check hydraulic lines at regular intervals for leaks and visible external damage, replace if necessary.
Q
Grease the bearings for the clam bucket and the locking cylinders every 50 operating hours. For quality of grease, see page 178.
Q
Always relieve the pressure in the hydraulic system before starting maintenance or repair work.
Q
Work in hydraulic systems must only be performed by authorized personnel.
Operating techniques
102
Buckets High tipping bucket (optional equipment) The high tipping bucket is a combination of carrier and bucket. During tilting the carrier acts like an extension of the lifting frame, thereby providing a high dumping height. During loading and transport the bucket is tilted backwards between the carrier and the bucket body is almost in the same position as a normal bucket, so that there are almost no disadvantages with respect to breakout force, lifting force and tipping load. – The bucket cylinder is activated in the 'tilt function' by means of the lever (2). – For loading, transporting and lifting tilt the bucket fully backwards.
M300099A
– Empty the bucket only when the desired lifting height is reached. NOTE! Avoid tilting of the high tipping bucket with the standard tipping function, or if necessary tilt only with low tilting speed, so that the bucket remains fully tilted backwards on the carrier.
N R
1
2
1041423
– Avoid tilting the high tipping bucket forward or backwards with full power against the end stops to prevent bucket and cylinders from being damaged. Q
Clean the carrier arms regularly from dirt deposits.
Q
Check hydraulic lines at regular intervals for leaks and visible external damage, replace if necessary.
Q
Check the rubber buffers on the tipping back stops at regular intervals, replace if necessary.
Q
Lubricate the bucket support and cylinder bearings every 50 operating hours. For quality of grease, see page 178.
Q
Always relieve the pressure in the hydraulic system before starting maintenance or repair work.
Q
Work in hydraulic systems must only be performed by authorized personnel.
Operating techniques
Buckets
103
Side tipping bucket (optional equipment) The side tip bucket is suited for all possible earth movements such as filling up service trenches without major turning manoeuvres. – The bucket cylinder is activated in the "tilt function" by means of the lever (2). – For loading, transporting or lifting the load higher, the bucket must be tipped over until it is stopped by the support. – When the end position is almost reached, the bucket must be emptied or inverted carefully (not at full power) to prevent the bucket and the cylinder from being damaged. NOTE! Wet or very dense material may affect the stability of the machine when the tip bucket is emptied. Therefore do not perform any unnecessary steering movements when the lifting arms are up and the bucket cylinder is fully extended.
WARNING! M300102A
For longer transport and road travel the bucket must generally be properly locked and secured on the support.
Q
Check hydraulic lines at regular intervals for leaks and visible external damage, replace if necessary.
Q
Lubricate the bucket support and cylinder bearings every 50 operating hours. For quality of grease refer, see page 178.
Q
Always relieve the pressure in the hydraulic system before starting maintenance or repair work.
Q
Work in hydraulic systems must only be performed by authorized personnel.
N R
1
2
1041423
Operating techniques
104
Buckets Scrap bucket (optional equipment) The scrap bucket is most suitable for the loading of light metal scrap, e.g. aluminium scrap, tinplate and similar bulky material.
M300100A
Universal fork with hydraulic gripper (optional equipment) The universal fork is most suitable for the loading and transport of e.g. biological waste, tree branches, hay, manure and similar bulky materials. – The clamshells are actuated with the lever (2). – When entering into the material keep the gripper fully open, as otherwise the resulting very high pressure may cause leaks on hoses and seals.
M300103A
– Do not operate the gripper with full power against the end stop. Due to the high opening/closing speed the cylinders may be damaged. Q
Material which is trapped between cylinder and bucket must be immediately removed, as otherwise the piston rod of the cylinder may be damaged or bent.
Q
Check hydraulic lines at regular intervals for leaks and visible external damage, replace if necessary.
Q
Grease the bearings on gripper and cylinders every 50 operating hours. For quality of grease, see page 178.
Q
Always relieve the pressure in the hydraulic system before starting maintenance or repair work.
Q
Work in hydraulic systems must only be performed by authorized personnel.
N R
1
2
1041423
Operating techniques
Buckets
105
Clamshell bucket (optional equipment) The clamshell bucket (also called Mulch grab bucket) is most suitable for loading bulky material, e.g. biological waste, tree branches, bulky refuse as well as for manoeuvring the shredder machine. – The clamshells are actuated with the lever (2). – When entering into the material keep the clamshells fully open, as otherwise the resulting very high pressure may cause leaks on hoses and seals. – Do not operate the clamshells with full power against the end stop. Due to the high opening/closing speed the cylinders may be damaged. M300101A
NOTE! In order to manoeuvre the shredder machine with the ball button tilt the clamshell bucket fully backwards and close the clamshell. Q
Material which is trapped between cylinder and bucket must be immediately removed, as otherwise the piston rod of the cylinder may be damaged or bent.
Q
Check hydraulic lines at regular intervals for leaks and visible external damage, replace if necessary.
Q
Grease the bearings on claws and cylinders every 50 operating hours. For quality of grease, see page 178.
Q
Always relieve the pressure in the hydraulic system before starting maintenance or repair work.
Q
Work in hydraulic systems must only be performed by authorized personnel.
N R
1
2
1041423
Operating techniques
106
Timber grapples (optional equipment)
Timber grapples (optional equipment) The log loader is a universal gripper. It is most suitable for loading and sorting timber logs. – The hydraulic gripper is operated with the lever (2). NOTE! If the machine has been equipped with Boom suspension system (BSS), this system must not be engaged when a high degree of accuracy is required for loading or unloading.
WARNING! The large clearance radius when handling round timber, means that the operator must take great care not to hit anyone or anything in the vicinity of the machine. M300104A
N R
1
2
1041423
Q
Check hydraulic lines at regular intervals for leaks and visible external damage, replace if necessary.
Q
Grease the bearings on gripper and cylinders every 50 operating hours. For quality of grease, see page 178.
Q
Always relieve the pressure in the hydraulic system before starting maintenance or repair work.
Q
Work in hydraulic systems must only be performed by authorized personnel.
Operating techniques
Special hydraulics
107
Special hydraulics Special hydraulics at front, electrically switchable "Up/Down" (optional equipment) N
1
R
2
This function enables the operation of hydraulic quick change attachments, such as clamshell bucket, gripper bucket, tree clamp etc. with only one lever (1), i.e. without having to change over to lever (2). However, the function of lever (2) is still available, to ensure an engagement position for road sweeper operation etc. and to be able to relieve the hydraulic couplings when the engine is shut down. This function can only be activated when the engine is running. – Operate the push button (arrow) in lever (1) and hold it. The special hydraulics function is enabled: – "Locking/unlocking" the SW attachment carrier, see "Installation and removal of quick change attachment with auxiliaryhydraulics". – Attachment equipment "Open/Close".
1041423
– Release the push button (arrow) = standard function Up/Down/ Float position.
WARNING! If the button (arrow) is released during the opening/closing movement, the system immediately changes to the "Up/ Down" function, i.e. the lifting frame may perform an undesired stroke.
1
1041566
Q
Always relieve the pressure in the hydraulic system before starting maintenance or repair work.
Q
Work in hydraulic systems must only be performed by authorized personnel.
Operating techniques
108
Special hydraulics Hydraulic circuit no. 4 electrically switchable (optional equipment) This function enables the operation of two hydraulic quick change attachment units with two independent hydraulic functions such as road sweeping machine hydraulically slewable or clamp fork with rotation drive. – Changing to the 4th hydraulic circuit is accomplished by actuating and holding the button (arrow) in lever (2).
2
1041567
– Release the push button (arrow) = function special hydraulics e. g. SW-attachment carrier "Lock/Unlock". IMPORTANT! To relieve the pressure in the quick hydraulic couplings of the 4th hydraulic circuit, shut the engine down, turn the ignition switch to position I (ignition) and move lever (2) with the push button (arrow) actuated forward and back (approx. 5 sec. each). Q
Always relieve the pressure in the hydraulic system before starting maintenance or repair work.
Q
Work in hydraulic systems must only be performed by authorized personnel.
Operating techniques
Pallet forks
109
Pallet forks B
A (90o) C L66614A
Checking fork tines A Angle B Attaching lugs C Thickness
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. 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.
IMPORTANT! With attached loading fork the machine must not be used in public traffic. IMPORTANT! Make sure that stops (D) are properly located, thus preventing the fork arms from sliding off the fork frame. Particularly important when the fork arms are moved sideways manually. Make sure that the fork arms are locked against the fork retainer. The locking prevents the fork arms from moving sideways inadvertently.
D 1027071
Fork frame D Stop
WARNING! When detaching pallet forks from the machine, stabiliser legs should be placed against the ground.
Q
Check the pallet forks regularly as regards wear. It is particularly important to check the heel of the fork tine.
Q
Check that stops (D) for the fork arms are properly located.
Q
Check that the fork arms are locked against the fork frame.
Q
The fork tine should not be used any more if: – the fork tine has been worn down to 90% of its original thickness – the angle between fork tine and shank has become greater than 93°. – the attaching lugs are worn or cracked.
Q
Cracks or wear must not be made good by welding.
Operating techniques
110
Pallet forks Operating with pallet forks The most important points for work with pallet forks are: Q
The operator should have suitable training.
Q
The operator is responsible for that permissible load values are not exceeded.
Q
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.
Q
The fork must not be raised other than when stacking or depositing pallets.
Q
When operating without a load in the fork, the tines should be held low and tilted upward.
Q
When stacking material, the fork tines should be kept horizontal.
Q
Choose the most suitable travel path with the smoothest surface or, when required, rectify by levelling off the ground.
Q
The travelling speed should be adapted to the ground conditions.
Q
For increased stability, when working with pallet forks, it is important that the tyre pressure is correct according to recommendations.
Q
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.
Q
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.
Operating techniques
Pallet forks
111
Picking up a load Q
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.
Q
Place the load as close to the vertical shank of the fork as possible.
Q
Lift the load with the least possible inclination of the pallet fork.
Q
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
Q
Keep the load low 30–40 cm (12–16 in) above the ground to achieve the best possible stability and vision.
Q
Tilt the load rearward to hold it more secure.
Q
If the load obscures the vision, reverse the machine to the place where the load is to be deposited.
Q
Adapt the speed to the existing conditions.
Q
When handling high loads, use a special load support.
Combi-forks 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:
WARNING
Q
Palletised goods and round timber.
Q
Within the pulp industry and on building sites, where both palletised goods and compressed material (waste paper, packaging material etc.) are handled.
WARNING! When detaching pallet forks from the machine, stabiliser legs should be placed against the ground.
Approval and legal provisions 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: L67323A
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.
Operating techniques
112
Material handling arm
Material handling arm Material handling arm L45F (optional equipment) 1 Material handling arm, rigid Effective load at Z-attachment carrier: 1550 kg (3417 lb) Effective load at V-attachment carrier: 1400 kg (3086 lb)
2 Material handling arm, mechanically extendable The material handling arm can be mechanically extended in 3 steps (of 200 mm (79 in) each) from a minimum length of 1060 mm (417 in) to a maximum length of 1660 mm (654 in).
1
Z-equipV-equipment carrier ment carrier Effective load: at
2
M300247B
1060 mm = (417 in) =
1550 kg (3417 lb)
1400 kg (3086 lb)
1260 mm = (496 in) =
1450 kg (3197 lb)
1300 kg (2866 lb)
1460 mm = (575 in) =
1350 kg (2976 lb)
1200 kg (2646 lb)
1660 mm = (654 in )=
1250 kg (2756 lb)
1100 kg (2425 lb)
WARNING! There is no end stop beyond a length of 1660 mm (654 in), so there is a risk of the inner arm being pulled out then. The operator is responsible for ensuring that the lifted load does not exceed the permitted machine and fork lift attachment loads.
WARNING! Remember that the stability of the machine when straight is reduced when turning. – Installation of material handling arm, see "Installation and removal of quick change attachment equipment without auxiliary hydraulics".
WARNING! Make sure that the material handling arm is correctly locked and secured. NOTE! If the machine has been equipped with lifting arm suspension (BSS), this system must not be engaged when a high degree of accuracy is required for loading or unloading.
Operating techniques
Material handling arm
113
Material handling arm L50F (optional equipment)
1
1 Material handling arm, rigid Effective load at Z-attachment carrier: 1800 kg (3968 lb) Effective load at V-attachment carrier: 1650 kg (3638 lb)
2 Material handling arm, mechanically extendable The material handling arm can be mechanically extended in 3 steps (of 200 mm (79 in) each) from a minimum length of 1060 mm (417 in) to a maximum length of 1660 mm (654 in).
2
Z-equipment carrier
V-equipment carrier
1060 mm = 417 in =
1800 kg (3968 lb)
1650 kg (3638 lb)
1260 mm = 496 in =
1700 kg (3748 lb)
1550 kg (3417 lb)
1460 mm = 575 in =
1600 kg (3527 lb)
1450 kg (3197 lb)
1660 mm = 654 in =
1500 kg (3307 lb)
1350 kg (2976 lb)
M300247B
Effective load: at
WARNING! There is no end stop beyond a length of 1660 mm (654 in), so there is a risk of the inner arm being pulled out then. The operator is responsible for ensuring that the lifted load does not exceed the permitted machine and fork lift attachment loads.
WARNING! Remember that the stability of the machine when straight is reduced when turning. – Installation of material handling arm, see "Installation and removal of quick change attachment equipment without auxiliary hydraulics".
WARNING! Make sure that the material handling arm is correctly locked and secured. NOTE! If the machine has been equipped with lifting arms springiness (BSS), this system must not be engaged when a high degree of accuracy is required for loading or unloading.
Operating techniques
114
Material handling arm Load hook on bucket back (optional equipment) The load hook (arrow) on the back of the bucket allows for the attachment of a rope or a chain to secure the load which is being lifted, transported or lowered. The permissible effective load depends on the machine size, bucket type and machine configuration and can be requested from Volvo upon submission of the data referred to above. Due to the machine construction the effective load must never exceed 2500 kg (5512 lb).
M300106A
WARNING! The operator is responsible for ensuring that the lifted load does not exceed the permitted machine and fork lift attachment loads. NOTE! If the machine has been equipped with lifting arms springiness (BSS), this system must not be engaged when a high degree of accuracy is required for loading or unloading.
Operating techniques
Road sweeping (optional equipment)
115
Road sweeping (optional equipment) Q
When using the machine on public roads check which local and national regulations concerning the attachment of road sweeping equipment must be complied with.
Q
The road sweeping machine is most suitable for sweeping paved surfaces, but not for hazardous substances and health threatening dusts.
Q
Connect the hydraulic hoses correctly so that the hoses are free and not squashed when starting the road sweeper.
Q
For road sweeping machines with water spraying device plug the electric plug for the water pump into the socket on the front frame.
Q
During operation make sure that the height adjustable supporting wheels are adjusted to such a height, that the horizontally adjusted broom drum only just touches the ground. The weight of the road sweeping machine must always rest on the supporting wheels and not on the brushes. If the brushes are adjusted too low the broom bristles will brake and the steering rollers will vibrate.
Q
All guards and safety devices must always be in place. During work the resting supports must be in raised position.
Q
The working speed should be 4-8 km/h (2.5-5 mph) (select speed range gear stage "1").
Q
Grease all lubrication points on the road sweeping machine after approx. 30 operating hours (for quality of grease, see page 178).
Q
The condition of hydraulic oil lines must be examined at least once every year, replace if necessary.
Operating techniques
116
Lifting objects
Lifting objects When using the machine for lifting, e.g. the lifting of freely suspended loads, you must strictly comply with the statutory and locally valid safety regulations.
Working with a load hook During lifting work the stability of the machine must be assured. For safe performance of the work the driver himself must strictly observe the respective conditions and prerequisites. Q As far as this is possible, the machine should be standing on a firm and level base. Q On soft, uneven or sloping surfaces, if there is a risk of collapsing, application of transverse loads or other dangers of similar nature greatest care must be exercised. Q If the machine is standing on a sloping surface the centre of gravity is displaced and during lifting a position may be reached in which the machine will turn over. Q Use only suitable lifting tackle. Q When driving with hanging load keep the load as low as possible. Q Operate machine and load hook with careful movements to avoid pendulum movements of the load, if necessary stabilize load with lashing ropes. Q The speed must be adjusted to the condition of the driving ground.
Slinging
L64488A
Make sure that the chain or rope used to secure the load is not fitted in a perpendicular direction and that it cannot be damaged by sharp edges. No persons must remain under the unsecured load when attaching the chain or rope, or when lifting loads. Q Boards, planks, reinforcing irons or similar should have the sling arranged so that they cannot fall out of the loops. Q Girders should generally be lifted with a clamping device. Q Padding made from, for example, cut up compressed-air hoses, may be used in order to protect the slings. Q The slings should be well tightened.
WARNING! Never attach a lifting device (chain, sling or similar) around the teeth on the bucket when lifting. If a tooth should break, there is a risk of serious injury.
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.
Operating techniques
Signalling diagram
117
Signalling diagram If the operator's view is restricted by e.g. an obscuring load, a signal man must be used. The faster the required machine movements (lifting, lowering, travel) are to be performed, the more lively should the signal man's movements be carried out. If two or more operators make use of the same signal man, an agreement should be made beforehand how the lifting operation is to be carried out and how the signals should be given to the respective operator.
L67279A
L67281A
L67280A
START Both arms are extended horizontally to the side 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
LOWER Right arm pointing downward with the palm facing forward and the hand slowly making a circle
HORIZONTAL DISTANCE The hands indicate the relevant distance
L67284A L67285A
MOVE FORWARD Both arms under an angle, the palms of the hands face up. The lower arms are moved several times towards the chest.
MOVE REARWARD Both arms under an angle, the palms of the hands face down. The lower arms are moved several times from the chest down.
DANGER (EMERGENCY STOP) Both arms pointing upward, the palms facing forward
Operating techniques
118
Signalling diagram
L67286A
DRIVE IN INDICATED DIRECTION The arm is extended horizontally with the palm facing downward and the arm making small slow movements to the right and back
L67287A
DRIVE IN INDICATED DIRECTION The arm extended horizontally with the palm facing downward and the arm making small slow movements to the left and back
L67288A
VERTICAL DISTANCE The hands indicate the relevant distance
Safety when servicing
Service position
119
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 information and warning texts are given within the respective sections. NOTE! Lifting with a jack must only be carried out by trained personnel.
Service position
WARNING! If work has to be carried out on the machine before it has cooled down, care must be observed with regard to hot liquids and hot machine parts – risk of burns.
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.
P
P
1041521
1041522
1
The attachment should be resting on the ground.
5
Lock the articulation joint.
2
Apply the parking brake. Turn off the engine and take out the ignition key.
6
Block the wheels in a safe way, e.g. with wheel blocks.
3
Carefully release the pressure in pressure lines and accumulators to avoid risks.
7
Switch off the battery disconnect switch.
4
Attach a black and yellow label to the steering wheel.
8
Allow the machine to cool.
Safety when servicing
120
Before service read
Before service read Preventing personal injury
L64527A
Q
Read the Operator’s Manual before the service work is started. It is also important to read and follow information and instructions on plates and decals.
Q
Do not wear loose-fitting clothing or jewellery, which can get caught and cause injury.
Q
Always wear a hard hat, protective goggles, gloves, protective shoes and other protective articles when the work so requires.
Q
Make sure that the ventilation is sufficient when starting the engine indoors.
Q
Do not stand in front of or behind the machine when the engine is running.
Q
If service work has to be carried out under raised lifting arms, these must first be secured. (Engage the control lever lockout and apply the parking brake if the machine is equipped with one).
Q
Turn off the engine before opening doors or engine cover.
Q
When the engine is stopped, there is a remaining accumulated pressure in the pressurised systems. If a system is opened without having first released the pressure, liquid under high pressure will jet out.
Q
When checking for leaks, use paper or hardboard, not your hand.
Q
Make sure that stepping surfaces, handholds and anti-slip surfaces are free from oil, diesel fuel, dirt and ice. Never step on parts of the machine that are not intended for this.
Q
It is important to use correct tools and equipment. Broken tools or equipment should be repaired or changed.
Preventing machine damage Q
When lifting or supporting the machine or parts of the machine, use equipment with a sufficient lifting capacity.
Q
Lifting devices, tools, working methods, lubricants and parts prescribed in the Operator’s Manual should be used. Volvo CE will not accept any responsibility otherwise.
Q
Make sure that no tools or other objects, which may cause damage, have been forgotten in or on the machine.
Q
Release the pressure in the hydraulic system before starting the service work.
Q
Never set a relief valve to a higher pressure than that recommended by the manufacturer.
Q
Machines, which are used within a polluted or in another way insanitary area should be equipped for this kind of work. Special safety regulations apply when servicing such a machine.
Q
When installing two-way radio, mobile telephone or similar equipment, the installation should be carried out in accordance with the manufacturer’s instructions in order to eliminate interference with the electronic system and components intended for the function of the machine, see page 8.
Q
Measures to be taken in connection with electric welding, see page 124.
Q
Make sure that all covers on the machine are in position before the engine is started and the machine is put to work.
Safety when servicing
Before service read
121
Preventing 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. Q
When draining, oils and liquids must be collected in suitable vessels and steps taken to avoid spillage.
Q
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.
Q
Batteries contain substances dangerous to the environment and health. Used batteries must therefore be handled as waste dangerous to the environment.
Q
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.
Safety when servicing
122
Fire prevention
Fire prevention WARNING! If the machine is used in an environment where the risk of fire is particularly high, e.g. in explosive environment, special equipment is required. There is always a risk of fire. Find out what kind of fire extinguisher is used on your working site and how to use it. If the machine is equipped with a fire extinguisher, it should be kept inside the cab on the left side of the operator. If the machine is to be provided with a hand-held fire extinguisher, it should be of the ABE type (ABC in North America). The designation ABE means that it is possible to extinguish fires in both solid organic material and liquids, and that the fire extinguishing compound does not conduct electricity. Efficiency class I means that the effective operating time of the extinguisher must not be less than 8 seconds, class II at least 11 seconds and grade III at least 15 seconds. A hand-held fire extinguisher ABE I normally corresponds to a powder content of 4 kg (8.8 lb) (EN-grade 13A89BC), standard EN 3-1995, parts 1, 2, 4 and 5.
Fire prevention measures Q
Do not smoke or have an open flame near a machine when filling with fuel or when the fuel system is opened and in contact with the surrounding air.
Q
Diesel fuel oil is flammable and must not be used for cleaning. Use conventional car care products meant for cleaning or degreasing. Also bear in mind that certain solvents can cause skin rashes, damage to the paint finish and constitute fire hazard.
Q
Keep the place clean where the service is to be carried out. Oil and water can make the floor slippery and is also dangerous in connection with electrical equipment or electrically powered tools. Oily and greasy clothes are a serious fire hazard.
Q
Check daily that the machine and the equipment, e.g. underbelly plates are free from dust and oil. Besides reducing the risk of fire, it is also easier to detect faulty or loose components.
NOTE! Take great care if a high-pressure wash is used for cleaning. Electrical components and electrical leads can be damaged even at a moderately high pressure and temperature. Protect electrical leads in an appropriate way. Q
Take extra care when cleaning a machine working in a fire-sensitive environment, e.g. saw-mill and refuse dumps. The risk of spontaneous combustion can be further reduced by installing insulation of the silencer guard.
Q
It is important that the fire extinguisher is maintained in order to work when it is needed.
Safety when servicing
Fire prevention Q
123
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.
Q
Do not weld or grind on components which are filled with flammable liquids, e.g. tanks and hydraulic pipes. Exercise care with such work also in the proximity of such places. A fire extinguisher should be kept near to hand.
Actions in case of fire If the circumstances permit and your own safety is not jeopardised, take the following steps at the slightest sign of fire: 1 Stop the machine, if the machine is in motion. 2 Lower attachments to the ground. 3 Move the control lockout lever to locked position, if so equipped. 4 Turn the ignition key to stop position. 5 Exit the cab. 6 Call the fire brigade. 7 If possible to access safely, turn off the battery disconnect switch. 8 Attempt to put out the fire, if possible. Otherwise, move away from the machine and out of the danger zone.
Actions after fire When handling a machine which has been damaged by fire or been exposed to intense heat, the following protective measures must be followed: Q
Use thick, protective gloves made of rubber and wear goggles.
Q
Never touch burnt components with your bare hands in order to avoid contact with melted polymer materials. First wash thoroughly with plenty of lime water (a solution consisting of calcium hydroxide, i.e. slaked lime in water).
Q
Handling heated fluoro-carbon rubber, see page 125.
Safety when servicing
124
Handling hazardous materials
Handling hazardous materials Heated paint
WARNING! All paint decomposes when heated and forms compounds which may be irritating and after long or frequent exposure also very unhealthy. Heated paint gives off poisonous gases. Therefore, paint must be removed from an area with a radius of at least 10 cm (4 in) before carrying out welding, grinding or gas cutting. 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 Q
Blasting – use respiratory protective equipment and protective goggles
Q
Paint remover or other chemicals – use a portable air extractor, respiratory protective equipment and protective gloves
Q
Grinding machine – use a portable air extractor, respiratory protective equipment and protective gloves and goggles
Never burn painted parts after they have been discarded. They should be disposed of by a licensed disposal plant.
Heated rubber and plastics 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 respiratory protective equipment.
Safety when servicing
Handling hazardous materials
125
Heated fluoro-carbon rubber
WARNING! Certain seals which are designed to withstand high operating temperatures, e.g. in engine, main control valve, hydraulic motor and pumps may be made from fluoro-carbon rubber. When heated to high temperatures, fluoro-carbon rubber decomposes to hydrogen fluoride and hydrofluoric acid, which is strongly corrosive on skin and respiratory tracts. When handling a machine which has been damaged by fire or been exposed to intense heat, the following measures should be taken: Q
Use thick, rubber gloves and wear protective goggles.
Q
Discard gloves, rags and other items that have been in contact with heated fluoro-carbon rubber after first having washed these items in lime water (a solution of calcium hydroxide, i.e. slaked lime in water).
Q
The area around a part which has been very hot and which may be made of fluoro-carbon rubber should be decontaminated by thorough and ample washing with lime water.
Q
As a precaution, all seals (O-rings and other oil seals) should be handled as if they were made of fluoro-carbon rubber.
Q
The hydrofluoric acid may remain on the machine parts for several years after a fire.
Q
If swelling, redness or a stinging feeling appears and one suspects that the cause may be contact with heated fluoro-carbon rubber, contact a medical doctor immediately. Several hours may pass, however, before any symptoms appear and there is no immediate warning.
Q
The acid cannot be rinsed or washed off from the skin. Treat instead with Hydrofluoric Acid Burn Jelly or similar before contacting a medical doctor.
Refrigerant NOTE! All kinds of service on the air conditioning unit must be carried out by accredited workshops by, or under the guidance of, a person in a leading position with certified competence.
WARNING! Refrigerant R134a easily causes frost-bite if it comes into contact with bare skin. When heated, gases are formed, which can be harmful to lungs and nervous system. The air conditioning unit of the machine is filled with refrigerant R134a at the factory. R134a has no harmful influence on the ozone layer, but contributes, however, to the greenhouse effect and must therefore never intentionally be released into open air. IMPORTANT! R134a must never be mixed with another kind of refrigerant, e.g. R12, as this leads to a breakdown of the unit.
Safety when servicing
126
Handling hazardous materials In case of contact with escaping refrigerant, the following measures should be taken: Q
If a leak is suspected, leave the risk area and contact an accredited workshop to get information about measures.
Q
The gases formed by heated refrigerant, may be harmful to lungs and nervous system even at low concentrations when no smell is apparent. High concentrations have a narcotic effect. Exposed persons should be remove from the risk area and out into the fresh air. Seek medical advice, if the symptoms remain.
Q
When fluid, the refrigerant may cause frost-bite. Warm carefully the injured area with lukewarm water or warm clothes. Seek medical advice, if the symptoms remain.
Q
Seek medical advice, if liquid refrigerant has come into someone’s eyes.
Batteries
WARNING! Batteries contain sulphuric acid, which is strongly corrosive to skin. Q
Do not smoke near batteries as these give off explosive gases.
Q
Make sure that metal objects, e.g. tools, rings and watch straps, do not come into contact with the battery pole studs.
Q
Make sure the protections are always installed over the battery pole studs.
Q
Do not tilt a battery in any direction. Battery electrolyte may leak out.
Q
Do not connect a discharged battery in series with a fully charged battery. Risk for explosion.
Q
When removing a battery, disconnect the ground cable first and when installing, connect the ground cable last in order to reduce the risk of sparks.
Q
Discarded batteries must be taken care of according to national environmental requirements.
Crystalline silica (quartz) dust
WARNING! Avoid exposure to dust containing crystalline silica particles as it can cause serious injury to the lungs (silicosis). Crystalline silica is a basis component of sand and granite. Therefore, many activities at construction and mining sites, such as trenching, sawing and boring, produce crystalline silica dust. This dust can cause silicosis. The employer or working site management should provide the operator with information about the presence of crystalline silica in the work site along with specific work instructions and precautions and also necessary personnel protection equipment. Also check the local / national regulations regarding silica / silicosis.
Service and maintenance
127
Service and maintenance If the machine is to function satisfactorily and at lowest possible cost, it requires careful maintenance.
Lubrication and service chart The section “Lubrication and service chart” describes the maintenance work which the operator should carry out. If certain operations require trained workshop personnel and special equipment, this will be indicated. See page 166.
Service history After each completed service at a workshop authorised by Volvo CE, the Service History should be filled in, see page 200. The Service History is a valuable document, which can be referred to when for example selling the machine.
Arrival and delivery inspections
L52168B
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 the applicable form, which must be signed.
Delivery instructions
DELIVE VERY DE INSTRU INS RUCTIONS 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.
AR ARRIVAL L AND AND DELIVE DE VERY INSPEC I ECTI TION ON Machines manufactur ed by Volvo Construc tion Equipment
2 Presentation of the machine including optional equipment.
Operating hours
Arrival date
Delivery date
Page
1 (2)
Review o f the Operator ’s Manual with e mphasis on the following point s. Arriv al inspection by
Perfo rmed
1 Check together with the owner/operator that the delivered machine corresponds to the order.
Construct ion Equipment
Serial no.
Machine Model
Delivery inspection by
When handing the machine over, the dealer must give the buyer delivery instructions according to the applicable form, which must be signed, if the warranty is to apply.
(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.
Service programme
– 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.
Construct ion Equipment
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. – 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. 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 sp@volvo.com – 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. Machine model
Serial no.
Delivery instruction carriedout on the
Owner
Operator(Recipient)
10 Check that there are no fuel, water or oil leaks. If necessary, check-tighten connections, clamps – Steering, secondary steering. 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.
1015444
The Service Programme is to be used in connection with warranty inspections and 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.
– 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
Please esnd commentsaboutthe Inpection Programm e to sp@volvo.com
Please send com ments about the Inspection Programm e to sp@volvo.com
Warranty inspections Two warranty inspections should be carried out at a workshop authorised by Volvo CE, the first at 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. At these inspections there are, among other measures, oil and fluid changes, which must be carried out before the ordinary intervals. Maintenance Regarding intervals for other maintenance, see the Service Programme or the Lubrication and Service chart in this chapter.
Condition test Condition tests are carried out at a workshop authorised by Volvo CE and provide information about the general condition of the machine. The condition test is carried out as a supplementary work to the service programme.
128
Service and maintenance Cleaning 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. Recommendations for cleaning the machine Q
Place the machine in a place intended for cleaning.
Q
Follow the instructions supplied with the car care product.
Q
The water temperature must not exceed 60 °C (140 °F).
Q
If high-pressure wash is used, keep a distance of at least 20–30 cm (8–12 in) between nozzle and machine surface. Too high pressure and too short distance may cause damage. Protect electrical leads in an appropriate way.
IMPORTANT! If using a high-pressure wash, pay attention to the decals since they easily can come loose. Q
Use a soft sponge.
Q
Finish by rinsing the whole machine with only water.
Q
Always lubricate the machine after washing.
Q
Touch-up the paint finish when required.
Paint finish maintenance Q
Machines which are used in corrosive environment suffer more from rust than others. As a preventive measure it is recommended that the paint finish should be maintained every sixth months.
Q
At first clean the machine.
Q
Apply Dinol 77B (or corresponding transparent waxy anti-rust agent) at a thickness of 70–80 µ.
Q
A protective layer of underseal Dinitrol 447 (or corresponding) may be applied under the mudguards where mechanical wear is expected.
Touching up paint finish Q
Check if there are any damaged areas of the paint finish.
Q
At first clean the machine.
Q
Rectify any damage to paint finish in a professional way.
Service points
129
Service points 11
5 12 13
14 8
15
18 17 1
9
3 2 4 7
20
6
19
10
16
1041236
1
Engine oil filling point
11
Air filter intake resp. raw air intake (rain cap)
2
Engine oil dipstick
12
Cab ventilation filters (behind the cover)
3
Engine oil drain valve
13
Batteries (inside the battery box)
4
Engine oil filter
14
Battery disconnect switch
5
Fuel filling point
15
Hydraulic oil level glass
6
Primary fuel filter
16
Hydraulic oil filling point
7
Secondary fuel filter
17
Hydraulic oil filter
8
Fuel system breather filter (behind the cover)
18
Hydraulic system breather filter
9
Engine air cleaner
19
Windscreen washer reservoir
10
Coolant filling point (expansion tank cap)
20
Cover for V-belts
130
Engine
Engine Engine oil level, checking Check engine oil level every 10 hours. The oil level should be checked before starting the engine. 1 Park the machine on level ground. Apply the parking brake. 2 Turn off the engine.
WARNING! The engine has rotating part. Therefore do not open the engine hood while the engine is running. 3 Open the engine hood. NOTE! The level check should be carried out when the oil has had time to run down to the bottom of the sump. 4 Pull the dipstick out and wipe it clean with a lint-free cloth, reinsert it until it bottoms and pull it back out.
MAX MIN
Engine oil dipstick
1041527
The dipstick should be covered with oil up to the upper mark (MAX). If the oil level is near or even below the bottom mark (MIN) top up oil immediately to avoid severe engine damage. For quality of oil, see page 177. NOTE! Always take care that the oil level is close to the MAX level when the machine is operated in slanted conditions.
Engine
131
Engine oil, changing Change the engine oil every 500 hours. The conditions for the 500 hours interval between oil changes are that: – the oil filter is replaced every time the oil is changed. – the oil filter is a genuine Volvo filter. – the correct oil viscosity for the ambient temperature is selected according to diagram, see page 177. – the oil is of a certain quality grade, see table below. – When operating permanently at ambient temperatures below 10°C (+14°F) the oil change intervals must be halved. NOTE! Interval shorter than 500 hours also means shorter interval for replacing fuel filters, see page 135. Follow recommended interval between changes given in the table according to the quality grade of the oil and the sulphur content of the fuel.
Sulphur content of the fuel Oil grade
< 0.3 %
0.3–0.5 %
> 0.5 %
Oil change interval Volvo Ultra Diesel Engine oil VDS-3 VDS-2 plus ACEA-E7
500 hours
250 hours
125 hours
250 hours
125 hours
75 hours
125 hours
75 hours
50 hours
VDS-2 plus API CI-4 VDS-2 plus EO-N Premium plus VDS-2 VDS plus ACEA-E3 ACEA: E7, E5, E4 API: CI-4, CH-4, CG-4
132
Engine Draining Drain the oil while the engine is shut down and still warm.
WARNING! Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch. 3 Open the engine hood.
WARNING! The engine, turbocharger and exhaust system may still be very hot. 4 Use a suitable draining container to collect the engine oil. 5 Unscrew the cap from drain valve (A). 6 Lead a drain hose through the hole under the drain valve and direct it to the container. 7 Screw the drain hose onto the drain valve. NOTE! Screwing the drain hose on opens the drain valve and allows the oil to flow out. 8 Once all old oil has run out, unscrew the drain hose and screw the cap back on the drain valve.
A B
Take care of filters/oils/liquids in an environmentally safe way, see page 91.
MAX MIN
Engine oil changing A Drain valve B Engine oil filling point
1041307
Filling 1 Fill with new oil through engine oil filling point (B). Change capacity including filter: 16 litres (4.2 US gal). For quality of oil, see page 177. 2 Screw the cap back on. 3 Start the engine and let it run at low idle for two minutes. 4 Turn off the engine. 5 The level check should be carried out when the oil has had time to run down to the bottom of the sump. 6 Check the oil level on the dipstick and top up to the MAX - mark if necessary.
Engine
133
Engine oil filter, replacing Replace the engine oil filter every 500 hours. Replace the oil filter every time the oil is changed. 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch. 3 Open the engine hood.
WARNING! The engine, turbocharger and exhaust system may still be very hot. 4 Clean around the filter head and filter before removing the filter.
A A
1041528
5 Loosen engine oil filter (A) with a filter wrench and unscrew it.
Engine oil filter
WARNING! Work carefully when handling oil filters as hot oil can cause severe burns to unprotected skin. 6 Clean the sealing surface of the filter head from any dirt. 7 Fill the new filter with oil and apply some oil to the rubber seal on the filter. 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. 8 Screw the filter on by hand until the seal touches the surface. M300070A
9 Tighten the filter a further ½ turn by hand. 10 Start the engine and check the filter for leaks. IMPORTANT! If any leakages occur, the sealing surface needs to be checked. Usually it does not help to tighten harder. IMPORTANT! Excessive tightening of the filter may damage the thread or the seal of the filter element. 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 121.
134
Fuel system
Fuel system Fuel, filling The fuel tank should be filled at the end of each work day. This prevents the formation of condensation water, as far as possible. The fuel filling point is located on the right-hand side of the machine. – Thoroughly clean the area around the tank lid. – Only fill with clean fuel! Clean fuel is essential for trouble-free operation of the diesel engine. Fuel tank capacity approx. 150 litres (39.6 US gal)
A
WARNING!
1040821
Never have open flame or sparks when filling fuel or when working on the fuel system. Do not smoke near the machine. A drop in engine power can be caused by a clogged fuel filter. If a fuel filter clogs too quickly, check the fuel for contamination. Clean the tank, make sure it is properly closed.
Fuel tank A Fuel filling point
NOTE! Bleeding of the fuel system is not necessary.
Water separator, draining – Check the water separator every 10 hours. Drain if necessary.
D
– Drain the water separator every 250 hours. – Take care of fuel spillage by using a plastic hose and a vessel. 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.
A
C
B
Primary fuel filter A Filter element B Water separator C Draining nipple D Hand pump
1041237
Proceed as follows: 1 Connect a plastic hose to draining nipple (C) and place the end of the hose in a suitable draining container. 2 Loosen the draining nipple until fuel runs out through the hose. 3 Tighten the draining nipple after draining is completed. 4 Remove the hose. 5 Push hand pump (D) several times until water separator (B) is filled up and a resistance becomes noticeable. IMPORTANT! 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 91.
Fuel system
135
Fuel filters, replacing Replace the fuel filters every 500 hours, or when replacing the engine oil filter (which may mean a shorter interval).
D
NOTE! If the filters become clogged earlier, they must be replaced.
Primary fuel filter, replacing 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch. 3 Open the engine hood.
A
C
B
Primary fuel filter A Filter element B Water separator C Draining nipple D Hand pump
1041237
WARNING! The engine has rotating part. Therefore do not open the engine hood while the engine is running. 4 Drain water separator (B) (step 1-4), see previous page. NOTE! Do not use the hand pump at this stage. 5 Clean around the primary fuel filter before removing filter element (A). 6 Loosen the filter element with a filter wrench and unscrew it. 7 Clean the sealing surface on the filter head carefully. 8 Unscrew water separator (B) from the filter element and clean it. 9 Check the sealing for damage, replace if necessary. 10 Apply some oil to the sealing. 11 Screw the water separator onto the new filter element. 12 Apply some oil to the sealing and screw on the filter element by hand until the sealing touches the surface. Then tighten a further ½ turn by hand. 13 Push hand pump (D) several times until the water separator is filled up and a resistance becomes noticeable. 14 Start the engine and let it idle for a few minutes. Check for leaks. IMPORTANT! The hand pump must not be used when the engine is running. NOTE! The engine may run unevenly to start with until the system is completely free from air. Take care of filters/oils/liquids in an environmentally safe way, see page 91. For information about belt tension, see page 143.
136
Fuel system Secondary fuel filter, replacing 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch. 3 Open the engine hood.
WARNING! The engine has rotating part. Therefore do not open the engine hood while the engine is running. 4 Clean around the filter head and filter before removing the filter.
A A
1041238
Secondary fuel filter
5 Loosen secondary fuel filter (A) with a filter wrench and unscrew it. 6 Clean the sealing surface on the filter head from any dirt. 7 Fill the new filter with diesel fuel and apply some oil to the sealing on the filter or wet it with diesel fuel respectively. 8 Screw on the new filter by hand, until the sealing just touches the sealing surface on the filter head. Then tighten a further ½ turn by hand. 9 Start the engine and let it idle for a few minutes. Check for leaks. NOTE! The engine may run unevenly to start with until the system is completely free from air.
M300074A
Take care of filters/oils/liquids in an environmentally safe way, see page 91.
Breather filter, fuel system, replacing Replace the filter every 2000 hours. 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch. 3 Open the engine hood.
WARNING!
B A 1041451
A B
Bolts Partition wall
The engine has rotating part. Therefore do not open the engine hood while the engine is running. 4 Unscrew and remove bolts (A) and carefully remove partition wall (B) and put it on the fender. 5 Loosen screw on hose clamp (C). 6 Remove breather filter (D). 7 Install the new breather filter and tighten the screw on the hose clamp.
D C D
Hose clamp Breather filter
C
1041452
Fuel system
137
Fuel system, draining WARNING! When working on the fuel system do not use open fire. Do not smoke!
WARNING! Make sure the fuel tank has cooled down from operating temperature, as warm fuel can cause burns to unprotected skin. IMPORTANT! If the fuel has become contaminated, the fuel tank must be drained immediately. – Place a container underneath the fuel tank drain plug. The fuel tank capacity is approx. 150 litres (39.6 US gal). – Remove the drain plug and drain all the fuel. – Wash the inside of the fuel tank with clean fuel. – Replace the O-ring on the drain plug and apply some oil to it or wet it with clean diesel fuel respectively. – Mount the drain plug and tighten it carefully with 10-15 Nm. NOTE! It can be required to also change the fuel filters. Take care of filters/oils/liquids in an environmentally safe way, see page 121.
138
Engine air cleaner
Engine air cleaner The degree of engine wear depends largely on the cleanliness of the induction air. The engine air cleaner prevents dust and other impurities from entering the engine. Therefore, it is very important that the engine air cleaner should be checked regularly and maintained correctly. IMPORTANT! A damaged filter should always be replaced.
Dust discharge valve – Empty dust discharge valve (A) by squeezing the discharge slot together. 1041239
Engine air cleaner
– Remove possible dust deposits by squeezing the upper part of the valve.
Primary air filter, cleaning and replacing C B
Replace primary air filter (B) every 1000 hours, when the alarm text for clogged engine air filter is shown, or when the filter has been cleaned five times. – 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. NOTE! Check the air lines (filter to turbocharger and for L50F also the charge-air lines) for leaks during every maintenance. Replace defective parts, tighten loose hose clamps.
Cleaning of primary air filter
A M300059A
Engine air cleaner A Dust discharge valve B Primary air filter C Secondary air filter
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.
Secondary air filter, replacing Replace secondary air filter (C) every 2000 hours or when the primary air filter has been replaced three times. IMPORTANT! The secondary air filter cannot be cleaned, but must be replaced. IMPORTANT! Never remove the secondary air filter unless it is to be replaced. – While servicing the primary air filter the secondary air filter should remain inside the engine air cleaner. – The number of services (replacements or cleaning of the primary air filter) should be marked in the respective fields on the secondary air filter. – If the alarm text for clogged engine air filter is shown again after the service of the primary air filter, then also the secondary air filter has to be replaced. Take care of filters/oils/liquids in an environmentally safe way, see page 91.
Engine air cleaner
139
Pre-cleaner (optional equipment) When the machine is operated in a particularly dusty environment, we recommend the use of a pre-cleaner. The pre-cleaner is installed on the air intake instead of the rain cap. The type of pre-cleaner shall be a centrifugal dry separator, as the Turbo 2 pre-cleaner. IMPORTANT! Oil bath air cleaners are not approved.
1041529
Pre-cleaner (optional equipment)
140
Cooling system
Cooling system For the cooling system to function without problems, the coolant level should be checked regularly and the radiator be blown clean.
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
Use Volvo coolant VCS only
For cooling system capacity when changing, see page 180. If concentrated Volvo Coolant VCS and clean water (see page 179) 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%
–35 °C (–31 °F)
50%
–46 °C (–51 °F)
60%
Take care of filters/oils/liquids in an environmentally safe way, see page 121.
Cooling system
141
Coolant level, checking Check the coolant level every 50 hours. 1 Turn off the engine and apply the parking brake. 2 Open the engine hood.
WARNING! The engine has rotating part. Therefore do not open the engine hood while the engine is running. 3 Let the cooling system cool down.
A Expansion tank A Expansion tank cap
1041240
4 Check that the coolant level stands between the markings MIN and MAX on the expansion tank.
Topping up coolant If the alarm text for low coolant level comes up you must top up with coolant. IMPORTANT! Volvo Coolant VCS must not be mixed with any other coolants or corrosion protection agents, as this may cause engine damage. 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch. 3 Open the engine hood.
WARNING! The engine has rotating part. Therefore do not open the engine hood while the engine is running. 4 Let the cooling system cool down. 5 Slowly unscrew expansion tank cap (A).
WARNING! Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling system. 6 Top up with coolant until the coolant level stands between the markings MIN and MAX on the expansion tank. 7 Screw the expansion tank cap back on tightly and check the system for leaks.
142
Cooling system Coolant, changing Change coolant every 6000 hours or at least every fourth year.
Draining
A
1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch. 3 Open the engine hood.
WARNING! The engine has rotating part. Therefore do not open the engine hood while the engine is running. 1040792
A
Expansion tank cap
4 Let the cooling system cool down. 5 Slowly unscrew the expansion tank cap (A).
WARNING! Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling system. 6 Place a draining container (approx. 30 litres (7.9 US gal)) underneath drain valve (B). 7 Connect a hose to the drain valve and direct it to the draining container. 8 Open the drain valve completely and drain the coolant. 9 Close the drain valve. Take care of filters/oils/liquids in an environmentally safe way, see page 91.
B
Filling Coolant capacity when changing: 20 litres (5.3 US gal) 1040793
B
Drain valve
IMPORTANT! Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. IMPORTANT! Volvo Coolant VCS must not be mixed with any other coolants or corrosion protection agents, as this may cause engine damage. 1 Fill with coolant until the level is between the markings MIN and MAX on the expansion tank. 2 Screw expansion tank cap (A) back on tightly. 3 Run the engine until it is warm so that the cooling system is completely filled and all air has been removed. 4 Check the system for leaks. 5 The level should be checked again after the engine has cooled down, top up if necessary.
Cooling system
143
Coolant pump Check the V-belt tension every 500 hours.
WARNING! The engine must be turned off when checking belt tension rotating parts may cause personal injury. NOTE! The V-belt also drives the fuel feed pump for the fuel system.
Belt tension, checking 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch and remove it. 3 Open the engine hood. 4 Unscrew the bolts and remove the cover for the V-belts.
A A
1041303
V-belt (for coolant pump)
– Examine the V-belts for damage. IMPORTANT! If a V-belt is damaged it has to be replaced. Contact a workshop authorized by Volvo CE. 5 Use a measuring gauge for checking the belt tension. – Lower the indicator arm (1) fully into the gauge (3).
AUTOMOTIVE KG (&LD) BELT
20
– Position the gauge (3) on the V-belt (2) between the two Vbelt pulleys.
30
TENSIONER TESTER
100
150
1
4
3
2
1041306
Measuring gauge
– Press on the push button (4) and keep the pressing force perpendicular to the V-belt (2), until the spring is noticeably released (it “clicks”). 6 Lift the measuring gauge carefully without changing the position of the indicator arm (1). 7 Read the measuring value at the intersection (arrow) of the measuring scale and the indicator arm (1).
Belt tension, checking without a gauge Without a measuring gauge, the belt tension has to be checked by hand. At correct tension, it should be possible to deflect the belt approx. 15 mm (0.6 in) applying a fairly hard pressure, executed with the thumb. Tolerance for V-belt tension: 350–450 N (90–112 lbf) NOTE! After at least 15 minutes of operation under load. Tolerance for V-belt (new) tension: 600–700 N (135–157 lbf) NOTE! After initial installation.
Belt tension, adjusting The belt tension has to be adjusted if it is out of tolerance. 1 Loosen bolts (B) and (C) slightly. 2 Use a socket wrench with an extension bar which fits square hole (D). 3 Use the socket wrench to adjust the belt tension. 4 Tighten bolt (C). 5 Check that the belt tension for V-belt (A) is within tolerance.
A B
D C
1 041304
6 Tighten bolt (C) and (B) firmly when the belt tension is within tolerance.
144
Cooling system Radiator, coolers and condenser (if A/C installed), cleaning
B
â&#x20AC;&#x201C; Coolers: Oil cooler and charge-air cooler (L50F only) Clean the radiator, oil cooler, charge-air cooler (L50F only) and the condenser (if A/C installed) every 500 hours.
A
When operating under especially dusty conditions the radiator and coolers should be checked daily or even in shorter intervals. 1041241
Radiator, coolers and condenser, cleaning A Hatches B Condenser (if AC installed)
WARNING! Always stop the engine and allow it to cool before cleaning the machine. 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch. 3 Open the engine hood. 4 Undo hatches (A) and fold down the condenser (if A/C installed). 5 Blow the radiator, oil cooler and charge-air cooler (L50F only) clean with compressed air from the outside, the condenser (if A/C installed) from the top side. 6 Blow the grilles (left side and right side) in the engine hood clean with compressed air from the inside. 7 Remove all dirt from the coolers compartment. Also clean the engine compartment. NOTE! For easier accessibility the fender can be removed. IMPORTANT! High-pressure wash must not be used! IMPORTANT! The cores of radiator, oil cooler, charge-air cooler (L50F only) and condenser (if A/C installed) can be easily damaged if not handled carefully. IMPORTANT! The grilles in the engine hood are closemeshed to protect radiator, coolers and condenser from incoming dirt, for example pebble and leaves. Even particles as fluff will be kept away to a certain extent. Therefore the grilles should be cleaned regularly. IMPORTANT! Check condition of the sealings on the engine hood. Replace damaged or worn parts.
Reversible cooling fan (optional equipment) In very dirty environments it is recommended to clean the radiator and coolers often. If the machine is equipped with a reversible cooling fan, the fan can be made to temporarily change direction to blow the radiator and coolers clean at set intervals. Dirt particles caught on the grilles in the engine hood are blown off. To check the setting of the reversible cooling fan, see menu on the display unit, see page 33. Setting is carried out with the keypad under menu Engine, see page 33.
Electrical system
145
Electrical system Check travel lights, working lights, back-up alarm and the function of the control lamps daily.
Battery disconnect switch The battery disconnect switch (A) is located on the left-hand side of the machine just below the door. For longer downtime of the machine or for repair work on the electric system the battery disconnect switch must always be switched off.
A 1041295
A
Battery disconnect switch
Batteries The batteries (two 12 V batteries which are connected in series providing a system voltage of 24 V) are located in the battery box on the right-hand side of the machine. The original battery installed in the machine is both completely impermeable and maintenance free. The battery may only be replaced by a battery with identical technological characteristics. This rules out the danger of service personnel being affected by acid or acid vapour should the machine tip over. Q
In order to remove the battery firstly disconnect the negative clamp (-). In order to install the battery firstly connect the positive clamp (+). Any contact made between a tool and the cable connecting the positive clamp and the frame may cause sparks.
Q
For longer storage periods disconnect the battery.
1039101
Batteries
WARNING! Keep sparks and open fire away from the battery! Danger of explosion! In case of contact with battery acid flush off immediately with lots of water. In case of caustic injury of the eyes contact a doctor for medical advice. NOTE! Check that the cable terminals and pole studs are clean, well tightened and coated with vaseline or similar. NOTE! Dispose old batteries environmentally. For safety regulations, see page 126.
Three-phase generator Q
The connecting poles of the battery must never be mixed up by mistake. The poles are distinctly marked with (+) or (-). Incorrect connection immediately damages the rectifier in the generator.
Q
Check that the cable terminals and pole studs are clean, well tightened and coated with vaseline or similar.
146
Electrical system Welding Q
Before welding is carried out on the machine or attachment, turn off the battery disconnect switch.
Q
Because of the sensitivity of the electrical system, the ECUs must be disconnected before welding. Contact an authorised dealer workshop.
Q
Connect the welding equipment ground lead as close to the welding point as possible.
Batteries, charging WARNING! Hydrogen gas is formed during battery charging. Hydrogen gas is flammable and may be explosive. A short circuit, open flame or spark near the battery can cause a powerful explosion. Therefore, ventilate well. Never smoke near batteries. L64558A
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. Starting with booster batteries, see page 74.
Electrical system
147
Alternator Check the V-belt tension every 500 hours.
WARNING! AUTOMOTIVE KG (&LD) BELT
20
The engine must be turned off when checking belt tension rotating parts may cause personal injury.
30
TENSIONER TESTER
100
Belt tension, checking
150
1
1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch and remove it. 3 Open the engine hood. 4 Unscrew the bolts and remove the cover for the V-belts.
4
3
2
1041306
– Examine the V-belts for damage. IMPORTANT! If a V-belt is damaged it has to be replaced. Contact a workshop authorized by Volvo CE.
Measuring gauge
5 Use a measuring gauge for checking the belt tension. – Lower the indicator arm (1) fully into the gauge (3). – Position the gauge (3) on the V-belt (2) between the two Vbelt pulleys.
A
– Press on the push button (4) and keep the pressing force perpendicular to the V-belt (2), until the spring is noticeably released (it “clicks”). 6 Lift the measuring gauge carefully without changing the position of the indicator arm (1). 7 Read the measuring value at the intersection (arrow) of the measuring scale and the indicator arm (1).
B
Belt tension, checking without a gauge Without a measuring gauge, the belt tension has to be checked by hand. At correct tension, it should be possible to deflect the belt approx. 15 mm (0.6 in) applying a fairly hard pressure, executed with the thumb. Tolerance for V-belt tension: 350–450 N (90–112 lbf) NOTE! After at least 15 minutes of operation under load. Tolerance for V-belt (new) tension: 600–700 N (135–157 lbf) NOTE! After initial installation.
Belt tension, adjusting
C
The belt tension has to be adjusted if it is out of tolerance. 1 Loosen stop screw (A). 2 Adjust the belt tension with adjusting screw (B). 3 Check that the belt tension for V-belt (C) is within tolerance.
1041242
Adjusting tension for alternator V-belt A Stop screw B Adjusting screw C V-belt
4 Tighten the stop screw when the belt tension is within tolerance.
148
Electrical system Relays and fuses Relays and fuses are positioned in the electrical distribution box behind the operator seat and become accessible after the service cover for the electrical distribution box has been opened. A decal on the inside of the service 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).
A Rear cab wall A Service cover
1041249
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.
Axles
149
Axles Front axle oil, changing Oil change interval every 1000 hours, but at least once every year. Planetary drives and differential have a common oil household.
WARNING! Drain the oil only at operating temperature. Attention! Danger of scalding!
A
M400667A
– Before unscrewing the plugs thoroughly clean the respective areas. A Drain- and level control plug on planetary drive B Drain plug on differential
Wheel hubs A Level/drain plug
C Filler- and level control plug on axle housing – When changing the oil drain the oil from the planetary drives (A) and the differential (B). – To avoid any injuries caused by the pressure increase in the planetary drive, move the machine to bring the drain- and level control plug (A) to top position, loosen and unscrew the plug carefully. Then bring the drain bore to bottom position and let the oil run out. – Screw in drain plug (B) with new O-ring. – For filling turn the wheel hub until the word "Oil level" is in horizontal position. – Fill oil into both wheel hubs until it starts to flow over.
C B Front axle B Drain plug C Filling/level plug
– Screw in level/drain plug (A) with new O-rings. 1041243
– Fill in oil through the filler-/level control bore (C) until it starts to flow over. – Screw filling/level plug (C) back in with a new O-ring. Take care of filters/oils/liquids in an environmentally safe way, see page 91. Capacity when changing oil: 17.5 litres (4.6 US gal) For quality of oil, see page 177. – Check the oil level after a few minutes and, if necessary, top up until the specified oil level is reached and remains constant.
150
Axles Rear axle with transfer box oil, changing Oil change interval every 1000 hours, but at least once every year. The transfer box is flanged to the rear axle and has a common oil household with the axle.
A
WARNING! M400667A
Wheel hubs A Level/drain plug (one on each side)
Drain the oil only at operating temperature. Attention! Danger of scalding! Before unscrewing the plugs thoroughly clean the respective areas: A Level/drain plug on wheel hubs B Drain plug on the rear axle C Filling/level plug on the rear axle D Drain plug on transfer box E Filling/level plug on transfer box 1 When changing the oil, drain the oil from the wheel hubs (A), the rear axle (B) and the transfer box (D). 2 To avoid any injuries caused by the pressure increase in the wheel hubs, move the machine to bring level/drain plug (A) to top position, loosen and unscrew the plug carefully. Then bring the drain bore to bottom position and let the oil run out. 3 Screw in drain plugs (B) and (D) with new O-rings.
C B
1041243
4 For filling turn the wheel hub until the word "Oil level" is in horizontal position. 5 Fill oil into both wheel hubs until it starts to flow over.
Rear axle B Drain plug C Filling/level plug
6 Screw in level/drain plug (A) with new O-rings. 7 Fill in approx. 1 litre of oil through the filler bore (E) on the transfer box. 8 Subsequently, fill in oil through the filler-/level control bore (C) until it starts to flow over. 9 Screw the plugs (E) and (C) with new O-rings. Take care of filters/oils/liquids in an environmentally safe way, see page 91. Capacity when changing oil: 18.7 litres (4.9 US gal) For quality of oil, see page 177. â&#x20AC;&#x201C; Check the oil level after a few minutes and, if necessary, top up until the specified oil level is reached and remains constant.
E Transfer box D Drain plug E Filling/level plug
D
1041244
Brake system
151
Brake system The brake system consists of the service brake and the parking brake system. The service brake system is hydraulic and uses the hydraulic oil tank. For checking and changing oil, see page 160.
WARNING! Before maintenance and before any repair work the brake system must be depressurized. Shut the engine down and operate the brake pedal approx. 30 times. IMPORTANT! All maintenance and repair work must only be carried out by a workshop authorized by Volvo CE.
WARNING! An accumulated pressure remains in the brake system even if the engine has been stopped. If the system is opened without first releasing the pressure, oil under high pressure will jet out. â&#x20AC;&#x201C; Discarded accumulators should be taken care of by an authorized workshop and "punctured". â&#x20AC;&#x201C; There is a risk of explosion if an accumulator is heated.
Parking brake linings, checking Brake linings must be checked for wear every 500 hours. Contact a workshop authorized by Volvo CE.
Service brake discs, checking Brake discs must be checked for wear every 1000 hours. Contact a workshop authorized by Volvo CE.
Parking brake, checking of function WARNING! The parking brake must only be checked in a specially secured location. Make sure that there are no persons or obstructions in the vicinity of the machine. 1 2 3 4 5 6
No load must be carried in/on the working attachment. The working attachment should be kept in transport position. Park the machine in a 20% slope. Apply the parking brake. Leave the engine running. Neutral position should be selected, see page 50. Check that the parking brake is able to hold the machine from moving. IMPORTANT! If the machine moves, the parking brake must be checked further. Contact a workshop authorized by Volvo CE.
152
Tyres
Tyres Inflating tyres Check the tyres for damages and correct air pressure every 50 hours. For tyre size and recommended air pressure, see page 190. Recommended air pressure should be followed. Special handling operations may require an adjustment of the air pressure. In such cases follow the instructions from the tire manufacturer and do not exceed the maximum permissible air pressures according to the recommendations. 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. The adherence to the specified air pressure has a decisive influence on the lifetime of the tires.
WARNING! Repair work on tyres and rims must be carried out by personnel who have been especially trained for this and have the correct equipment. – When checking the tyre pressure, the tyre should be cold and the machine without a load. – Ask all other persons to leave the danger area (in front of the rim). – Use a long air hose (with a self-attaching air chuck) which allows you to stand outside the danger area. – Stand by the tyre tread as shown in the figure. Tyre installed on a split rim may explode causing injury or in the worst case death. – Never attempt to force back into position, or in any other way reposition, rim parts or lock ring which have worked loose, while there still is air pressure in the tire. – Do not combine rim parts of different dimensions and do not use damaged or defective parts. – Always relieve the tire pressure before removing foreign obstacles from the tread of a tire. – After checking and filling screw the valve cap back on. – 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. – 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.
Wheel nuts, checking tightening After having changed a tyre or if the wheel has been removed and installed for any other reason, the wheel nuts must be check-tightened after eight hours of operation. Tightening torque: 560–600 Nm (413–443 ft lb)
Cab
153
Cab A
Cab, cleaning and replacing ventilation filters
B
The cab ventilation filters consist of prefilter and main filter. The clogging up of the filters is entirely dependent on the working environment of the machine, 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. 1026286
A B
Prefilter Main filter (inside the plastic casing)
Cleaning 1 Use a respirator (face mask). 2 Open the side cover and remove the filters. 3 Carefully shake the filters without damaging them. Avoid using compressed air, vacuum cleaner or water.
Asbestos filter (optional equipment) The filter is especially intended for use in environments where there may be asbestos dust, but it is of course effective against all other kinds of dust when the operator needs highly filtered air in the cab. Testing: The filter meets the requirements according to DOPMIL standard 282 and thereby also the requirements of the National Swedish Board of Occupational Safety and Health regulations Asbestos AFS 1996:13. It also meets the requirements according to EN 1822:1 filter class H13. Pay attention to any national regulations issued for work in hazardous environments.
Asbestos Advice for operating in environments where dust / asbestos dust is present Q 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. Q The cab should be ventilated through its ventilation system, which also provides excess pressure in the cab. Q Replace filters (main filter and prefilter) every 1000 hours or more often when necessary and be careful with the new filter, so that it is not damaged. When installing, check that the filter edge forms a tight seal. Q 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.
154
Windscreen washer system
Windscreen washer system Windscreen wiper - wiper blades Check the condition of the wiper blades, replace if worn or damaged. Also replace the wiper blades if they leave stripes on the windscreen.
Washer reservoir A A
Washer reservoir
The reservoir is used for the windshield and the rear window washer. 1041247
â&#x20AC;&#x201C; Fill up washer reservoir (A) when necessary. â&#x20AC;&#x201C; With temperatures around or below freezing make sure that a sufficient amount of anti-freeze is added.
Air conditioning (optional equipment)
155
Air conditioning (optional equipment) The air conditioning system should be inspected and tested by authorized personnel at least once every year.
Refrigerant (R134a) The pressurised system contains HFC – refrigerant R134a. It is illegal to purposely release refrigerant into the open air. Any service, refilling or emptying of the refrigerant circuit must only be carried out by a trained and accredited person. The air conditioning system of the machine is factory filled with refrigerant R134a.
WARNING! Refrigerant R134a easily causes frost-bite, if it comes into contact with bare skin. When heated, gasses are formed, which can be harmful to the lungs and nervous system even at low concentrations, when no smell is apparent. The symptoms may arise several hours (up to 24 hours) after exposure to the gas.
Suspected leakage The system is pressurised and the refrigerant can unintentionally leak out. Never disconnect hoses and never remove the filler plug from the compressor. If a leak is suspected, the system must not be topped up – leave the area where the leak has taken place and contact your authorised dealer workshop for action to be taken.
First aid measures In case of accidental contact with escaping refrigerant, take the following measures: – Refrigerant in gaseous form (e. g. by heating) can, even in low concentrations, have a damaging effect, particularly on the nervous system. At high concentrations, the gas has a narcotic effect. In both cases go outside to breath fresh air or move affected personnel from the danger area. In severe cases seek medical advice. – If large amounts of liquid refrigerant has come into contact with unprotected skin, the injured area should be carefully warmed with lukewarm water or warm clothes. Seek medical advice if there are remaining symptoms. – If liquid refrigerant comes into contact with someone's eyes, seek professional medical help immediately.
156
Air conditioning (optional equipment)
AUTOMOTIVE KG (&LD) BELT
20
Compressor belt, checking and adjusting tension
30
TENSIONER TESTER
100
150
1
Check the belt tension every 500 hours.
WARNING! The engine must be turned off when checking belt tension rotating parts may cause personal injury.
4
3
2
1041306
Measuring gauge
Checking belt tension 1 Turn off the engine and apply the parking brake. 2 Switch off the battery disconnect switch and remove it. 3 Open the engine hood. 4 Unscrew the bolts and remove the cover for the V-belts. – Examine the V-belts for damage. IMPORTANT! If a V-belt is damaged it has to be replaced. Contact a workshop authorized by Volvo CE. 5 Use a measuring gauge for checking the belt tension. – Lower the indicator arm (1) fully into the gauge (3). – Position the gauge (3) on the V-belt (2) between the two Vbelt pulleys. – Press on the push button (4) and keep the pressing force perpendicular to the V-belt (2), until the spring is noticeably released (it “clicks”). 6 Lift the measuring gauge carefully without changing the position of the indicator arm (1). 7 Read the measuring value at the intersection (arrow) of the measuring scale and the indicator arm (1).
Checking belt tension without a gauge Without a measuring gauge, the belt tension has to be checked by hand. At correct tension, it should be possible to deflect the belt approx. 15 mm (0.6 in) applying a fairly hard pressure, executed with the thumb. Tolerance for V-belt tension: 350–450 N (90–112 lbf) NOTE! After at least 15 minutes of operation under load. Tolerance for V-belt (new) tension: 600–700 N (135–157 lbf) NOTE! After initial installation.
Adjusting belt tension The belt tension has to be adjusted if it is out of tolerance. 1 Loosen bolt (A) slightly. 2 Bend carefully with a heavy duty screw driver (B) to adjust the belt tension. IMPORTANT! Do not bend so hard that the compressor or other parts are damaged.
B A B C
A C
Bolt Screw driver V-belt (for compressor)
1041305
3 Tighten the bolt. 4 Check that the belt tension for V-belt (C) is within tolerance. 5 Tighten the bolt firmly when the belt tension is within tolerance.
Air conditioning (optional equipment)
157
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 째C (+32 째F), 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 째C (+34 째F). NOTE! Make sure that the exhaust gases are extracted or removed by ventilation in a suitable way.
Condenser, cleaning
B
See also page 144. IMPORTANT! High-pressure wash must not be used. Clean the condenser at regular intervals as follows: 1 Open the engine hood. 2 Undo hatches (A) and fold down the condenser.
A
1041241
Condenser, cleaning A Hatches B Condenser
3 Blow the condenser clean from the top side with compressed air.
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 IMPORTANT! High-pressure wash must not be used. Clean the evaporator at regular intervals. A simple cleaning is done with the evaporator in position. 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 done by a workshop authorized by Volvo CE. L65987D
158
Bucket teeth, replacing (Volvo tooth system)
Bucket teeth, replacing (Volvo tooth system) WARNING! Use protective goggles, gloves protective shoes and respirator for your personal safety. 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.
Special tool
Removing tooth 1 Lower the bucket to the ground and angle it slightly upward. 2 Clean the opening for tooth adapter locking device. 3 Knock out the locking device with a hammer and the tool or other 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. 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.
Locking device A Steel pin B Lock retainer
6 Knock down the locking device further with a hammer and the tool or other suitable drift until the upper part is just below the scored line in the hole. NOTE! Replace the steel pin in connection with replacement of tooth adapter.
1019824
The locking device should be just below the scored line.
Hydraulic system
159
Hydraulic system IMPORTANT! 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.
Hydraulic oil level, checking Check the hydraulic oil level every 10 hours.
B
Travel/working and steering hydraulics work with one common oil household. 1 Place the machine on firm and level ground. 2 Lower the lifting arms to the ground. 3 Turn off the engine and apply the parking brake. 4 Open the engine hood. 5 Check the oil level in hydraulic oil level glass (A). The level should be between the two marks in the glass. NOTE! The hydraulic oil level glass is positioned behind the rear fender on the right-hand side of the machine. 6 If necessary, top up through hydraulic oil filling point (B).
A A B
1041439
Hydraulic oil level glass Hydraulic oil filling point
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 authorized by Volvo CE. For oil quality, see page 177.
160
Hydraulic system Hydraulic oil, changing Hydraulic oil change interval every 1500 hours, but at least once every year. Replace the hydraulic oil filter and the breather filter with every hydraulic oil change. 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. 1 Place the machine on firm and level ground. 2 Lower the lifting arms to the ground. 3 Turn off the engine and apply the parking brake. 4 Release the pressure in the brake system by depressing the brake pedal approx. 30 times.
A
5 Switch off the battery disconnect switch. 6 Open the engine hood. 7 Remove the cap from hydraulic oil filling point (B). 8 Place a draining container (of at least 140 litres (37 US gal)) below hydraulic oil drain valve (A) on the hydraulic oil tank. 9 Unscrew the cap from the drain valve. 1041245
A
Hydraulic oil drain valve
10 Screw a drain hose onto the drain valve and direct the hose to the draining container (the drain hose for the engine oil can be used). NOTE! Screwing the drain hose on opens the drain valve and allows the oil to flow out.
WARNING! Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. 11 Once all old oil has run out, unscrew the drain hose and screw the cap back onto the drain valve.
B
IMPORTANT! Do not fill the hydraulic system before the filters have been changed. 12 Fill with new hydraulic oil in through hydraulic oil filling point (B). 13 Check the hydraulic oil level after a test run. Take care of filters/oils/liquids in an environmentally safe way, see page 91. Hydraulic oil change capacity: 95 litre (25 US gal). For hydraulic oil quality, see page 177.
Hydraulic system, draining sludge 1041246
B
Hydraulic oil filling point
Drain sludge and condensation water from the hydraulic oil tank via the hydraulic oil drain valve every 1000 hours.
Hydraulic system
161
Hydraulic oil filter, replacing Replace the hydraulic oil filter every 1500 hours, but at least once every year. IMPORTANT! Replace the filter element immediately when the alarm text â&#x20AC;&#x153;Hydraulic oil filter cloggedâ&#x20AC;? occurs.
A
IMPORTANT! Replace the filter before filling the hydraulic system. 1 Turn off the engine and apply the parking brake.
B
2 Switch off the battery disconnect switch. 3 Open the engine hood. 4 Unscrew breather filter (A) to relieve the overpressure in the hydraulic oil tank. IMPORTANT! Before unscrewing hydraulic oil filter cover (B), breather filter (A) must be unscrewed to relieve the overpressure in the hydraulic oil tank. 5 Unscrew hydraulic oil filter cover (B).
1039089
Hydraulic oil filter, replacing A Breather filter B Hydraulic oil filter cover
6 Lift the hydraulic oil filter out by the handle. 7 Clean the filter bowl with a lint-free cloth. Take care not to damage the pipe system and the valves. 8 Check the seals, replace them if necessary. 9 Insert a new filter element. Make sure the filter element fits tightly inside the bowl. IMPORTANT! Make sure the rod is properly fixed on the bottom of the filter cover. The rod maintains the attachment of the filter element when the cover is tightly screwed on. 10 Screw the hydraulic oil filter cover back on tightly. 11 Screw the breather filter back on tightly. 12 Check the hydraulic oil level after a test run.
Hydraulic system breather filter, replacing 1039099
Replace the hydraulic breather filter with every hydraulic oil change, but at least once every year. 1 Unscrew breather filter (A). 2 Apply some oil to the sealing of the new breather filter. 3 Screw the new breather filter on tightly. Take care of filters/oils/liquids in an environmentally safe way, see page 91.
1039100
162
Accumulators, releasing pressure
Accumulators, releasing pressure The pressure in the accumulators for brake system, Boom Suspension System and servo system is released as shown below:
L66320A
WARNING! Even if the engine has been stopped, there is still an accumulated pressure in the system. If the system is opened, without having first released the pressure, oil under high pressure will jet out and this could cause injuries. Even retightening of leaking couplings and unions should not be done until the pressure in the system has been fully released.
Brake system 1 Stop the engine. 2 Depress the brake pedal several times (30â&#x20AC;&#x201C;40 times).
Boom Suspension System (BSS) 1 If there is a need to release the pressure in the accumulators for the Boom Suspension System, please contact an authorised Volvo workshop.
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 must not be thrown away unless they first have been taken care of by a workshop and carefully "punctured". If a pressurised accumulator is heated, there is a risk that it may explode.
Greasing
163
Greasing 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: â&#x20AC;&#x201C; Add grease to the bearing to reduce friction between pin and bushing. â&#x20AC;&#x201C; Replace old grease which may contain dirt. The grease in the space inside the outer seal collects dirt and prevents dirt and also water from penetrating into the bearing. Therefore, grease the bearing until new, clean grease is forced out through the outer seal. For recommended grease, see page 177. Wipe off grease nipples and grease gun before greasing, so that dirt and sand is not introduced through the grease nipples.
Symbol key
L63189A
These standard symbols have been used in the "Lubrication and Service Chart" on page 166.
Lubrication
Engine
Transmission
Grease nipple 1027023
L66542A
Hydraulic system
Oils/fluids L66627A
L66543A
Brake system
L66625A
Filter
L66637A
Axles
Air filter L66626A
Fuel system L66546A
Level check L66636A
Battery
Belt tension
L66633A
L66639A
Coolant
Control lamps L66638A
L66545A
Air conditioning
Draining L66632A
L66640A
164
Greasing Articulation joints, lubricating Lubricate the lower bearing every 50 hours. NOTE! Lubricate daily in tough operating conditions. Lubricate the upper bearing every 250 hours. NOTE! Lubricate every 50 hours in aggressive/corrosive environment.
Steering cylinder bearings, lubricating Lubricate the bearings every 125 hours. NOTE! Lubricate every 50 hours in aggressive/corrosive environment.
Greasing bearings 1 2 3 4 5
Lower the lifting arms to the ground. Turn off the engine and apply the parking brake. Lifting and tilting hydraulics should be without pressure. Clean the grease nipples before greasing. Sufficient lubrication if grease emerges from the bearing.
For quality of grease, see page 177.
D B
C
A 1041534
A B C D
Grease nipple, articulation joint, lower bearing Grease nipple, articulation joint, upper bearing Grease nipple, steering cylinders, rear bearings (one on each side) Grease nipple, steering cylinders, front bearings (one on each side)
Greasing
165
Lifting frame, lubricating Lubricate the lower bucket pins every 50 hours. Lubricate the lifting frame every 125 hours. NOTE! Lubricate daily in tough operating conditions. NOTE! Lubricate every 50 hours in aggressive/corrosive environment. 1 Lower the lifting arms to the ground. 2 Turn off the engine and apply the parking brake. 3 Lifting and tilting hydraulics should be without pressure. 4 Clean the grease nipples before greasing. 5 Sufficient lubrication if grease emerges from the bearing. For quality of grease, see page 177.
1041536
166
Lubrication and service chart
Lubrication and service chart Checks, oil changes and lubrication Intervals: Daily (10 hours), 50, 125, 250, 500, 1000, 1500, 2000 and 6000 hours (for symbol key, see previous page).
1000h
1500h
2000h
6000h
500h 250h 125h 50h 10h
6
4
14/ 16
2
4
7
1
9
1
5
3 2 13
8
10h 50h 125h 250h
10
500h
11
1
11
12
1041537
Lubrication and service chart
Item
Page
167
Measures DAILY (every 10 hours) Check travel lights, working lights, back-up alarm and the function of the control lamps.
1
130
Check the engine oil level
2
159
Check the hydraulic oil level
134
Check the fuel system water separator A = EVERY 50 HOURS After carrying out Daily service
3
141
Check the coolant level
152
Check tyres (air pressure and damage) 1)
4
165
Lubricate lower bucket pins 2)
5
164
Lubricate articulation joint, lower bearing 2) B = EVERY 125 HOURS After carrying out Daily service and A services
6
165
Lubricate the lifting frame 2), 3)
7
164
Lubricate the steering cylinder bearings 3) C = EVERY 250 HOURS After carrying out Daily, A and B services
8
134
Drain the fuel system water separator
9
164
Lubricate the frame articulation joint, upper bearing 3) D = EVERY 500 HOURS After carrying out Daily, A, B and C services
10
147
Check the belt tension for the alternator.
11
131133
Change the engine oil and replace the engine oil filter 4)
12
136
Replace the secondary fuel filter 5)
13
135
Replace the primary fuel filter
144
Check the engine radiator, hydraulic oil cooler, charge air cooler and A/C condenser 6) Check for leakages
1) Check daily if there is a risk of damages to the tires, e.g. when handling sharp rocks. 2) Lubricate daily in tough operating conditions. 3) Lubricate every 50 hours in aggressive/corrosive environment 4) At least once every year. For conditions which have to be met, if the interval is to apply, see page 131. 5) At least once every year. 6) Cleaning should be carried out at regular intervals. When operating under especially dusty conditions, the radiator and coolers should be checked daily.
168
Lubrication and service chart
18
24
6000h 2000h 1500h 1000h
16
15
16
F R
14 21 20
25
26 22
23
19 17 1000h 1500h 2000h 6000h
1041538
Lubrication and service chart
Item
Page
169
Measures E = EVERY 1000 HOURS After carrying out Daily, A, B, C and D services
14
149
Change the oil in the front axle 5)
15
150
Change the oil in rear axle with transfer box 5)
16
151
Check the brake discs
17
138
Replace the primary air filter (main cartridge) 7)
18
153
Replace the cab ventilation pre filter
19
160
Drain the hydraulic system, condensation water and sludge F = EVERY 1500 HOURS After carrying out Daily, A, B, C, D and E services
20
161
Replace the hydraulic oil filter 5)
21
161
Replace the hydraulic system breather filter 5)
22
160
Change the hydraulic oil 5), 10) G = EVERY 2000 HOURS After carrying out Daily, A, B, C, D, E and F services
23
138
Replace the secondary air filter (safety cartridge) 8)
24
153
Replace the cab ventilation main filter 9)
25
136
Replace the fuel system breather filter EVERY 6000 HOURS
26
142
Change the coolant 11)
5) At least once every year. 7) Replace every 1000 hours or after max. 5 times of cleaning. 8) Replace every 2000 hours or when the primary air filter has been replaced max. 3 times. 9) The interval between cab filter replacements can be increased or reduced depending on how dusty the working environment is. 10) When using external hydraulic equipment, e.g. road sweeper, drill, snow blower or similar, the oil should be changed every 1000 hours. 11) Change coolant every 6000 hours or at least every fourth year.
170
Automatic greasing system (optional equipment)
Automatic greasing system (optional equipment) Checking and adjusting greasing cycles is done with the aid of the keyboard and the display unit, see page 37.
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. Check the following regularly: – that there is sufficient lubricant in the reservoir. Top up when required, see page 37. 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 174. – 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
System testing button Filling
Automatic greasing system (optional equipment)
171
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.
172
Automatic greasing system (optional equipment) 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. Q
Do not mix different types of lubricants. When changing, all lubricant must be changed, not only in the reservoir.
Q
There must be no additives of graphite or Teflon in the lubricant.
Q
The use of molybdenum disulphide (MoS2) is only permissible 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.
Automatic greasing system (optional equipment)
173
Changing lubrication cycle If the preselected lubrication cycle does not suit the working and loading conditions to which the machine is exposed, the operator can alter the lubrication cycle. Checking and adjusting greasing cycles is done with the aid of the keyboard and the display unit, see page 37. The display unit has a menu for central lubrication (automatic greasing). When changing lubrication cycle, the ignition key must be in position 1 (running position). To be able to change the lubrication cycle again the ignition key must first be turned to the 0 position and then a new lubrication cycle can be selected. NOTE! If the ignition key is turned to position 0 within 20 seconds, the latest selected lubrication cycle will be erased. Therefore, wait for at least 20 seconds after the setting has been made, before turning the ignition key to position 0.
174
Automatic greasing system (optional equipment) 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 2â&#x20AC;&#x201C;6 s. 3 The lubrication cycle starts.
Test button
4 The test cycle is ended automatically. If the test lubrication cycle has been used to obtain an additional 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 ignition key to position 0. The test cycle is not ended automatically.
Automatic greasing system (optional equipment)
175
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 3–6 in order to bleed the other main line. 8 Test the system using the method “Single test lubrication cycle”, see previous page. 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 additional lubrication.
176
Specifications
Recommended lubricants
177
Specifications Recommended lubricants The viscosity indications are according to SAE J 300 MAR93. Other mineral oils can be used if they conform to our viscosity recommendations and meet our quality requirements. Approval must first be obtained from Volvo CE before another base oil quality (e.g. biologically degradable oil) is used. In case of lower ambient temperatures than in this recommendation, contact your local Volvo Service organisation for further information. Oil grade ENGINE
HYDRAULIC SYSTEM Steering Travel hydraulics Working hydraulics Brake
Recommended viscosity at varying ambient temperatures
Volvo Ultra Diesel Engine Oil or Engine oil VDS-3 or VDS-2 + ACEA-E7 or VDS-2 + API CI-4 or VDS-2 + EO-N Premium plus
Volvo Super Hydraulic Oil Mineral oil based HVLP acc. to DIN 51524-3 ISO 11158: HV or Biologically rapidly degradable HEES acc. to VDMA 24568 synthetic ester based (do not mix with mineral oil)
ISO VG 32 HV ISO VG 46 HV ISO VG 68 HV 1041418
or Engine oil min. requirement API SF/CE
SAE 10W/30 SAE 15W/40 SAE 30 1041419
AXLES Transfer box Axle differential Axle planetary hubs
Volvo Super Transmission Oil with Limited-Slip additives API GL-5 / LS
SAE 80W-90, SAE 85W-90/ LS SAE 90/ LS M201081B
COOLING SYSTEM
Volvo Coolant VCS Volvo Coolant VCS should be used only. (Water 50%, anti-freeze 50%), see page 179.
Specifications
178
Recommended lubricants
Grease General lubrication points 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.
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 131. 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 5% bio-diesel fuel in the diesel fuel, ready mixed from the oil companies. A higher intermix than 5% 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 5% of bio-diesel fuel.
Specifications
Coolant
179
Coolant Use the same coolant as the system is already filled with, see page 140. Do not mix different coolants or corrosion protection as this may result in engine damages. If using concentrated coolant and clean water, the mixture should contain 40–60% concentrated coolant and 60–40% clean water. The content of coolant must not be less than 40% of the total mixture, see table below. Freeze protection down to
Content 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. The clean water for the cooling system must also meet the following requirements:
Description
Value
Total number of soild particles
< 340 ppm
Total hardness
< 9.5 °dH
Chloride
< 40 ppm
Sulphate
< 100 ppm
pH value
5.5–9
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
If in doubt of the water’s quality, use a ready-mixed coolant. Do not mix different ready-mixed coolants as this may result in engine damages.
Specifications
180
Service capacities and change intervals
Service capacities and change intervals Oils and fluids
Filling capacities
Engine, incl. filter
16 litres (4.2 US gal)
Front axle
17.5 litres (4.6 US gal)
Rear axle with transfer box
18.7 litres (4.9 US gal)
Hydraulic system, incl. tank
95 litres (25 US gal)
Fuel tank
150 litres (39.6 US gal)
Coolant
20 litres (5.3 US gal)
Air conditioning (option) (initial filling)
1.85 kg (4.1 lb)
Oil and fluid changes
Change interval *)
Engine oil
500 operating hours
Front and rear axle with transfer box
1000 operating hours
Hydraulic oil
1500 operating hours
Coolant (VCS coolant)
6000 operating hours
Filter replacements
Change interval *)
Engine, oil filter
500 operating hours
Air cleaner, primary filter
1000 operating hours
Fuel filters, primary and secondary
500 operating hours
Hydraulic oil filter and breather filter
1500 operating hours
Fuel system, breather filter
2000 operating hours
Air cleaner, secondary filter
2000 operating hours
*) These intervals apply under normal operating conditions and the recommended fuels and lubricants.
Specifications
Engine
181
Engine L45F Make
4-stroke diesel engine with direct injection and turbocharger, Tier3 compliant with mechanical control, internal EGR.
Model
TCD 2013 L04 2V m
Designation
D5DCAE3
Rated power at 2200 rpm, SAE J1995, gross
74.9 kW (102 hp)
Rated power at 2200 rpm, SAE J1349, net
73 kW (99 hp)
Max. torque at 1600 rpm, gross
420 Nm (310 ft lb)
Max. torque at 1600 rpm, net
409 Nm (302 ft lb)
Low idle speed
850 - 950 rpm
High idle speed
2250 - 2350 rpm
Number of cylinders/design
4/in line
Compression ratio
18:1
Cylinder bore
108 mm (4.25 in)
Stroke
130 mm (5.12 in)
Displacement
4761 cm3 (291 cu in)
Lubrication
Force-feed lubrication
Lubricating oil pressure, minimum
80 kPa (0.8 bar)
Oil temperature, normal
114 째C (237째F)
Oil temperature, maximum
140 째C (284째F)
Oil flow at high idle
65 l/min (17.2 US gal/min)
Firing sequence
1-3-4-2
Specifications
182
Engine
L50F Make
4-stroke diesel engine with direct injection, turbocharger and charge-aircooled, Tier3 compliant with mechanical control, internal EGR.
Model
TCD 2013 L04 2V m
Designation
D5DCBE3
Rated power at 2200 rpm, SAE J1995, gross
87 kW (118 hp)
Rated power at 2200 rpm, SAE J1349, net
85 kW (116 hp)
Max. torque at 1600 rpm, gross
490 Nm (361 ft lb)
Max. torque at 1600 rpm, net
478 Nm (353 ft lb)
Low idle speed
850 - 950 rpm
High idle speed
2250 - 2350 rpm
Number of cylinders/design
4/in line
Compression ratio
18:1
Cylinder bore
108 mm (4.25 in)
Stroke
130 mm (5.12 in)
Displacement
4761 cm3 (291 cu in)
Lubrication
Force-feed lubrication
Lubricating oil pressure, minimum
80 kPa (0.8 bar)
Oil temperature, normal
114 째C (237째F)
Oil temperature, maximum
140 째C (284째F)
Oil flow at high idle
65 l/min (17.2 US Gal/min)
Firing sequence
1-3-4-2
Specifications
Electrical system
183
Electrical system System voltage
24 V
Battery
2 pcs
Battery voltage
12 V
Battery capacity
2 x 90 Ah
Alternator, rated output
1.54 kW
Alternator, current rating
55 A
Starter motor output
4.0 kW (5.4 hp)
Relays and fuses in the engine compartment NOTE! Use only fuses of specified capacity (Ampere rating). Risk of damage or burning in the printed circuit board!
1 100
2
1
RE6401 RE3301 RE2319
2
FU70
125
40
FU71 FU73 1041438
RE
A
Function
RE
A
Function
6401
150
Aux steering pump
2319
40
Engine preheating, glow plugs
3301
20
Starter motor
FU
A
Function
FU
A
Function
70
100
Cab power supply
73
40
Starter motor and engine preheating, glow plugs
71
125
Aux steering pump
Specifications
184
Electrical system
Bulbs
Watt
Socket
Head lights: - High beam - Low beam
70 W H3 65 W H7
PK 22s RX 26 d
Parking lights, front/rear
T 4 W / R 10 W
BA 9 s / BA 15 s
Number plate light
R 10 W
BA 15 s
Tail lights
R 10 W
BA 15 s
Brake lights
P 21 W
BA 15 s
Direction indicators, front/rear
P 21 W / P 21 W
BA 15 s
Interior light
P 21 W
BA 15 s
Working lights
70 W H3
PK 22 s
Rotating warning beacon
70 W H1 and 5 W
PK 14.5 s
Backup lights
P 21 W
BA 15 s
Specifications
Electrical system
185
Relays and fuses on the circuit board Relays
DA
DB
DI07
DI23
DI17 R02
DI06 DI22
DI21
DI10
DI08
R09
RE3303
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
RE06
RE09
RE08
RE11
RE10
RE12 DI05
RE07
RE05
DI12
RE02
RE01
DI13
RF1
C01
30K
32 33 34 35 36
R10
DE
R08
DI04 DI02
R05 R06
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
1041448
RE
A
FUNCTION
RE
A
FUNCTION
01
20
Bucket positioner
12
20
30 feed controlled by I-ECU Holding voltage RE 13
02
20
Back-up alarm
13
40
Voltage supply V-ECU, T-ECU
03
20
Water pump on road sweeper
14
20
Voltage supply ECC (air conditioning)
04
20
Working lights, rear
15
20
Windscreen wiper
05
20
Boom kick-out
16
40
15A feed
06
20
Starter relay
17
40
15A feed
07
20
Working lights cab front
18
20
15EA feed
08
20
Boom Suspension System â&#x20AC;&#x201C; BSS
09
20
Rear window wiper
RF 1
15
Flasher relay
10
20
Stop lights
11
20
Not used
RE3303
20
Key delay
Specifications
186
Electrical system
Fuses
DA
DB
DI07
DI23
DI17 R02
DI06 DI22
DI21
DI10
DI08
R09
RE3303
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
DI15
RE04
RE06
RE08
RE09
RE11
RE10
RE12 DI05
RE07
RE05
DI12
RE03 RE02
RE01
DI13
RF1
C01
32 33 34 35 36
R10
R08
DE
DI04 DI02
R05 R06
P1 R04
DF
37 38 39 40 41
DG
DI11 RE18
42 43 44 45 46
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
1041448
30K
Specifications
Electrical system
187
Fuses FU
A
FUNCTION
FU
A
FUNCTION
01
5
Brake lights
31
5
Joystick supply, differential lock
02
10
–
32
10
Attachment lock open, pallet forks, float position
03
15
Working lights cab, front
33
10
Tilt, lift automatic, hydraulic functions on lever
04
5
Voltage supply to RE14
34
10
Headlight flasher, windshield wiper and washer front
05
5
Instrument lighting, parking light left front, parking light right rear
35
10
Windshield wiper and washer rear
06
5
Parking light right front, parking light left rear, lighting license plate
36
5
Alternator, hour counter
07
5
Low beam, left
37
5
Direction indicators
08
5
Low beam, right
38
5
Electrically heated fuel filter
09
10
Back-up alarm, reverse travel lights, reverse warning light.
39
10
Horn, electrically heated rearview mirrors, control of water pump on road sweeper
10
5
High beam, right
40
10
–
11
5
High beam, left
41
10
Air suspension operator seat with seat heating, position sensor air suspension operator seat
12
5
15RA supply radio, voltage converter
42
5
Boom suspension system (BSS)
13
15
Water pump on road sweeper
43
5
Automatic greasing / Central lubrication
14
5
Hazard warning
44
5
–
15
15
Working lights cab rear
45
5
–
16
15
Optional working lights
46
10
15EA sensor supply
17
10
Voltage supply I-ECU, holding voltage RE13
47
10
–
18
10
Power socket 24 V (lighter)
48
5
Parking brake
19
15
Travel lights (Head lights)
49
5
–
20
10
Ignition switch voltage supply
50
5
VCADS
21
10
Rotating warning beacon, interior lighting
51
5
Ignition dependent voltage feed I-ECU, V-ECU, T-ECU, ECC
22
5
Voltage supply to RE12 (I-ECU)
23
5
Engine Starter Motor
24
15
–
25
15
Voltage supply V-ECU
26
15
Voltage supply T-ECU
27
20
Cab fan
28
10
AC compressor
29
5
ECC (air conditioning)
30
5
–
Specifications
188
Transmission
Transmission Hydrostatic travel system Hydraulic pump Model
A4VG90DA
Hydraulic motor Model
A6VM200HA1R2
Travel speeds Position "1" forward/reverse
0-5 km/h (0-3 mph)
Position "2" forward/reverse
0-20 km/h (0-12 mph)
Front Axle Model
ZF
Type
MT-L3045
Operation
Fixed mounted
Transmission ratio, total
16:1
Differential lock
100% dog clutch
Rear Axle Model
ZF
Type
MT-L3045
Operation
Oscillating
Transmission ratio, total
16:1
Differential lock
100% dog clutch
Specifications
Brake system and steering system
189
Brake system and steering system Brakes Service brake, type
Oil-immersed disc brake in rear axle. Single circuit brake system with 1 pressure accumulator.
Service brake, disc thickness, new
5.5 mm (0.22 in)
Service brake, disc thickness, wear limit
4.5 mm (0.18 in)
Inching brake pedal
Hydraulic inching brake pedal for infinitely variable control of travel speed and service brake application. Double pedal arrangement.
Parking brake, type
Dry disc brake on front axle input flange. Hand lever operation.
Parking brake, disc thickness, new
12.7 mm (0.50 in)
Parking brake, disc thickness, wear limit
10.0 mm (0.39 in)
Steering Steering system, type
Articulated frame steering with Hydrostatic LS steering unit
Steering pump, type
Gear pump
Steering pump, flow, max.
64 l/min (16.9 US gal/min)
Number of steering wheel revolutions, total
4.2
Steering cylinders
2 pcs., double-acting
Steering angle
¹40°
Specifications
190
Tyre sizes and pressures
Tyre sizes and pressures Tires
L45F
L50F
Air pressures: bar / psi front
rear
front
rear
15.5 - 25
3.5 (51)
2.5 (36)
3.5 (51)
2.5 (36)
15.5 R 25
3.25 (47)
2.5 (36)
3.5 (51)
2.5 (36)
17.5 - 25
3.0 (44)
2.5 (36)
3.5 (51)
2.5 (36)
17.5 R 25
3.0 (44)
2.5 (36)
3.5 (51)
2.5 (36)
440 / 80 R 24
3.0 (44)
2.5 (36)
3.25 (47)
2.75 (40)
500 / 70 R 24
2.75 (40)
2.0 (29)
3.0 (44)
2.25 (33)
540 / 65 R 24
2.25 (33)
2.0 (29)
2.5 (36)
2.25 (33)
600 / 55 - 26.5
1.75 (25)
1.25 (18)
2.0 (29)
1.25 (18)
The stated tyre pressures are guide values. – 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.
Wheel nuts, tightening torque Tightening torque
560 – 600 Nm (413 – 443 lb ft)
Specifications
Cab
191
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). Number of emergency exits
1 (rear window to be smashed with emergency hammer)
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)
80 mm (3.15 in)
Longitudinal adjustment
160 mm (6.3 in)
Adjustment for driver weight
40–130 kg (88–287 lb)
Adjustment of back-rest, (adjustable backrest inclination)
12°
Upholstery
Fire resistant
Lap type seat belt with reel
Yes
Specifications
192
Cab
Vibration and sound information 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. Vibration emission value aw,eqx (m/s² RMS)
Vibration emission value aw,eqy (m/s² RMS)
Vibration emission value aw,eqz (m/s² RMS)
V-shaped loading and carrying work
0.6
0.6
0.6
Loading and carrying work
0.5
0.5
0.6
V-shaped loading and carrying work with pallet fork
0.5
0.5
0.5
Transporting operation
0.5
0.5
0.6
Typical operating conditions
The following vibration directions are defined: x = fore and aft 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/CEN Technical Report is recommended. To ensure that the whole-body vibration emission during machine use is kept to a minimum, see page 86.
Sound information, L45F Sound pressure level (LpA) at operator position 70 LpA 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)
102 LwA dB(A)
Sound information, L50F Sound pressure level (LpA) at operator position 70 LpA 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)
102 LwA dB(A)
Blauer Engel (optional equipment) Equipment which concerns the noise emission of the machine must be kept clean and must, when required, be replaced. Settings made at the factory must not be changed so that the noise emission of the machine is impaired.
Specifications
Hydraulic system
193
Hydraulic system Working hydraulics Type
Closed-center LS system with flow sharing, main control valve pilotoperated.
Hydraulic pump, type
A10VO60DFR1
Hydraulic pump, flow, max
132 l/min (34.9 US gal/min)
Tilt cylinder
1 pcs., double-acting
Lifting cylinders
2 pcs., double-acting
Cycle times
L45F
L50F
Lift-up (loaded)
5.3 sec.
6.4 sec.
Tipping
1.1 sec.
1.6 sec.
Lift-down (empty)
3.2 sec.
3.9 sec.
Specifications
194
Dimensions and performance values
Dimensions and performance values
a4
a1
V
X F
a3
D C B A
a2
Y
S
L45F with attachment carrier type
L45F with TP-linkage, TPZ attachment carrier and 15.5-25 tires Z B 5325 mm 17' 6" C 2650 mm 8' 8" D 395 mm 1' 4" F 2950 mm 9' 8" G 1000 mm 3' 3" J 3430 mm 11' 3" K 3685 mm 12' 1" O O 55 ° P 45 ° 45 ° L R M P S 75 ° K Z J N H U 255 mm 0' 10" X 1750 mm 5' 9" R G Y 2150 mm 7' 1" U T Z 3360 mm 11' 0" a2 4745 mm 15' 7" a3 2555 mm 8' 5" 1040976 a4 ± 40 °
Data according to bucket type
Bucket type
L45F with TP-Linkage, TPZ attachment carrier and 15.5-25 tires m³ Capacity heaped
yd³
General purpose
Light material
4-in-1
High-tip
1.4 1.8
1.6 2.1
1.8 2.4
2.0 2.6
1.3 1.7
2.0 2.6
Material density
kg/m³ lb/yd³
1900 3203
1600 2697
1400 2360
1300 2191
1900 3203
1100 1854
Static tipping load straight
kg lb
6220 13713
6120 13492
6020 13272
5890 12985
6050 13338
5260 11596
Static tipping load at full turn, 40° Hydraulic lifting capacity, max.
kg lb
5500 12125
5420 11949
5330 11751
5210 11486
5350 11795
4650 10251
kN lbf
74.0 16636
72.5 16299
71.3 16029
69.5 15624
72.0 16186
62.0 13938
Breakout force
kN lbf
66.0 14837
60.5 13601
55.5 12477
50.0 11240
65.0 14613
---
A Overall length
mm ft in
6260 20'6"
6335 20'9"
6415 21'1"
6525 21'5"
6270 20'7"
6825 22'5"
L Lifting height, max.
mm ft in
4680 15'4"
4750 15'7"
4820 15'10"
4890 16'1"
4730 15'6"
5610 18'5"
V Bucket width
mm ft in
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
a1 Clearance circle
mm ft in
10125 33'3"
10165 33'4"
10210 33'6"
10275 33'9"
10165 33'4"
10590 34'9"
T Digging depth
mm ft in
90 0'4"
90 0'4"
90 0'4"
90 0'4"
45 0'2"
80 0'3"
H Dump height, 45°
mm ft in
2875 9'5"
2815 9'3"
2755 9'0"
2675 8'9"
2865 9'5"
4140 13'7"
M Reach at max. height
mm ft in
860 2'10"
900 2'11"
955 3'2"
1030 3'5"
850 2'9"
1370 4'6"
N Reach, max.
mm ft in
1685 5'6"
1725 5'8"
1780 5'10"
1855 6'1"
1670 5'6"
2540 8'4"
Operating weight
kg lb
8580 18916
8620 19004
8610 18982
8640 19048
8830 19467
9030 19908
Data with loading fork Distance to centre of gravity 500 mm Tipping load at full turn Payload acc. to EN 474-3, 60/80%
kg (lb) kg (lb)
Payload 80%, transport position, 40° full turn
kg (lb)
4670 (10296) 2800/3730 (6173/8223) 4000 (8818)
Specifications
Dimensions and performance values
195
L45F with attachment carrier type V, welded version L45F with TP-linkage, TPV attachment carrier (welded version) and 15.5-25 tires B 5320 mm 17' 5" C 2650 mm 8' 8" D 395 mm 1' 4" F 2950 mm 9' 8" G 1000 mm 3' 3" J 3430 mm 11' 3" O K 3685 mm 12' 1" O 55 ° P 45 ° L R 45 ° M P K J S 75 ° Z N H U 255 mm 0' 10" X 1750 mm 5' 9" R G Y 2150 mm 7' 1" U T Z 3445 mm 11' 4" a2 4745 mm 15' 7" a3 2555 mm 8' 5" 1040976 a4 ± 40 °
a4
a1
V
X F
a3
D
S
C B A
a2
Y
Data according to bucket type
Bucket type
L45F with TP-linkage, TPV attachment carrier (welded version) and 15.5-25 tires m³ Capacity heaped yd³
Universal bucket
Light material bucket
4-in-1 bucket
High tipping bucket
1.4 1.8
1.5 2
1.8 2.4
2.0 2.6
1.2 1.6
2.0 2.6
Material density
kg/m³ lb/yd³
1800 3034
1700 2865
1400 2358
1200 2023
1900 3203
1000 1686
Static tipping load straight
kg lb
5970 13162
5930 13073
5780 12743
5670 12500
5650 12456
4950 10913
Static tipping load at full turn, 40° Hydraulic lifting capacity, max.
kg lb
5290 11662
5250 11574
5120 11288
5020 11067
5000 11023
4370 9634
kN lbf
70.0 15736
69.4 15602
67.5 15175
66.0 14837
66.5 14950
57.5 12927
Breakout force
kN lbf
62.0 13938
59.7 13421
53.0 11915
48.0 10791
66.0 14837
---
A Overall length
mm ft in
6350 20'10"
6385 20'11"
6505 21'4"
6615 21'8"
6295 20'8"
6955 22'10"
L Lifting height, max.
mm ft in
4740 15'7"
4790 15'9"
4810 15'9"
4940 16'2"
4815 15'10"
5695 18'8"
V Bucket width
mm ft in
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
a1 Clearance circle
mm ft in
10300 33'10"
10320 33'10"
10390 34'1"
10460 34'4"
10305 33'10"
10675 35'0"
T Digging depth
mm ft in
85 0'3"
85 0'3"
85 0'3"
85 0'3"
120 0'5"
95 0'4"
H Dump height, 45°
mm ft in
2800 9'2"
2780 9'1"
2690 8'10"
2610 8'7"
2790 9'2"
4230 13'11"
M Reach at max. height
mm ft in
930 3'1"
945 3'1"
1025 3'4"
1100 3'7"
815 2'8"
1490 4'11"
N Reach, max.
mm ft in
1750 5'9"
1770 5'10"
1850 6'1"
1925 6'4"
1640 5'4"
2670 8'9"
Operating weight
kg lb
8630 19026
8650 19070
8660 19092
8690 19158
8850 19511
9090 20040
Data with loading fork Distance to centre of gravity 500 mm Tipping load at full turn Payload acc. to EN 474-3, 60/80%
kg (lb) kg (lb)
Payload 80%, transport position, 40° full turn
kg (lb)
4420 (9744) 2650/3530 (5842/7782) 4000 (8818)
Specifications
196
Dimensions and performance values
L45F with attachment carrier type V, cast version L45F with TP-linkage, TPV attachment carrier (cast version) and 15.5-25 tires B 5320 mm 17' 5" C 2650 mm 8' 7" D 395 mm 1' 4" F 2950 mm 9' 8" G 1000 mm 3' 3" J 3430 mm 11' 3" O K 3685 mm 12' 1" O 54 ° P 45 ° L R 44 ° M P K J Z S 76 ° N H U 255 mm 0' 10" X 1750 mm 5' 9" R G Y 2150 mm 7' 1" U T Z 3445 mm 11' 4" a2 4745 mm 15' 7" a3 2555 mm 8' 5" 1040976 a4 ± 40 °
a4
a1
V
X F
a3
D
S
C B A
a2
Y
Data according to bucket type
Bucket type
L45F with TP-linkage, TPV attachment carrier (cast version) and 15.525 tires m³ Capacity heaped yd³
Universal bucket
Light material bucket
4-in-1 bucket
High tipping bucket
1.4 1.8
1.5 2
1.8 2.4
2.0 2.6
1.2 1.6
2.0 2.6
Material density
kg/m³ lb/yd³
1800 3034
1700 2865
1400 2358
1200 2023
1900 3203
1000 1686
Static tipping load straight
kg lb
5940 13095
5860 12919
5710 12588
5600 12346
5580 12302
4880 10759
Static tipping load at full turn, 40° Hydraulic lifting capacity, max.
kg lb
5250 11574
5190 11662
5050 11133
4960 10935
4940 10891
4320 9524
kN lbf
70.0 15736
69.4 15602
67.5 15175
66.0 14837
66.5 14950
57.5 12927
Breakout force
kN lbf
61.0 13713
59.7 13421
53.0 11915
48.0 10791
66.0 14837
---
A Overall length
mm ft in
6370 20'11"
6385 20'11"
6505 21'4"
6615 21'8"
6295 20'8"
6955 22'10"
L Lifting height, max.
mm ft in
4740 15'7"
4790 15'9"
4810 15'9"
4940 16'2"
4815 15'10"
5695 18'8"
V Bucket width
mm ft in
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
2250 7'5"
a1 Clearance circle
mm ft in
10310 33'10"
10320 33'10"
10390 34'1"
10460 34'4"
10305 33'10"
10675 35'0"
T Digging depth
mm ft in
85 0'3"
85 0'3"
85 0'3"
85 0'3"
120 0'5"
95 0'4"
H Dump height, 45°
mm ft in
2800 9'2"
2780 9'1"
2690 8'10"
2610 8'7"
2790 9'2"
4230 13'11"
M Reach at max. height
mm ft in
940 3'1"
960 3'2"
1040 3'5"
1115 3'8"
830 2'9"
1500 4'11"
N Reach, max.
mm ft in
1770 5'10"
1785 5'10"
1860 6'1"
1935 6'4"
1650 5'5"
2685 8'10"
Operating weight
kg lb
8680 19136
8700 19180
8710 19202
8740 19268
8900 19621
9140 20150
Data with loading fork Distance to centre of gravity 500 mm Tipping load at full turn Payload acc. to EN 474-3, 60/80%
kg (lb) kg (lb)
Payload 80%, transport position, 40° full turn
kg (lb)
4380 (9656) 2620/3500 (5776/7716) 4000 (8818)
Specifications
Dimensions and performance values
197
L50F with attachment carrier type Z L50F with TP-linkage, TPZ attachment carrier and 17.5-25 tires B 5385 mm 17' 8" C 2650 mm 8' 8" D 435 mm 1' 5" F 2980 mm 9' 9" G 1000 mm 3' 3" J 3525 mm 11' 7" K 3780 mm 12' 5" O O 55 ° P 45 ° R 50 ° L M P S 75 ° Z J K N H U 255 mm 0' 10" X 1730 mm 5' 8" R G Y 2190 mm 7' 2" U T Z 3455 mm 11' 4" a2 4760 mm 15' 7" a3 2540 mm 8' 4" 1040976 a4 ± 40 °
a4
a1
V
X F
a3
D
S
C B A
a2
Y
Data according to bucket type
Bucket type
L50F with TP-linkage, TPZ attachment carrier and 17.5-25 tires m³ Capacity heaped
yd³
Universal bucket
Light material bucket
4-in-1 bucket
High tipping bucket
1.6 2.1
1.8 2.4
2.0 2.6
2.5 3.3
1.4 1.8
2.3 3.0
Material density
kg/m³ lb/yd³
1800 3033
1600 2696
1400 2360
1100 1854
1900 3202
1100 1854
Static tipping load straight
kg lb
6840 15080
6730 14837
6600 14551
6540 14418
6770 14925
5960 13140
Static tipping load at full turn, 40° Hydraulic lifting capacity, max.
kg lb
6050 13338
5960 13140
5840 12875
5970 13162
6000 13228
5280 11640
kN lbf
90.0 20233
88.5 19896
86.5 19446
85.0 19109
88.5 19896
78.0 17535
Breakout force
kN lbf
74.0 16636
68.0 15287
61.0 13713
53.0 11915
71.0 15691
---
A Overall length
mm ft in
6400 20'12"
6480 21'3"
6590 21'7"
6740 22'1"
6430 21'1"
6890 22'7"
L Lifting height, max.
mm ft in
4840 15'11"
4900 16'1"
4915 16'2"
5170 17'0"
4825 15'10"
6200 20'4"
V Bucket width
mm ft in
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
a1 Clearance circle
mm ft in
10325 33'10"
10370 34'0"
10440 34'3"
10530 34'7"
10355 33'12"
10635 34'11"
T Digging depth
mm ft in
100 0'4"
100 0'4"
100 0'4"
95 0'4"
60 0'2"
95 0'4"
H Dump height, 45°
mm ft in
2900 9'6"
2845 9'4"
2770 9'1"
2660 8'9"
2890 9'6"
4230 13'11"
M Reach at max. height
mm ft in
880 2'11"
930 3'1"
1005 3'4"
1100 3'7"
890 2'11"
1350 4'5"
N Reach, max.
mm ft in
1725 5'8"
1775 5'10"
1850 6'1"
1950 6'5"
1740 5'9"
2540 8'4"
Operating weight
kg lb
9330 20569
9370 20657
9350 20613
9400 20723
9570 21098
9780 21561
Data with loading fork Distance to centre of gravity 500 mm Tipping load at full turn Payload acc. to EN 474-3, 60/80%
kg (lb) kg (lb)
Payload 80%, transport position, 40° full turn
kg (lb)
5100 (11244) 3060/4000 (6746/8818) 4000 (8818)
Specifications
198
Dimensions and performance values
L50F with attachment carrier type V, welded version L50F with TP-linkage, TPV attachment carrier (welded version) and 17.5-25 tires B 5380 mm 17' 8" C 2650 mm 8' 8" D 435 mm 1' 5" F 2980 mm 9' 9" G 1000 mm 3' 3" J 3525 mm 11' 7" K 3780 mm 12' 5" O O 55 ° P 45 ° R 45 ° L M P S 75 ° Z J K N H U 255 mm 0' 10" X 1730 mm 5' 8" R G Y 2190 mm 7' 2" U T Z 3535 mm 11' 7" a2 4760 mm 15' 7" a3 2540 mm 8' 4" 1040976 a4 ± 40 °
a4
a1
V
X F
a3
D
S
C B A
a2
Y
Data according to bucket type
Bucket type
L50F with TP-linkage, TPV attachment carrier (welded version) and 17.5-25 tires m³ Capacity heaped yd³
Universal bucket
Light material bucket
4-in-1 bucket
High tipping bucket
1.5 2.0
1.6 2.1
1.8 2.3
2.0 2.6
1.4 1.8
2.3 3.0
Material density
kg/m³ lb/yd³
1900 3203
1800 3034
1500 2023
1400 1517
1900 3203
1000 1517
Static tipping load straight
kg lb
6640 14639
6580 14506
6480 14286
6360 14021
6160 13580
5620 12390
Static tipping load at full turn, 40° Hydraulic lifting capacity, max.
kg lb
5870 12941
5820 12831
5730 12632
5630 12412
5450 12015
4970 10957
kN lbf
86.5 19446
86.0 19334
84.5 18996
83.0 18659
81.5 18322
73.0 16411
Breakout force
kN lbf
73.0 16411
70.0 15737
65.0 14613
59.0 13264
66.0 14837
---
A Overall length
mm ft in
6445 21'2"
6480 21'3"
6565 21'6"
6675 21'11"
6645 21'10"
7015 23'0"
L Lifting height, max.
mm ft in
4880 16'0"
4900 16'1"
4980 16'4"
5235 17'2"
4905 16'1"
5915 19'5"
V Bucket width
mm ft in
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
a1 Clearance circle
mm ft in
10355 33'12"
10380 34'1"
10430 34'3"
10500 34'5"
10470 34'4"
10735 35'3"
T Digging depth
mm ft in
100 0'4"
100 0'4"
100 0'4"
100 0'4"
135 0'5"
110 0'4"
H Dump height, 45°
mm ft in
2870 9'5"
2850 9'4"
2780 9'1"
2700 8'10"
2750 9'0"
4300 14'1"
M Reach at max. height
mm ft in
955 3'2"
990 3'3"
1030 3'5"
1105 3'8"
955 3'2"
1495 4'11"
N Reach, max.
mm ft in
1800 5'11"
1820 5'12"
1880 6'2"
1960 6'5"
1800 5'11"
2700 8'10"
Operating weight
kg lb
9360 20635
9380 20679
9370 20657
9400 20723
9620 21208
9840 21693
Data with loading fork Distance to centre of gravity 500 mm Tipping load at full turn Payload acc. to EN 474-3, 60/80%
kg (lb) kg (lb)
Payload 80%, transport position, 40° full turn
kg (lb)
4850 (10692) 2910/3880 (6415/8554) 4000 (8818)
Specifications
Dimensions and performance values
199
L50F with attachment carrier type V, cast version L50F with TP-linkage, TPV attachment carrier (cast version) and 17.5-25 tires B 5380 mm 17' 8" C 2650 mm 8' 8" D 435 mm 1' 5" F 2980 mm 9' 9" G 1000 mm 3' 3" J 3525 mm 11' 7" K 3780 mm 12' 5" O O 54 ° P 45 ° R 44 ° L M P S 76 ° Z J K N H U 255 mm 0' 10" X 1730 mm 5' 8" R G Y 2190 mm 7' 2" U T Z 5535 mm 18' 2" a2 4760 mm 15' 7" a3 2540 mm 8' 4" 1040976 a4 ± 40 °
a4
a1
V
X F
a3
D
S
C B A
a2
Y
Data according to bucket type
Bucket type
L50F with TP-linkage, TPV attachment carrier (cast version) and 17.525 tires m³ Capacity heaped yd³
Universal bucket
Light material bucket
4-in-1 bucket
High tipping bucket
1.5 2.0
1.6 2.1
1.8 2.3
2.0 2.6
1.4 1.8
2.3 3.0
Material density
kg/m³ lb/yd³
1900 3203
1700 2865
1500 2528
1300 2191
1900 3203
1000 1686
Static tipping load straight
kg lb
6560 14462
6510 14352
6400 14110
6290 13867
6080 13404
5550 12236
Static tipping load at full turn, 40° Hydraulic lifting capacity, max.
kg lb
5810 12809
5750 12677
5670 12500
5570 12280
5390 11883
4910 10825
kN lbf
86.5 19446
86.0 19334
84.5 18996
83.0 18659
81.5 18322
73.0 16411
Breakout force
kN lbf
72.0 16186
69.0 15512
64.0 14388
58.0 12364
65.0 14613
---
A Overall length
mm ft in
6460 21'2"
6495 21'4"
6580 21'7"
6690 21'11"
6560 21'6"
7030 23'1"
L Lifting height, max.
mm ft in
4880 16'0"
4900 16'1"
4980 16'4"
5235 17'2"
4905 16'1"
5915 19'5"
V Bucket width
mm ft in
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
2250 7'4"
a1 Clearance circle
mm ft in
10360 33'12"
10385 34'1"
10435 34'3"
10505 34'6"
10475 34'4"
10740 35'3"
T Digging depth
mm ft in
95 0'4"
95 0'4"
95 0'4"
95 0'4"
130 0'5"
105 0'4"
H Dump height, 45°
mm ft in
2865 9'5"
2845 9'4"
2775 9'1"
2695 8'10"
2745 9'0"
4330 14'2"
M Reach at max. height
mm ft in
965 3'2"
1000 3'3"
1040 3'5"
1115 3'8"
965 3'2"
1505 4'11"
N Reach, max.
mm ft in
1810 5'11"
1830 6'0"
1890 6'2"
1970 6'6"
1810 5'11"
2710 8'11"
Operating weight
kg lb
9410 20745
9430 20790
9420 20768
9450 20834
9670 21319
9890 21804
Data with loading fork Distance to centre of gravity 500 mm Tipping load at full turn Payload acc. to EN 474-3, 60/80%
kg (lb) kg (lb)
Payload 80%, transport position, 40° full turn
kg (lb)
4810 (10604) 2880/3640 (6349/8025) 4000 (8818)
Specifications
200
Service history
Service history Type of service
Service 100 hours Date
Hours
Date
Hours
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Signature and stamp
Service and maintenance
Type of service
Service 3000 hours
Signature and stamp
Service and maintenance
Type of service
Service 2500 hours
Signature and stamp
Service and maintenance
Type of service
Service 2000 hours
Signature and stamp
Warranty Inspection Service and maintenance
Type of service
Service 1500 hours
Signature and stamp
Service and maintenance
Type of service
Service 1000 hours Date
Warranty Inspection
Type of service
Service 500 hours
Signature and stamp
Service and maintenance
Signature and stamp
Specifications
Service history Type of service
Service 3500 hours Date
Hours
Date
Hours
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Signature and stamp
Service and maintenance
Type of service
Service 6500 hours
Signature and stamp
Service and maintenance
Type of service
Service 6000 hours
Signature and stamp
Service and maintenance
Type of service
Service 5500 hours
Signature and stamp
Service and maintenance
Type of service
Service 5000 hours
Signature and stamp
Service and maintenance
Type of service
Service 4500 hours Date
Service and maintenance
Type of service
Service 4000 hours
Signature and stamp
Service and maintenance
Signature and stamp
201
Specifications
202
Service history Type of service
Service 7000 hours Date
Hours
Date
Hours
Hours
Date
Hours
Date
Hours
Date
Hours
Date
Hours
Signature and stamp
Service and maintenance
Type of service
Service 10000 hours
Signature and stamp
Service and maintenance
Type of service
Service 9500 hours
Signature and stamp
Service and maintenance
Type of service
Service 9000 hours
Signature and stamp
Service and maintenance
Type of service
Service 8500 hours
Signature and stamp
Service and maintenance
Type of service
Service 8000 hours Date
Service and maintenance
Type of service
Service 7500 hours
Signature and stamp
Service and maintenance
Signature and stamp
Alphabetical index
203
Alphabetical index Accidents .......................................................................68 Accumulators, releasing pressure................................162 Adjusting heating and ventilation ...................................64 Air conditioning (optional equipment)...........................155 Air suspended seat (optional equipment) ......................60 Alarm texts .....................................................................42 Alternator .....................................................................147 Anti-theft device (optional equipment) .......................7, 47 Arrival and delivery inspections....................................127 Articulation joints, lubricating .......................................164 Attachment brackets ......................................................94 Attachments ...................................................................92 Auto engine shutoff (optional equipment) ......................67 Automatic greasing system (optional equipment) ........170 Axles ............................................................................149 Back-up alarm (optional equipment) ..............................58 Back-up alarm switchable (optional equipment) ............58 Batteries .......................................................................145 Batteries, charging .......................................................146 Battery disconnect switch ............................................145 Bearings, greasing .......................................................163 Before service read ......................................................120 Blauer Engel (optional equipment)...............................192 Boom kick-out (optional equipment)...............................57 Boom suspension system (BSS)....................................97 Brake system and steering system ..............................189 Brake system ...........................................................6, 151 Braking ...........................................................................77 Breather filter, fuel system, replacing...........................136 Bucket operation ............................................................98 Bucket positioner ...........................................................56 Bucket teeth, replacing (Volvo tooth system)...............158 Buckets ..........................................................................98 Cab post panel ...............................................................21 Cab ..................................................................6, 153, 191 Cab, cleaning and replacing ventilation filters..............153 CE marking, EMC directive ............................................10 Ceiling panel ..................................................................20 Centre instrument ..........................................................26 Choosing bucket ............................................................98 Clamshell bucket (optional equipment) ........................105 Cleaning machine ........................................................128 Climate control system...................................................62 Combi-forks..................................................................111 Communication equipment, installation ...........................8 Compressor belt, checking and adjusting tension........156 Condenser, cleaning ....................................................157 Condition test ...............................................................127 Connecting and disconnecting attachments ..................93 Controls..........................................................................49 Coolant level, checking ................................................141 Coolant pump...............................................................143 Coolant.................................................................140, 179 Coolant, changing ........................................................142 Cooling system ............................................................140 Delivery instructions .....................................................127 Differential lock ..............................................................76 Dimensions and performance values...........................194 Display unit ....................................................................30 Dumping load ...............................................................100 Dust discharge valve....................................................138 Electrical system ..............................................5, 145, 183 Engine air cleaner ........................................................138 Engine oil filter, replacing .............................................133 Engine oil level, checking.............................................130 Engine oil, changing.....................................................131 Engine ..............................................................5, 130, 181 Equipment ........................................................................7 Evaporator, cleaning ....................................................157 Excavating .....................................................................99
Fire prevention............................................................. 122 Foreword.......................................................................... 1 Frame .............................................................................. 6 Front axle oil, changing................................................ 149 Fuel filters, replacing.................................................... 135 Fuel system ................................................................. 134 Fuel system, draining................................................... 137 Fuel.............................................................................. 178 Fuel, filling.................................................................... 134 Gear shifting .................................................................. 75 Gravel and heap loading................................................ 99 Grease ......................................................................... 178 Greasing ...................................................................... 163 Guidelines for reducing vibration levels on earthmoving machines................................................... 86 Handling hazardous materials ..................................... 124 High tipping bucket (optional equipment) .................... 102 High voltage overhead power line ................................. 88 Hydraulic circuit no. 4 electrically switchable (optional equipment) .................................................... 108 Hydraulic oil filter, replacing......................................... 161 Hydraulic oil level, checking......................................... 159 Hydraulic oil ................................................................. 159 Hydraulic oil, changing................................................. 160 Hydraulic system breather filter, replacing................... 161 Hydraulic system ............................................. 6, 159, 193 Hydrostatic travel system............................................. 188 Identification number ....................................................... 2 Inflating tyres ............................................................... 152 Information and warning decals..................................... 12 Information..................................................................... 32 Instrument panel, front................................................... 18 Instrument panels .......................................................... 17 Intended use .................................................................... 5 Interior lighting ............................................................... 20 Keypad for display unit .................................................. 31 L45F with attachment carrier type V, cast version....... 196 L45F with attachment carrier type V, welded version .. 195 L45F with attachment carrier type Z ............................ 194 L50F with attachment carrier type V, cast version....... 199 L50F with attachment carrier type V, welded version .. 198 L50F with attachment carrier type Z ............................ 197 Levelling....................................................................... 100 Lifting fork operation / Hose rupture protection (optional equipment) ..................................... 55 Lifting frame, lubricating............................................... 165 Lifting machine............................................................... 84 Lifting objects............................................................... 116 Load hook on bucket back (optional equipment) ......... 114 Loading .......................................................................... 96 Lubrication and service chart............................... 127, 166 Machine description......................................................... 9 Machine operator safety ................................................ 69 Machine view ................................................................... 9 Material handling arm .................................................. 112 Measures before operating............................................ 71 Measures when getting stuck ........................................ 80 Modifications of machine ................................................. 7 Multi-purpose bucket (optional equipment).................. 101 On another vehicle......................................................... 83 Operating Information display screen ............................ 30 Operating instructions.................................................... 67 Operating techniques..................................................... 85 Operating with pallet forks ........................................... 110 Operator obligations ...................................................... 68 Operator seat................................................................. 59 Operatorâ&#x20AC;&#x2122;s comfort ......................................................... 59 Other controls ................................................................ 49 Paint finish maintenance.............................................. 128 Pallet forks ................................................................... 109 Parking brake linings, checking ................................... 151 Parking brake, checking of function............................. 151
Alphabetical index
204 Parking ...........................................................................79 Positioning of transporting vehicle ...............................100 Pre-cleaner (optional equipment).................................139 Presentation .....................................................................5 Pressure release ............................................................95 Primary air filter, cleaning and replacing ......................138 Product plates ................................................................11 Radiator, coolers and condenser (if A/C installed), cleaning........................................................................144 Rear axle with transfer box oil, changing .....................150 Rear cab wall .................................................................25 Recommended lubricants ............................................177 Recovering and towing ..................................................81 Relays and fuses in the engine compartment ..............183 Relays and fuses on the circuit board ..........................185 Relays and fuses .........................................................148 Reversible cooling fan (optional equipment) ................144 Road sweeping (optional equipment) ..........................115 Running-in instructions ..................................................67 Safety regulations ............................................................1 Safety rules when operating ..........................................68 Safety when servicing ..................................................119 Scrap bucket (optional equipment) ..............................104 Seat belt .........................................................................61 Secondary air filter, replacing ......................................138 Separate attachment locking .........................................94 Service and maintenance ............................................127 Service brake discs, checking......................................151 Service capacities and change intervals ......................180 Service history .....................................................127, 200 Service points ..............................................................129 Service position............................................................119 Service programme......................................................127 Settings ..........................................................................39 Side tipping bucket (optional equipment) .....................103 Signalling diagram .......................................................117 Special hydraulics at front, electrically switchable "Up/ Down" (optional equipment).........................................107 Special hydraulics ........................................................107 Specifications ...............................................................177 Starting engine in cold weather......................................73 Starting with booster batteries .......................................74 Starting...........................................................................72 Steering cylinder bearings, lubricating .........................164 Steering system ...............................................................6 Stopping .........................................................................78 Symbol key ..................................................................163 Table of contents .............................................................3 Three-phase generator ................................................145 Timber grapples (optional equipment) .........................106 Touching up paint finish ...............................................128 Transmission............................................................5, 188 Transporting load (loading â&#x20AC;&#x201C; carrying) .........................100 Transporting machine ....................................................83 Travelling and operating (working) on a public road ......70 Turbocharger .................................................................72 Tying down machine ......................................................83 Tyre sizes and pressures .............................................190 Tyres ............................................................................152 Underground cables and pipes ......................................89 Universal fork with hydraulic gripper (optional equipment) ....................................................104 USA federal clean air act ...............................................15 Vibration and sound information ..................................192 Warning..........................................................................43 Warranty inspections ...................................................127 Washer reservoir..........................................................154 Water separator, draining ............................................134 Welding ........................................................................146 Wheel nuts, checking tightening ..................................152 Wheel nuts, tightening torque ......................................190 Whole-body vibrations ...................................................86
Windscreen washer system......................................... 154 Windscreen wiper - wiper blades................................. 154 Working hydraulics ...................................................... 193 Working in cold weather ................................................ 91 Working in water ............................................................ 90 Working on slopes ......................................................... 90 Working where there is risk of landslip .......................... 89 Working within dangerous areas ................................... 88
Ref.No. VOE21A1004613 Printed in Sweden Volvo, Eskilstuna
English CST