ProductManual EC250DtoEC480D en IL 30 20026740-A

7/25/2019 ProductManual EC250DtoEC480D en IL 30 20026740-A

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EC250D, EC300D, EC380D, EC480DFOR INTERNAL USE ONLY

VOLVO EXCAVATORS

PRODUCT MANUAL


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3/68

Contents

Contents

Salesmen Walkaround 4

EC250D Specifications 8




Engine 12

New D8 & D13 Volvo engine Stage IIIB/Tier 4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12New Volvo engine with V-ACT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Filter and Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13EGR and ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Air Handling and Turbo Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Micro Mesh (Dust Nets). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Remote hydraulic oil cooler/condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Thermostatically Controlled Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Reversible Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Automatic Idling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Automatic engine shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electrical System 19

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Electrical Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Standard Working Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Additional Halogen Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20MATRIS (Machine Tracking Information System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20CareTrack as standard fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Auto-lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Superstructure 22

Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.5 mm Superstructure Underside HD Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Steps and Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Anti-Slip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Swing gear box and motor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Slew (swing) Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Undercarriage 25

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Gearbox and Track Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Idler Bracket Wear Strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Additional Idler/Motor Bracket Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Top Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Bottom Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Track Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Track Guards (Guides) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3110 mm Undercarriage Underside HD Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Fixed Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Mechanical Variable Width (compared to fixed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Cab 33Care Cab - ROPS certified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Rubber/Silicone oil viscous mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Monitor (I-ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
http://-/?-http://-/?-


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Contents

Control Panel (Key Pad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Consoles/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Work Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Joysticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Pilot control pattern change valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Push Button, Toggle and Proportional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Foot Pedals/Rests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Straight Travel Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Climate Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37AM/FM stereo, CD Player and MP3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Openable Roof Hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Screens/Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Rain Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Sun Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Rear View Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Roll Over Protective Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Cab Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Hydraulic System 43

Overload Warning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Hydraulic Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Digging power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Positive Control hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Negative Control Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Faster cycle time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Response Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Hose Rupture Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Automatic Boom, Arm and Slew Priority System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Boom Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Boom-Down/Arm-in Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Flow Summation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Bucket Conflux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Attachment Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48X1 hammer/shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48X3 rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Travel Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Travel Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Smooth Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50ECO Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Digging unit 51Booms/Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51GP Boom/Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51ME Boom/Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Cylinder Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Pins and Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53HD Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542-Piece Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Arm Wear Strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Quick fits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

General Purpose Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Heavy Duty Rock Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55General Purpose (GPE) teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Abrasive Material Resistant (AMRE) teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Linkage Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56


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Contents

Service and Maintenance 57

Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Stays and Locking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Grouped Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Hydraulic Oil Sight Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Hydraulic Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Volvo Long Life Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Grouped Greasing Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Quick or Ecology Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61


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Digging powerPage 44(056)

Booms/ArmsPage 51(071) (780)

Bucket ConfluxPage 48(470)

LinkagePage 53(079)

Boom FloatPage 46(043)

Boom-Down/Arm-inRegenerationPage 47(042)

Flow SummationPage 47(041)

Arm Wear StripsPage 54(074)

Walkaround : Front

Walkaround : Left

Fixed WidthPage 32(660)

Mechanical Variable Width(compared to fixed)Page 32(670)

4.5 mm SuperstructureUnderside HD PlatesPage 22(054)

Travel ForcePage 49(430)

Travel SpeedPage 49(440)

Smooth TravelPage 50(450)

4 Salesmen Walkaround


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Walkaround : Left

UndercarriagePage 25 (058)

Gearbox and Track MotorsPage 25(059)

IdlersPage 26(060)

Idler Bracket Wear StripsPage 26(061)

SprocketPage 27(062)

Top RollersPage 28(063)

Track ChainsPage 30(065)

Bottom RollersPage 29(064)

Track ShoesPage 31(066)

Track Guards (Guides)Page 31(067)

Walkaround : Serviceability

ServiceabilityPage 57(040)

Grouped Greasing

PointsPage 60(093)

Grouped FiltersPage 58(087)

New D8 & D13 Volvo engineStage IIIB/Tier 4iPage 12(022) (220)

RadiatorsPage 16(034)

ThermostaticallyControlled Cooling

Page 17(036)

Reversible Cooling FanPage 17(037)

Remote hydraulic oil

cooler/condenserPage 16(370)

Swing gear box and motor(s)Page 24

5Salesmen Walkaround


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Walkaround : Cab

Care CabPage 33(001)

Roll Over ProtectiveStructurePage 41(002)

Consoles/SwitchesPage 34(005)

Monitor (I-ECU)Page 34(006)

AttachmentManagement System

Page 48(048)

Rubber/Silicone oilviscous mountsPage 33(004)

CareTrackPage 21(032)

Operator seat adjustmentsPage 33(009)

Automatic engine shutdownPage 18

ECO modePage 50

6 Salesmen Walkaround


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7


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EC250D Specifications8

EC250D Specifications

Engine Volvo D8H

Rated output at 30 r/s (1800 r/min)

ISO 9249/SAE J1349 net 151 kW (202 hp)

Breakout force* (Normal/Boost) 171kN/186kN

Bucket capacity 0.48 - 1.85 m3

Max digging reach* 10.26 m

Max digging depth* 6.98 m

Lifting capacity (along undercarriage) 9,710 kg

at reach / height 6,0 m / 1,5 m

Operating weight 24.6 - 28 t

*with 6.0 m boom / 2.97 m arm


11/68



Engine Volvo D8H


ISO 9249/SAE J1349 net 169 kW (227 hp)

Breakout force* (Normal/Boost) 188kN/205kN

Bucket capacity 0.52 - 2.02 m3

Max digging reach* 10.72 m

Max digging depth* 7.35 m

Lifting capacity along undercarriage 11,070 kg

at reach / height 6.0 m / 1.5 m

Operating weight 30 - 33 t



12/68

EC380D Specifications10


Engine Volvo D13H

Rated output at 28,33 r/s (1700 r/min)

ISO 9249/SAE J1349 net 208kW (283 hp)

Breakout force* (Normal/Boost) 221.7kN/242.7kN

Bucket capacity 1,35 - 3 m3

Max digging reach* 11,07 m

Max digging depth* 7,45 m

Lifting capacity (along undercarriage) 15 430 kg


Operating weight 37,8 t - 40,2 t



13/68



Engine Volvo D13H


ISO 9249/SAE J1349 net 256kW (348 hp)

Breakout force* (Normal/Boost) 260.9kN/284.4kN

Bucket capacity 1,77 - 3,8 m3

Max digging reach* 12,04 m

Max digging depth* 7,72 m

Lifting capacity (along undercarriage) 18080 kg


Operating weight 47,9 t - 50,7 t

*with 7 m boom / 4.8 m arm


14/68

Engine12

Engine

New D8 & D13 Volvo engine Stage IIIB/Tier 4i

New D8 & D13 Volvo engine Stage IIIB/Tier 4i

Volvo Construction Equipment is ready to comply with the tough new EUStage IIIB and US (EPA) Tier 4 interim legislation for off-road vehicles with

the introduction of a cascade of innovations in its new generation engineswith Volvo Advanced combustion technology (V-ACT).

D-Series excavators are equipped with a Volvo designed and manufactured6-cylinder, 8 & 13 liter in-line turbo charged diesel engine with highpressure unit injector system. The engine features a variable gauge turbo,externally cooled exhaust gas re-circulation (E-EGR) and a DieselParticulate Diffuser with active regeneration through a burner.

Customer benefit

Better fuel efficiency.

Higher torque and better engine response.

Proven technology.

No stop in production.

Lower external noise levels.

New Volvo engine withV-ACT

New Volvo engine with V-ACT

Available for EC250D, EC300D

(022)

(200)

(1)


(220)

(200)

(1)

At the heart of Volvos solution is its new generation electronically controlleddiesel engines with Volvo Advanced Combustion Technology (V-ACT).As well as lower emissions, they have enhanced engine monitoring andcontrol, and higher torque - as well as improved performance.

The fuel injection is electronically controlled and uses temperature,pressure, load and engine speed to optimize combustion efficiency.

Precise high injection pressures are obtained through an overheadcamshaft and rocker system. The fuel injectors are positioned in the centerof the cylinders for symmetrical fuel distribution.

Customer benefit

Fuel consumption is kept low, even at low engine speeds when torque ishigh. The smooth, direct throttle response gives optimum operability andmaximum operator satisfaction. Emission levels are low and comply withStage III B/Tier 4i. Engine response is improved at low engine speeds,and noise levels are low.


15/68

Engine 13

Filter and Regeneration

Filter and Regeneration



Diesel Particulate Filter (DPF)

Often called a particulate trap, the Diesel Particulate Filter (DPF) does justthat - traps the Particulate Matter. As more and more material is collected,back pressures increase and the filter must be cleaned. The filter cleansitself by oxidizing the material in a process called regeneration (see below).Therefore, the filter includes a catalyst and burner for regeneration.No conventional exhaust muffler is required. The particulate filter is of theactive type.

Filter regeneration

Any filter has a finite capacity. Diesel particulate filters must be cleaned out,intermittently or continuously to avoid clogging since an overfilled filter candamage the engine through excessive exhaust back pressure and can itselfbe damaged or destroyed. A method to collect the particulate must exist to

clean the filter at least every 4500 hours, mandated by EPA.Filter is designed to burn off the accumulated particulate, either through theuse of a catalyst (passive), or through an active technology, such as a fuelburner which heats the filter to soot combustion temperatures, throughengine modifications (the engine is set to run a certain specific way whenthe filter load reaches a pre-determined level, either to heat the exhaustgases, or to produce high amounts of NOx, which will oxidize theparticulates at relatively low temperatures), or through other methods.This is known as "filter regeneration".Volvo filter is the Fuel Burning Approach (active regeneration), which usesa small burner ahead of oxidation catalyst to increase the exhaust gastemperature sufficient to oxidize the soot.

For Active Regeneration to take place, an external source is needed tocreate enough heat to oxidize (burn) the PM. The target temperature in thisprocess is typically in the range of 550 C (1022 F).The D13H do not use a DOC, whereas the D8H use a fuel burner plus theDOC and DPF to remove the PM from the exhaust. It is important tomention that Volvo combines passive with active regeneration on the D8Hengines. This process is done every 8.0 hours for 25-45min which isdepending on work load, application and model.

Customer benefit

The process of removing exhaust particulate matter is a requirement ofthe Stage IIIB/Tier 4i emission standards. Thanks to Volvo technology,our engines meet this requirement while supplying full power that is

always availablewhile caring for the environment.


16/68

Engine14

EGR and ECU

EGR and ECU

Air Handlingand Turbo Charging

Air Handling and Turbo Charging

Turbo charging results in the capability to deliver the optimum pressure inthe intake and exhaust manifolds.

This makes it possible to tailor the EGR flow back to the inlet manifold andalso have optimum performance and fuel economy. Waste-gated turbo forEC250D/300D and Variable Geometry Turbo (VGT) for EC380D/480Doptions allow specific tuning based on performance requirements.

Customer benefit

Rapid and powerful boost and excellent torque and engine response

across the entire engine speed range.



High-efficiency Cooled External Exhaust Gas Recirculation (E-EGR)

The new units feature exhaust gas recirculation (E-EGR), which lowers theamount of oxygen in the combustion chamber, reducing combustion peaktemperature and in doing so lowering the formation of nitrogen oxides(NOx), a key requirement of the new regulations. Controlled amounts ofexhaust gas are routed through a cooler and routed back into the enginemixing with the fresh air in the cylinder. The process reduces the oxygenconcentration and lowers the combustion temperature.The cooled E-EGR system that will be used consists of the following mainelements:EGR control valve- controls the amount of exhaust gas allowed to returnto the inlet duct of the engine; positioned close to the turbocharger for mostefficient and precise EGR control.EGR cooler- made of stainless steel, in which a coolant cools therecirculated exhaust gas to the required temperature. An EGR flow meter

and a mixing chamber are also included.

Electronic Control Unit, ECU

With such sophistication, the new generation Volvo Engines with V-ACT,the electronic control unit (ECU) plays a fundamental role. The new versionboasts a more powerful processor with the capability to support morefunctions than its predecessor, at higher speeds and with more control.The ECU controls the entire EGR process, managing the mix of recirculatedexhaust gas and fresh air that is so crucial to reducing NOx and PMemissions, while maintaining performance and economy.

Customer benefit

Low emissions levels.




17/68

Engine 15

Air Filters

Air Filters

The location of the air filter elements offer ease of access. Replace outerelement after cleaning 5 times or maximum of 1 year. Never clean aircleaner safety element. Replace it after 3 outer elements or maximum of4000 hours or 2 years.

Customer benefit

Easy maintenance of air filter saves customer's maintenance time andeffort.

Micro Mesh (Dust Nets)

Micro Mesh (Dust Nets)

Micro Mesh in the engine acts as dust nets by preventing the accumulationof dust on the radiator core. This ensures effective engine cooling.

Customer benefit

Dust and debris is prevented from clogging the radiators.



(026)

(256)

(5)



(035)

(256)

(5)


18/68

Engine16

Remotehydraulicoil cooler/condenser

Remote hydraulic oil cooler/condenser

Remote coolers are utilized by the EC380D-EC480D models, thusminimizing the amount of warm air passing from one cooler to another inorder to achieve uniform cooling.

Customer benefit

As a result, excessive heat-build-up is effectively avoided which firstlyreduces the risk of downtime and secondly prevents the need for greatercooling and therefore reduced fuel consumption.

Radiators

Radiators

Air is drawn into the engine compartment and passes through the engineradiator, charge air cooler (CAC), hydraulic oil cooler and condenser as thefan rotates.

Customer benefit

Excellent cooling charicteristics help to ensure more up-time.Their location also facilitates exceptional cleaning/service, which furthercontributes to more up-time.


(370)

(261)

(3)


(034)

(261)

(4)


19/68

Engine 17

Thermostatically Controlled Cooling

Thermostatically Controlled Cooling

The viscous-clutch driven radiator fan (EC250D, EC300D) and hydraulicdriven oil cooler fan (EC380D, EC480D) is thermostatically controlled andtherefore speed of rotation is in relation to cooling needs determined byV-ECU.

Customer benefit

Reduced fuel consumption and noise results in greater operator comfortand reduced total cost of ownership.

Reversible Cooling Fan

Reversible Cooling Fan


(034)

(261)

(3)


(036)

(262)

(3)


(037)

(263)

(3)

Selectable via the monitor, 3 operating modes are available.

Customer benefit

Prevents the clogging of radiators in particularly dusty environments,therefore minimizing the possibility of overheating and extendingcomponent life. In addition, it significantly reduces the need for thereadiators to be cleaned by the service engineer, thus increasing

up-time.


20/68

Engine18

Automatic Idling System

Automatic Idling System

Automatic Idling reduces rpm when the controls have been inactive for apredetermined amount of time, which can be set between 3-20 secondsvia the I-ECU.This system reduces engine speed to idle when levers and pedals are notactivated.

Customer benefit

Resulting in less fuel consumption and low cab noise levels.

Automatic engineshutdown

Automatic engine shutdown

The engine automatically turns off if there's no operating of machine for 5minutes. The automatic engine shutdown time is adjustable throughVCADS-pro.

Customer benefit

Reduces fuel consumption and therefore running costs.



(025)

(271)

(4)




21/68


Electrical System

Batteries

Batteries

All models have a battery cover which protects the batteries, resulting inlong service life.

Customer benefit Longer life.

Good accessibility and maintenance.

Alternator

Alternator

A large capacity 80A alternator is installed as standard.

Customer benefit

The large 80A capacity alternator enables additional electricalequipment such as additional lighting to be installed.

Electrical Box

Electrical Box

All models feature a fully enclosed electrical box which resists the ingressof dirt and water for extended life/reliability.

Customer benefit

The electrical box is sealed to prevent the ingress of dirt and moisture.



(027)

(311)

(5)



(028)

(321)

(4)



(029)

(372)

(5)


22/68

Electrical System20

Standard Working Lights

Standard Working Lights

2 cab, 2 frame and 2 boom lights (1 at each side) are provided as standard.

Customer benefit

Provide good illumination and therefore visibility in order to ensure saferworking.

Additional HalogenWork Lights

Additional Halogen Work Lights

1 cab rear, 1 counterweight and 2 boom lights (1 at each side) are availableas optional equipment.

Customer benefit

Increase visibility should the machine work regularly after dark.

MATRIS(MachineTracking Information System)

MATRIS (Machine Tracking Information System)

Some 32 sets of valuable operational data can be downloaded for analysis,and includes, utilisation; the number of hours in a particular mode; hoursspent tracking; high idle engine shutdown and fuel consumption etc.

An undercarriage Wear Inspection Card can be used to monitorcomponent wear. In addition, it can identify the possible need for furtheroperator training. MATRIS comes with CareTrack Advanced free of charge.

Customer benefit

Customer's can identify correct usage of machine and build fuelconsumption costs into a project and reduce down-time as a result ofpossible operator misuse.



(030)

(350)

(5)



(031)

(350)

(5)



(033)

(390)

(4)


23/68


CareTrack as standardfit

CareTrack as standard fit

Caretrack is the state-of-the-art telematics system desgined for VolvoConstruction Equipment.

Stay informedReceive machine utilization reports and information such as fuel status,machine hours, and machine location.

Plan service more efficiently

Stay ahead of your machine problems and plan the service in advance.

Gain freedom and control

Stay updated without being logged on. CareTrack sends you urgent alarmsand regular reports to your e-mail or mobile phone.

Reduce your downtime

Your Volvo dealer can help you troubleshoot problems without being on site

and minimize the time for service.Improve your productivity

Receive accurate documentary evidence of operators and shiftperformance for comparison and staff training.

Retain and increase your competitive edge

In some markets, competitors are already installing these systems andreceiving the benefits. In other markets there is no major competition, so

you can take the advantage of being a pioneer in that market.

CareTrack may not be available in your market yet.

Caretrack is now standard fit on all GPPE machines.

Auto-lubrication

Auto-lubrication

Available as optional equipment and supplies precisely the correct amountof lubrication to all greasing points (with or without bucket linkage) on acontrol timed basis.

Customer benefit

Ensures that the pins and bushings are always greased with theprecisely the correct amount. No excess so reduced lubrication costs.



(032)

(390)

(4)

Available for EC250D


(094)

(170)

(5)


24/68

Superstructure22

Superstructure

Main Frame

Main Frame

The machines have strong frame made of high tensile steel for long servicelife and low risk of fatigue.

The main frame is required to absorb shocks which are transferred throughthe digging equipment. Therefore, the strength and durability of thisstructure is essential in order to prevent cracking or torsional distortion.Reinforced welding is evident on the connection between the center andside frames (on fixed width models), and the boom and boom cylindermounts for added durability and long life.

Customer benefit

Increased machine availability.

Reduced total cost of owership.

4.5mm Superstructure Underside HD Plates

4.5 mm Superstructure Underside HD Plates

Serve to protect components within the superstructure. Bolt-heads areprotected. Hinged plate.

Customer benefit

4.5 mm plate is fitted as standard on all model. On the EC480D theplates are hinged and as such provide not only excellent underside

protection, but also ensure safety for service personnel. All modelsbenefiting from bolt-head protection in the event of the underside beingscraped.


(052)

(710)

(4)


(710)

(052)

(4)


(054)

(715)

(3)


(715)

(054)

(3)


25/68

Superstructure 23

Steps and Handrails

Steps and Handrails

Footsteps and a handrail on the right side of the machine, thus allowingsafe access to the superstructure.

Customer benefit Safety for both the operator and service crew.

Anti-Slip Plate

Anti-Slip Plate

Punched anti-slip plate provides excellent grip.

Customer benefit

Safety for both the operator and service crew.



(055)

(827)

(5)



(053)

(717)

(5)


26/68

Superstructure24

Swing gear boxand motor(s)

Swing gear box and motor(s)

1 Pinion Gear a single slew motor and 2-stage planetary gearbox; EC480Dhave 2 units.The gearbox converts high speed/low torque output of the motor to lowspeed/high torque output and is used to drive the pinion gear, which rotatesaround the complete circumference of the slew ring, thus rotating thesuperstructure through 360 degrees.The motor contains a spring applied/servo pressure released mechanicaldisc brake which prevents the gearbox output shaft from turning when thecontrol levers are in neutral or when the engine is switched off. During slewoperations, a restricting orifice prevents oil from returning to tank too quicklyvia the slew delay valve which is closed, thus the brakes spring action fromapplying instantaneously to ensure smooth stops and avoid motor damage.An integral return valve allows oil return to tank. When thesuperstructure comes to a stop, pressure is still evident in the motor whichtends to turn the motor in the opposite direction. To prevent this, the anti-

rebound dampening valve connects the in/out ports of the motor to releasepressure to the tank.

Customer benefit

Efficient operation.

Durability.

Slew (swing) Ring

Slew (swing) Ring

All models feature a well proven large diameter slew ring, and as supportfor the superstructure, a single row and sealed ball bearing.

Customer benefit

In conjunction with the slew motor/gearbox, excellent torquecharacteristics are obtained for fast acceleration and ability even whenthe machine is positioned on an incline.



(057)

(971)

(4)


27/68

Undercarriage 25

Undercarriage

Undercarriage

Undercarriage

All models feature a 3-piece undercarriage which is made from high tensilestrength steel and are robotically welded to ensure consistent high quality.

Customer benefit As such, they are built to provide dependable long-term durability in the

toughest conditions.

Gearboxand Track Motors

Gearbox and Track Motors

The travel gearbox utilizes 3-stage planetary reduction gears. The automatic2-speed track motors are protected behind durable covers with recessedbolts.

Customer benefit

The durable gearboxes provide longevity even in the toughest

applications. The 2-speed motors result in fast across site travel, whilethe covers prevent damage and can more easily be removed due to therecessed bolts.


(058)

(770)

(3)


(770)

(058)

(3)

1 Gearbox - 2 Track Motor


(059)

(431)

(3)


(059)

(431)

(3)


28/68

Undercarriage26

Idlers

Idlers

The idlers are reinforced with increased metal thickness and superior metalspecifications when compared to previous models.

Customer benefit All models feature hardened, large radius idlers made from chromium

and molybdenum alloyed steel for long-term durability.

Idler Bracket Wear Strips

Idler Bracket Wear Strips

Wear Stripes on Idler bracket ensure consistent high quality.

Customer benefit

Provides protection to the idler bracket and Increases durability.


(060)

(775)

(3)


(775)

(060)

(3)


(061)

(775)

(3)


(061)

(775)

(3)


29/68

Undercarriage 27

Additional Idler/Motor Bracket Welding

Additional Idler/Motor Bracket Welding

Additional welding at the idler and motor bracket ends.

Customer benefit

Extended component life when working in harsh and demandingapplications.

Sprocket

Sprocket

Sprocket design boasts high quality manufacture, heat treatment andmaterial hardness.

Customer benefit

Durability in all application types.

D-Series tooth thickness has been increased.


(650)

(775)

(3)


(062)

(775)

(3)


(062)

(775)

(3)


30/68

Undercarriage28

Top Rollers

Top Rollers

Top rollers are made from forged steel.

Customer benefit

In contrast to cast iron types, excellent long-term durability is assured.


(063)

(775)

(3)


(063)

(775)

(3)


31/68

Undercarriage 29

Bottom Rollers

Bottom Rollers

Since production of the late C-Series, the roller shell bore hardness hasbeen increased, while excellent welding consistency is assured. Bi-metalicbushes (bushings) provide high strength, good load bearing capability andresistance to wear. EP (extreme pressure) oil is used to lubricate andensures high and consistent viscosity even under heavy loads.

Customer benefit

As a result, excellent long-term durability is proven.


(064)

(775)

(3)


(064)

(775)

(3)


32/68

Undercarriage30

Track Chains

Track Chains

Each track pin and bush (bushing) is sealed for life and feature EP2 grease,which offers excellent lubrication qualities for extended life.

Customer benefit As a result, internal friction is reduced and the links prove durable even

when subjected to high loads (travel), shock loads (the transfer of stresscaused by difficult digging in rock for example) and wet and temperatureextremes. Furthermore, travel resistance and travel noise is also reduced.

In addition, an M-type seal (polyurethane) serves to ensure that greaseremains inside the pin and bush (bushing) joint, while preventing theingress of dirt/abrasive materials.Available for EC250D, EC300D

(065)

(775)

(3)


(065)

(775)

(3)


33/68

Undercarriage 31

Track Shoes

Track Shoes

EC models have featured an improved heat treatment process in order tominimize the risk of bending. Various widths are of course available.Narrow shoes should be specified for rock extraction in order to minimizethe possibility of bending, whilst wider shoes ensure greater flotation andare therefore appropriate for softer underfoot conditions.

Customer benefit

Excellent heat treatment process serves to prevent shoe bending.

Track Guards(Guides)

Track Guards (Guides)

Four bolt on track guides are provided as standard to protect againstderailment. Full length bolt on track guides are available as optionalequipment and provide greater bottom roller protection from debris andreduce further the possibility of derailment. They should be specified if themachine is to undertake hard rock quarry work for example.

Customer benefit

Excellent long-term durability is assured.

10mm UndercarriageUnderside HDPlates

10 mm Undercarriage Underside HD Plates


(066)

(775)

(3)


(066)(775)

(3)


(067)

(775)

(3)


(775)

(067)

(3)

Available for EC250D, EC300D, EC380D, EC480D

(070)

(715)

(3)

Heavy duty plate with bolt head protection.

Customer benefit

10 mm undercarriage underside HD plates with bolt-head protection areprovided to prevent centre passage or hose damage in harsh operatingconditions.


34/68

Undercarriage32

Fixed Width

Fixed Width

Enables simpler machine transportation in markets that are subject to strictwidth regulations.

Customer benefit Machine can be transported with minimal movement notice given.

MechanicalVariableWidth (compared tofixed)

Mechanical Variable Width (compared to fixed)

Provides an additional 150 mm in width and 196 mm of ground clearance.

Customer benefit

Better stability with equal sized bucket. Larger buckets. Underside isbetter protected from debris. Retracted position aides transportation.


(660)

(775)

(3)

Available for EC480D

(670)

(775)

(2)


35/68


36/68

Cab34

Monitor (I-ECU)

Monitor (I-ECU)

Colour Monitor (I-ECU) which by use of a remote key pad, enables theoperator to safely navigate through the various menus. A Service Mode isalso incorporated and allows the service engineer to perform diagnosticchecks. In addition, the screen also permits the rear view camera image tobe displayed.

Customer benefit

Opertor convienience. More uptime. Operator and bystander safety.

Control Panel (KeyPad)

Control Panel (Key Pad)

Navigating through the monitor (I-ECU) is via a control panel (key pad)located on the right side console and within easy reach. Therefore, theoperator does not have to reach forward in order to change settings via themonitor itself as with competitive excavators, thus reducing fatigue and thepossible risk of inadvertently striking a joystick.

Customer benefit

Operator comfort and superior operating safety.

Consoles/Switches

Consoles/Switches

Consoles and the switches located on them exhibit a real quality feel.They are very well located and therefore provide excellent ergonomics.

Customer benefit

Quality and durable components. Appropriate switch positioningensures exceptional operator comfort.



(006)

(880)

(2)



(007)

(880)

(4)



(005)

(880)

(3)


37/68

Cab 35

Work Modes

Work Modes

I-Mode:Low idle, warm-up, and extremely precise operation such asloading machine on trailer when tracks and/or trailer are wet.F-Mode:Precision and maximum lifting power, and very precise grading.G-Mode:General purpose and maximum fuel savings.G1 (high):For light digging and trenching, truck loading from soft pile, andother applications.G2 (Middle) & G3 (low):For ditching, leveling, slope finishing, spreading,and other general applications where moderate speed is needed.H (heavy):High productivity for intensive bulk earth moving.P (Power Max):Provides additional 100 rpm for absolute maximumperformance on very hard digging, trenching, and truck loading from verydeep trenches.

Customer benefit

The I, F, G, H and P (P except NA) enable the operator to select the most

appropriate mode for the task at hand, thus ensuring optimumperformance and fuel efficiency.

Joysticks

Joysticks

Wrist control joysticks provide effortless control of the machine and can beequipped with push button, toggle and proportional switches.

Customer benefit

Short wrist control joysticks require minimal movement to ensurereduced operator fatigue.

Pilotcontrol patternchange valve

Pilot control pattern change valve

Pilot control pattern change valve is available (except Europe) and permitsfor example, conversion from ISO/SAE joystick control (standard) toBackhoe control.

Customer benefit

Ensures a quick change in pattern according to operator preference.


(008)

(880)

(3)


(008)

(880)

(4)



(010)

(880)

(5)



(051)

(880)

(5)


38/68

Cab36

PushButton,Toggle and Proportional Control

Push Button, Toggle and Proportional Control

3 options for Hammer/shear control switches that can be selected onI-ECU.As examples, push button control for hammers and toggle control tooperate drum cutters or vibrating plates. Proportional control via a slidingswitch permits extremely precise control of attachments including rotatinggrabs and tilt and rotating attachments.

Customer benefit

The result is a machine that is configured to the customer's preference.

Foot Pedals/Rests

Foot Pedals/Rests

Pedals are well-spaced, while large foot rests provide optimum comfort.

Customer benefit

Widely spaced and well postioned foot pedals are complemented bylarge foot rests for excellent comfort.

Straight Travel Pedal

Straight Travel Pedal

When the straight travel pedal is depressed, the straight travel valveconnects both pumps, resulting in each track motor receiving precisely thesame amount of oil flow for straight travel.

Customer benefit

Each track motor receives precisely the same amount of oil flow so theresult is straight travel. As a result, greater comfort during long traveldistances or when trenching is evident.

Rather than pushing right and left travel pedal at the same time theoperator can use the single straight travel pedal. It is useful for trenchingwork. This pedal can be locked and used as foot rest.



(047)

(880)

(4)



(011)

(880)

(5)



(069)

(880)

(5)


39/68

Cab 37

Climate Control System

Climate Control System

One of the most powerful climate control and defrosting system availablewith 14 vents.

Customer benefit Ensures that the operator is comfortable whatever the weather.

Cab Filter

Cab Filter

The location of the filter is directly behind the rear window on thesuperstructure.

Customer benefit

Therefore when removed dust does not fall on to the cab floor.

AM/FMstereo,CDPlayer and MP3

AM/FM stereo, CD Player and MP3

Adjustment is via a remote key pad which is located to the operator's lefthand on the console.

Customer benefit

Superior operator comfort.



(012)

(870)

(4)



(017)

(872)

(5)



(013)

(881)

(5)


40/68

Cab38

Visibility

Visibility

Slim cab pillars and large expanses of glass result in excellent all-roundvisibility. well positioned and longer wind screen wipers provides mostcoverage of front windows.

Customer benefit

Safety for both operator and bystanders, whilst a better view of theworking area ensures faster cycle times.

Openable Roof Hatch

Openable Roof Hatch

The openable roof hatch affords the operator a better view when working atheight.

Customer benefit

Offers the operator a better view when working at height.



(003)

(843)

(4)



(018)

(836)

(5)


41/68

Cab 39

Screens/Windows

Screens/Windows

The front screen (window) effortlessly slides above the operators head; thelower screen can be removed and placed inside the cab door; left sidewindow slides open to enable communication with bystanders.

Customer benefit

Operator convenience.

RainShield

Rain Shield

Rain shield serves to prevent rain water from dripping from the cab roof andon to the front screen.

Customer benefit

Results in superior visibility.



(015)

(843)

(5)


Available for EC380D, EC480D(019)

(843)

(5)


42/68

Cab40

SunShields

Sun Shields

Front, Top and Rear sunshield (sunblind's) protect the operator from thesun's glare.

Customer benefit Provide greater operator comfort and safety to the operator and therefore

bystanders.

Wipers

Wipers

The wiper provides excellent coverage and more so than any competitor.In addition, it sweeps water off to the side rather than down. An intermittantfunction is also provided and a lower wiper is available as an option.

Customer benefit

Provides excellent coverage in order to maintain excellent visibility.

Rear ViewCamera

Rear View Camera

The rear view camera provides excellent clarity via the monitor. As a result,the need for the operator to look through the rear screen and via mirrors isreduced.

Customer benefit

Enables the operator to observe what is behind him before operating themachine for increased safety.



(843)

(5)



(014)

(843)

(5)



(020)

(841)

(4)


43/68


44/68

Cab42

CabProtection

Cab Protection

Screen net, FOPS and cab or frame mounted FOG are available accordingto application requirements.

The cab mounted FOG (Falling Object Guard) is recommended for theprotection of theoperator, where there is a risk for falling objects from above or front, e.g. inquarries and demolition. The cab mounted FOG is approved according toISO 10262 and consists of FOPS and the front guard. The front guard istiltable and supported by a gas strut for easy access to the front window.This installation does not require welding on the superstructure.The new frame mounted FOG (factor fit only) is available for betterprotection of cabin and approved according to ISO 10262.

A cab mounted FOPS, (Falling Object Protection Structure), isrecommended for the protection of the operator, where there is a risk offalling objects, e.g. in demolishing or forest works. The FOPS is approved

according to ISO 3449 and is easy to install.The protection structure is bolted to the cab top. All mounting holes arealready installed in the cab.

Customer benefit

Ensure safety when working in applications that offer a greater risk of thecab being struck by flying or falling objetcs.



(021)

(860)

(5)


45/68

Hydraulic System 43

Hydraulic System

OverloadWarning Device

Overload Warning Device

The overload warning button is located on the Control Panel (Key Pad) andshould be selected before lifting operations commence. Should the

pressure switch sense system overload, then a pop-up message will bedisplayed with an audible warning.

Customer benefit

Safety for the operator and by-standers.

MainPump

Main Pump

Two well proven variable displacement working pumps are installed on allmodels to ensure long-term performance and reliability. The clutter freepump compartment ensures that pump access is unimpeded to facilitateexcellent service.

Customer benefit

Proven reliability and performance.

Hydraulic Piping

Hydraulic Piping

In order to provide protection, hoses are aligned along the top of the boominstead of along the side, therefore minimizing the risk of damage duringdeep trenching. Hoses can withstand temperatures down to -40 ' C/F.

Customer benefit

More up-time.



(049)

(860)

(5)


(038)

(910)

(4)



(050)

(910)

(5)


46/68

Hydraulic System44

Digging power

Digging power

Excellent ability to extract hard or/and compacted materials.

Customer benefit

Quicker cycle times in hard materials results in greater productivity.

Positive Controlhydraulics

Positive Control hydraulics

POSITIVE: Higher servo pressure results in higher pump flow.

The EC250D-EC300D models incorporate a positive hydraulic system.2 in-line variable displacement pumps and an open-centre system are stillevident, but in contrast, as servo pressure increases so to does pumpoutput. Joystick movement sends an input signal to the V-ECU, via a servopressure sensor. Pump pressure (pump internal signal) and the modesetting are still determined by the V-ECU as with negative systems.

However, regulator control (pump control) is totally electronic, wherebyPWM (Pulse Width Modulation) valves input a current value (electricalsignal), adjusting swash plate angle and ultimately pump output. The resultis faster pump response than with negative control systems. In addition,when the joysticks are in neutral, standby pressure is lower and as such sois fuel consumption.

Customer benefit

Results in faster reaction times of the digging equipment, slew (swing)and travel, thus, increased productivity.

Lower fuel consumption.


(056)

(910)

(1)


(056)

(910)

(1)


(039)

(910)

(1)


47/68

Hydraulic System 45

Negative ControlHydraulic System

Negative Control Hydraulic System

- NEGATIVE: Higher pilot pressure results in lower pump flow.The EC380D-480D employ 2 in-line variable displacement pumps.The system is an open-centre, negative control type, whereby the flowsensing valve monitors return hydraulic flow in the negative line and via the

joystick, MCV and pump pressure (internal signal) signal, and control viathe V-ECU, proportional valve and pump regulator, adjusts flow accordinglyto match pump and engine output so as to prevent overload.For example, if a joystick is pulled to the maximum position, this wouldcorrespond as increased flow required. Pressure in the negative line wouldthen fall and reduced pilot pressure would be evident. As a result, the VECUwould send the relevant mode setting signal (current value) to theproportional valve, which in turn would convert into a servo pressure signaland send to the pump regulator, thus swash plate angle is altered andincreased flow is delivered.

Customer benefit

This system offers proven reliability and performance.

Faster cycletime

Faster cycle time

- EC480D: Bucket-in speed increased 12%. Bucket-dump speedincreased 7%.- EC300D: Bucket-in speed increased 24%. Swing speed increased 5%.- EC250D: Bucket-in speed increased 8%. Swing speed increased 3%.

Customer benefit

Quicker cycle times result in greater productivity.

Response Mode

Response Mode

Active, Normal and Soft Modes can be selected and increase or decreasethe responsiveness of the digging equipment and the X1 functions ifspecified with proportional control.

Customer benefit

Permits the operator to increase or decrease the digging or X1 responsevia the monitor, according to application needs or own preference.


(039)

(910)

(4)

Available for EC250D, EC300D, EC480D

(420)

(910)

(1)


(044)

(914)

(2)


48/68

Hydraulic System46

HoseRuptureValves

Hose Rupture Valves

Boom and arm hose rupture valves (HRV) prevent the boom or arm fromcollapsing in the event of hose failure. Boom are standard but the inclusionof arm line rupture valves is depenent upon the specific market MRS.

Customer benefit

Prevent the boom and arm from dropping in the event of hydraulic failure.

Safety for both operator and by-stander.

Automatic Boom, Arm and SlewPrioritySystem

Automatic Boom, Arm and Slew Priority System

The system automatically prioritizes oil flow to the boom, arm or slewfunction according to requirements.- Boom priority: Gives priority to the boom operation for faster raising whenloading or performing deep excavations.- Arm priority: Gives priority to the arm operation for faster cycle times inleveling and for increased bucket filling when digging.- Swing priority: Gives priority to swing functions for faster simultaneousoperations.

Customer benefit

The result is faster cycle times.

Boom Float

Boom Float

The system automatically prioritizes oil flow to the boom, arm or slewfunction according to requirements.

Customer benefit

This feature is useful for better controllability in grading/finishingoperation and grab working.



(078)

(912)

(5)



(914)



(043)

(916)

(2)


49/68

Hydraulic System 47

Boom-Down/Arm-in Regeneration

Boom-Down/Arm-in Regeneration

The boom-down arm-in regeneration system provides flow to otherfunctions during simultaneous operations. For example, the system allowsoil from the boom cylinder piston side to the boom cylinder rod side insteadof returning to tank, thereby reducing the need for pump flow to thisservice.

Customer benefit

The result is greater efficiency and faster cycle times while reducing thepossibility of cavitation.

Flow Summation

Flow Summation


(042)

(916)

(2)


(042)

(916)

(2)


(041)

(916)

(3)


(041)

(916)

(2)

Provides oil from both working pumps when only a single function is used.

Customer benefit

Provides 2-pump flow to the boom, arm or X1(optional) when only asingle function is activated for increased speed and reduced cycle times.


50/68

Hydraulic System48

Bucket Conflux

Bucket Conflux

- 2-pump flow to bucket-in: EC380D, EC480D.- 2-pump flow to bucket-dump: EC480D.

Customer benefit Increased speed and reduced cycle times.

Attachment Management System

Attachment Management System

Depending on specification, the operator can chose Hydraulics to accessan existing hammer or shear (X1) setting (up to 18 stored pre-sets), 1 or2-way, push button, toggle or proportional. Alternatively, Setup to changeflow and pressure. X3 can be accessed via Setup and either push button,toggle or proportional if equipped.To prevent possible misuse and attachment damage, the system offers apassword selection function, whereby only approved personal can makechanges to the attachment parameter settings. With the passwordprotection system activated, the operator can only select the attachmentfrom the hydraulic menu.

Customer benefit

Manual set-up is not required, therefore the system provides not onlyease and convenience to the operator, but also more up-time, particularlyif hydraulic attachments are changed regularly.

X1 hammer/shear

X1 hammer/shear

The "optional" X1 hammer/shear function utilizes main system hydraulic

flow to operate attachments that require 1 or 2-way flow (unidirectional orbidirectional flow).

Customer benefit

This additional hydraulic service enables attachments such as hydraulicbreakers (hammers) to operated, thus increasing machine versatility.


(470)

(916)

(2)


(048)

(920)

(2)


(920)

(048)

(2)



(045)

(920)

(4)


51/68

Hydraulic System 49

X3rotation

X3 rotation

The "optional" X3 tilt/rotation function requires a separate 60 lpm gearpump to provide hydraulic flow to attachments that are required to rotate.

Customer benefit This additional hydraulic service enables attachments such as rotating

grabs to be operated, thus increasing machine versatility.

Travel Force

Travel Force

Travel force is increased.- EC380D: 3%- EC300D: 7%- EC250D: 4%

Customer benefit

Results in an excellent ability to climb gradients and where travelling overdifficult ground is required such as quarry applications.

Travel Speed

Travel Speed

Travel speed is improved.- EC380D: 8%- EC300D: 4%

Customer benefit

Reduction in travel time results in more time using the attachment andthus greater productivity.



(046)

(920)

(4)


(430)

(910)

(2)


(440)

(910)

(3)


52/68

Hydraulic System50

Smooth Travel

Smooth Travel

When the travel pedal is depressed, machine movement is controlledprogressively.

Customer benefit The result is excellent operator comfort and increased safety when

precise travel control is required - particularly when travelling while lifting.

ECOMode

ECO Mode

ECO mode is new feature that works in G to P Mode. Pump flow iscontrolled for combined digging and swinging operations to reduce theflow loss through the overload relief valves while maintaining digging powerand maximum swing torque.

- Added in addition to normal mode for better fuel efficiency.- ON/OFF switch on Keypad.

Customer benefit

Customer can select both normal and ECO mode according to workingcondition and preference.

By activating ECO mode, customers can get better fuel efficiency withminimum loss of performance for most operating conditions.


(450)

(910)

(2)



53/68

Digging unit 51

Digging unit

Booms/Arms

Booms/Arms

Built from high strength tensile steel. Double welds, castings, bulk-heads(internal stiffners) and forged bearings are evident in key areas.

Booms feature large cross sections.Customer benefit

Consistent, long term durability is assured even in the most severeapplications.

GPBoom/Arm

GP Boom/Arm

All models are available with general purpose mono booms. GP boomsand arms ensure a wide working envelope.

Customer benefit

As a result, they offer excellent versatility and are able to undertake a widevariety of applications. In addition, trucks and hoppers are not required

to be as close to the excavator as with ME configurations, therefore lessrepositioning of the excavator is required.


(780)

(970)

(3)


(071)

(2)

(970)


(790)(970)

(4)


54/68

Digging unit52

ME Boom/Arm

ME Boom/Arm

ME booms enable larger capacity buckets to be specified because thesuspended load is closer to the centre line of the machine, therefore higherproductivity is obtained making this the most beneficial configuration duringintensive truck loading applications. Furthermore, ME booms arestructurally stronger than GP and should therefore be selected to work inreally tough applications such as extracting poorly blasted rock.The 2.9 m ME arm utilizes a larger diameter bucket cylinder than the 2.9 mshort, thus greater breakout force is provided.

Customer benefit

Higher productivity. Higher durability.

Cylinders

Cylinders

Large bore, long stroke cylinders feature excellent welding quality for longlife dependability. Boom, arm and bucket cylinders incorporate a cushionring (at the piston end) and arm cylinder has a cushion plunger at the rodend, that serve to reduce shock loads through the machine, thus extendingcomponent life and increasing operator comfort. Effective seals preventseal leakage.These cylinders can be field serviced due to a special design whicheliminates the use of special tooling.

Customer benefit

Large diameter cylinders contribute to high digging forces and liftingcapability.

Excellent welding provides long term durability.

The cushion ring reduces shocks and extends component life andincreases operator comfort.

More uptime! Increased productivity!

Cylinder Mounts

Cylinder Mounts

Quality boom cylinder mounts are heavily constructed for robustness andreinforced to ensure longevity.

Customer benefit Excellent long-term durability.


(800)

(970)

(4)



(075)

(970)

(4)



(076)

(970)

(4)


55/68

Digging unit 53

Pins and Bushes

Pins and Bushes

Quality chrome pins and bushes are used throughout. Optional long-lifebushes extend boom and arm (only) greasing intervals to 500hours. However, if the machine is employed on continuing hammer work forexample, daily greasing is recommended.Boom cylinder and boom foot bushes utilize a copper base which absorbsshocks whilst the graphite spot provides consistent long-life lubrication.

Customer benefit

Durability. More uptime.

Linkage

Linkage

Yoke reinforcement incorporates a support bar which provides additionalstrength.

Customer benefit

Consistent, long term durability is assured even in the most severeapplications.



(077)

(970)

(5)


(079)

(974)

(3)


(079)

(974)

(3)


56/68

Digging unit54

HDBoom

HD Boom

HD booms are heavily reinforced.

Customer benefit

Able to withstand working in high impact materials such as blasted rock.

2-Piece Boom

2-Piece Boom

Due to the reduced front slewing radius, the machine can be operatedwithin a more confined area.Furthermore, the bucket can be worked closer to the undercarriage, whilemaximum dumping and cutting height is also invariably greater.

Customer benefit

Can work in more confined areas.

Versatility.

Greater performance.

Arm Wear Strips

Arm Wear Strips

Four long strips are welded to the inside of the arm.

Customer benefit

Protect the arm from damage when working with hard impact materialsfor long term durability.


(072)

(974)

(2)


(073)

(974)

(4)


(074)

(975)

(3)


(074)

(975)

(3)


57/68

Digging unit 55

Quick fits

Quick fits

Volvo's unique quick fits: SQF (only compatable with Volvo dedicatedattachments designed for that particular machine).

Universal quick fits: UQF (allows the quick fit to hook on to varying pincentres and pin diameters within a limited range) series quick fits arehydraulically activated and serve to increase excavator versatility.

The exchange of buckets can be conducted in a very short amount of timewithout the need to leave the cab.

Customer benefit

SQF: Retains high digging forces. Reduced weight increases liftingcapability.

UQF: Customer may be able to use existing attachments used oncompetitive machines.

More productivity.

General PurposeBucket

General Purpose Bucket

General Purpose (GP) buckets are predominately designed to work in lowimpact/low abrasive materials such as soils and clays. Weld-on adaptorsand teeth are fitted as standard.

Customer benefit

Suited to low impact/abrasive materials such as soils/clays.

Heavy Duty Rock Bucket

Heavy Duty Rock Bucket

Heavy Duty (HD) buckets are heavier than GP buckets, with increasedmetal thicknesses in all ground engaging areas for increased durability.They are suitable to work in soil mixed with rock, however, they should not

be used in extremely tough conditions, i.e. to extract poorly blastedand more importantly very abrasive materials such as granite orbasalt. Weld on adaptors and teeth are fitted as standard.

Customer benefit

Suited to mixed soil/rock and well blasted rock. Should not work inpoorly blasted rock or very abrasive materials.



(085)

(924)

(5)



(081)

(925)

(5)



(082)

(925)

(5)


58/68

Digging unit56

General Purpose (GPE) teeth

General Purpose (GPE) teeth

General Purpose (GPE) teeth can be specified if the excavator is toundertake numerous general purpose tasks, i.e. truck loading, trenchingand site clearance in lower impact/abrasive materials such as soils andclays and soil/rock mixed material.

Customer benefit

Suited to low impact/abrasive materials such as soils/clays.

AbrasiveMaterial Resistant (AMRE) teeth

Abrasive Material Resistant (AMRE) teeth

Abrasive Material Resistant (AMRE) teeth are self sharpening and featuremore wear material and a much thicker rib. They are suited to high impactand/or wearing materials such as granite, basalt, limestone and sandstone.

Customer benefit

Suited to all blasted and abrasive rock types.

LinkageHook

Linkage Hook

The linkage hook offers greater strength than when mounted on the bucketor quick fit and is available as optional equipment.

Customer benefit

The linkage hook offers greater strength than when mounted on thebucket or quick fit.



(083)

(925)

(5)



(084)

(925)

(5)



(080)

(926)

(5)


59/68


Serviceand Maintenance

Serviceability

Serviceability

Large opening compartment doors, grouped close to ground level.Accessible filter locations and radiators.

Customer benefit Reduced service time. Ground level filters significantly reduce the need

for the service engineer to work from the superstructure at height, thusincreasing safety.

Service Access

Service Access

All models feature large opening compartment doors to ensure excellentaccessibility to components.

Customer benefit

Excellent access for quick servicing.


(040)

(100)

(1)


(100)

(1)



(088)

(100)

(4)


60/68

Service and Maintenance58

StaysandLocking Devices

Stays and Locking Devices

Locks can easily be adjusted, thus doors can be held closed whichpreserves a quality "fit and finish". Volvos automatic stays mean that thedoors do not have to be manually fixed open.

Customer benefit

Properaly closing doors are beneficial to machineappearance. Automatic locks are not only convienient but also ensuresafety by preventing doors being blown closed.

GroupedFilters

Grouped Filters

Filters are grouped and accessible at ground level wherever possible.

Customer benefit

Faster servicing.



(096)

(83)

(5)


(087)

(170)

(3)


(087)

(170)

(3)


61/68


Hydraulic Oil Sight Gauge

Hydraulic Oil Sight Gauge

Hydraulic oil sight gauge is located on the tank for ground level inspection.

Customer benefit

Enables the operator to physically check for piece of mind. Simple andconvienient.

Hydraulic Oil

Hydraulic Oil

Hydraulic oil replacement interval is every 2,000 hours. Long Life oil offersup to 5,000 hour replacement intervals.

Customer benefit

Reduced operating costs and more up-time.

Hydraulic ReturnFilter

Hydraulic Return Filter

The hydraulic oil return filter needs replacing only every 2000 hours.

Customer benefit

Reduced operating costs and more up-time.



(089)

(170)

(5)



(090)

(170)

(4)



(091)

(170)

(4)


62/68

Service and Maintenance60

Volvo Long LifeCoolant

Volvo Long Life Coolant

Long life coolant provides system protection for up to 6000 hours.

Customer benefit

Ensure reduced operating costs and more up-time.

GroupedGreasing Points

Grouped Greasing Points

All models feature both boom and arm grouped greasing points forsimplicity. Intervals are at 50 hours, however, "Long Life" bushes(bushings) are available which extend intervals to 500 hours. Slew ringgreasing is at 250 hours.

Customer benefit

Simple to locate and access.



(092)

(170)

(4)



(093)

(170)

(4)


63/68


Quick or EcologyDrains

Quick or Ecology Drains

All machines are provided with simple quick drains on the underside of thesuperstructure with which to quickly and cleanly drain lubricants.

Customer benefit Quick and simple way to drain lubricants that is better for the

environment.



(095)

(170)

(5)


64/68

Index alpha

Index alpha

Numerics10 mm Undercarriage Underside HD Plates . . . . . . . . . . . . . . . . . . . . . . . .312-Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .544.5 mm Superstructure Underside HD Plates . . . . . . . . . . . . . . . . . . . . . . .22A

Abrasive Material Resistant (AMRE) teeth . . . . . . . . . . . . . . . . . . . . . . . . . 56

Additional Halogen Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Additional Idler/Motor Bracket Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Air Handling and Turbo Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19AM/FM stereo, CD Player and MP3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Anti-Slip Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Arm Wear Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Attachment Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Auto-lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Automatic Boom, Arm and Slew Priority System . . . . . . . . . . . . . . . . . . . . 46Automatic engine shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Automatic Idling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18BBatteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Boom Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Boom-Down/Arm-in Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Booms/Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Bottom Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Bucket Conflux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48CCab Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Cab Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Care Cab - ROPS certified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33CareTrack as standard fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Climate Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Consoles/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Control Panel (Key

ProductManual EC250DtoEC480D en IL 30 20026740-A

Documents