Volvo G960 G970 G976 Operator Manual

OPERATOR'S MANUAL

G930/G940/G946/G960/G970/G976/G990 Ser. No. G930 SHP 526003-, PED 502838-, G940 PED 503597G946 PED 504115-, G960 PED 505155G970 SHP 530031-, PED 506053G976 SHP 531020-, PED 507053G990 SHP 532006-, PED 508110-

Original Instructions

G930/G940/G946/G960/G970/G976/G990 Foreword

OPERATOR'S MANUAL

This operator's manual is intended as a guide for the correct use and maintenance of the machine. Read this manual carefully before you start and move the machine or before you carry out any preventive maintenance.

Keep this manual in the lockable storage compartment so that it is always available for easy reference. Replace it immediately if it is lost.

The operator's manual describes the applications for which the machine was primarily designed. It has been written to be valid on all markets.

Therefore, please ignore any sections which do not relate to your machine or to the work that you do with your machine.

NOTE! If the manual covers more than one machine, the information relates to all machines unless otherwise specified.

When designing this machine, much time has been invested in achieving the best possible efficiency and safety. But accidents do happen, and most of them can be attributed to human error. A safety-conscious person and a well-maintained machine make up a reliable, powerful, and profitable combination. Therefore, read the safety instructions and follow them.

We constantly strive to develop and improve the efficiency of our products by making changes to their design. We reserve the right to make design modifications to the products even after they have been delivered. Also, we reserve the right to change data and equipment, as well as the service and maintenance instructions, without prior notice.

Table of contents

Presentation

Instrument panels

Other controls

Operating instructions

Operating techniques

Safety when servicing

Service and maintenance

Specifications

Alphabetical index

Ref. No. 20036078-B The original language is English. Original instructions.

2013.05 Copyright © 2013, Volvo Construction Equipment. All rights reserved.

Foreword

2 Safety regulations The machine operator is responsible for being aware of and complying with the relevant, legally prescribed, national and regional safety instructions. The safety instructions in this operator's manual are applicable only in cases where no legislated safety instructions are in force.

DANGER The safety symbol combined with this signal word indicates a hazardous situation which, if not avoided, will result in death or serious injury. Danger is limited to the most extreme situations.

WARNING The safety symbol combined with this signal word indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION The safety symbol combined with this signal word indicates a hazardous situation which, if not avoided, could result in moderate or minor injury.

NOTICE Indicates a potentially hazardous situation which may result in machine damage.

NOTE! Used in order to refer to installation, operating, or maintenance information which is important but not danger-related.

Get to know the capacity and limits of your machine!

Foreword

Identification numbers

Identification numbers Enter the product identification number (PIN) of machine, manufacturer code and engine serial number. These numbers must be specified when contacting the manufacturer to order spare parts. For positions and explanation of the PIN plate, see page 22.

Manufacturer

Volvo Construction Equipment 312 Volvo Way Shippensburg, Pennsylvania 17257 USA

PIN of machine Manufacturer code Engine serial number

Please send comments about the Operator’s Manual to om@volvo.com

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Table of contents

5

Table of contents Foreword ................................................................. 1 Identification numbers ......................................................... 3

Presentation ............................................................ 7 Machine view ..................................................................... 17 CE-marking, EMC-directive ............................................... 19 Communication equipment, installation ............................. 21 Product plates ................................................................... 22 Information and warning decals ........................................ 24 USA federal clean air act ................................................... 30

Instrument panels .................................................. 33 Instrument panel, centre .................................................... 34 Display unit ........................................................................ 40 Instrument panel, pedestal ................................................ 65 Instrument panel, side ....................................................... 73 Instrument panel, rear ....................................................... 79

Other controls ........................................................ 82 Controls ............................................................................. 82 Operator comfort ............................................................. 103 Climate control system .................................................... 118

Operating instructions .......................................... 121 Safety rules when operating ............................................ 122 Measures before operating ............................................. 137 Starting engine ................................................................ 138 Gear shifting .................................................................... 141 Differential locks .............................................................. 163 Steering ........................................................................... 164 Braking ............................................................................ 168 Stopping .......................................................................... 171 Parking ............................................................................ 172 Retrieving and towing ...................................................... 174 Transporting machine ...................................................... 177

Operating techniques .......................................... 180 Whole-body vibrations ..................................................... 201 Working within dangerous areas ..................................... 202 Attachments .................................................................... 207 Attachments, connecting and disconnecting ................... 208 Attachments, installing .................................................... 209 Dozer blade ..................................................................... 224 Scarifier ........................................................................... 225 Ripper .............................................................................. 228 Signalling diagram ........................................................... 230

Safety when servicing .......................................... 232 Service position ............................................................... 232 Before service, read ........................................................ 233 Fire prevention ................................................................ 237 Handling hazardous materials ......................................... 241

Table of contents

6 Service and maintenance .................................... 244 General inspection of machine ........................................ 248 Service points .................................................................. 249 Engine ............................................................................. 251 Fuel system ..................................................................... 256 Turbocharger ................................................................... 260 Engine air cleaner ........................................................... 261 Cooling system ................................................................ 263 Electrical system ............................................................. 268 Transmission ................................................................... 274 Axles ................................................................................ 276 Tandems ......................................................................... 277 Brake system ................................................................... 278 Wheels ............................................................................ 282 Cab .................................................................................. 284 Windscreen wiper system ............................................... 286 Air conditioning ................................................................ 287 Hydraulic system ............................................................. 289 Attachments, maintenance .............................................. 292 Greasing .......................................................................... 301 Lubrication and service chart .......................................... 302

Specifications ...................................................... 307 Recommended lubricants ................................................ 307 Fuel system ..................................................................... 314 Service capacities and change intervals ......................... 315 Engine ............................................................................. 317 Electrical system ............................................................. 319 Transmission ................................................................... 324 Brake ............................................................................... 325 Steering ........................................................................... 326 Wheels ............................................................................ 327 Cab .................................................................................. 328 Hydraulic system ............................................................. 330 Machine weights .............................................................. 331 Dimensions ...................................................................... 332 Service history ................................................................. 333

Alphabetical index ............................................... 337

Presentation

7

Presentation

Intended use The machine (motor grader) is intended to be used only for the grading of gravel and soil, and for the removal of snow. Use of the machine for any other purpose, such as for towing other vehicles or equipment, is contrary to its designated use. The manufacturer and local authorised dealer or distributor cannot be held responsible for any damage resulting from such use.

The machine is not for use in other applications or in potentially hazardous environments. Contact the manufacturer's local authorised dealer or distributor for further information.

The risk of misuse lies entirely with the user.

Environmental requirements Be aware of the environment when operating and during service and maintenance of the machine. Always follow local and national environmental legislation applicable to all handling of the machine.

Machine The complete structural design of G900 Motor Graders is balanced to focus their weight and power for optimum blade down force and drawbar pull values.

Twin-gear direct-drive circle turn system provides maximum strength to either hold or to turn the moldboard smoothly while moving under full load; wide-stance blade lift cylinders provide stability for fine grade control.

Volvo D7 and D9 Tier 3/Stage IIIA engines; high torque at low RPM ensures excellent performance and fuel savings.

Advanced HTE840 and optional HTE1160 transmissions available with Manual or optional Autoshift modes to optimize performance and fuel economy.

Standard shuttle shift feature enables shifting between selected forward and reverse gears in single smooth motion.

Purpose-built front axle with high center ground clearance consists of a reduced number of components which ensures long life with minimum maintenance.

All wheel drive or Volvo exclusive creep mode for the industry’s best fine grading control.

Presentation

8 Robotic welding builds in consistent frame strength and durability, while the full-perimeter rear frame protects the powertrain from attachment-related load stresses.

Easy lift rear hood opens wide for easy cleaning access to the radiator.

Cover panels for the engine, hydraulic centre and battery pack all open up fully and quickly to provide unmatched access for ease of service.

Volvo APR70 and APR90 rear axles with planetary reduction final drives reduce loading on tandem chains for maximum service life.

Purpose built differential with hydraulic clutch lockup ensures maximum tractive effort at the flip of a switch.

Frame The frame articulates 23° (models G930 to G960) or 21° (models G970 to G990) to the left or to the right and uses lock valves to ensure stable operation.

Engine G930, G940, G946, G960 G930 Volvo D7EGCE3, G940 Volvo D7EGBE3, G946 and G960 Volvo D7EGAE3.

A 7.2 litre (439 in³) six cylinder, four-stroke, direct-injection, low emission engine which is turbocharged with charge air cooling of the air to air type. Common rail fuel system and internal exhaust gas recirculation (IEGR) are controlled by the engine electronic control unit (E-ECU) software. The engine has wet, replaceable cylinder liners and two valves per cylinder with replaceable valve guides and valve seat inserts. The accelerator position is transferred electrically from the accelerator pedal to the engine electronic control unit (E-ECU). All models have variable horsepower (VHP).

G970, G976, G990 G970 Volvo D9BGAE3, G976 and G990 Volvo D9BGBE3.

A 9.4 litre (574 in³) six cylinder, four-stroke, direct-injection, low emission engine which is turbocharged with charge air cooling of the air to air type. Overhead camshaft and unit injectors and internal exhaust gas recirculation (IEGR) are controlled by the engine electronic control unit (E-ECU) software. The engine has wet, replaceable cylinder liners and two valves per cylinder with replaceable valve guides and valve seat inserts. The accelerator position is transferred electrically from the accelerator pedal to the engine electronic control unit (E-ECU). All models have variable horsepower (VHP).

VHP (Variable Horsepower) All Volvo grader models have engines that provide three different power levels depending on the gear selected by the operator.

VHP engine power range

Transmission gear HTE840

HTE1160

Low

F1, F2, R1

F1, F2, F3, R1, R2

Mid

F3, F4, F5, R2, R3

F4, F5, F6, F7, R3, R4

High

F6, F7, F8, R4

F8, F9, F10, F11, R5, R6

Presentation

9 Instruments and controls, overview

An ergonomic design includes low-effort operating controls in front of the operator. The complete pedestal assembly slides and tilts to adjust easily to any operator’s preference. Highly responsive, industry-standard controls are precise and predictable.

The Volvo proportional demand flow (PDF) hydraulic system, balances flow between all grading functions for consistent and predictable implement control. The PDF hydraulic system is ideally suited for all leading automatic blade control systems.

An electronic display provides detailed system status to the operator in real time: records up to 25 points of interest for service analysis through the exclusive Matris system from Volvo.

Operator's station A rollover protective structure/falling objects protective structure (ROPS/FOPS) enclosed operator compartment lives up to every expectation for a Volvo cab with industry-leading comfort, safety and efficiency. The cab is equipped with an excellent HVAC system, AM/FM CD, deluxe suspension seat with tilt steering wheel and unobstructed wide angle views for reduced operator fatigue, high productivity and maximum safety.

The G900 cab builds on the Volvo tradition of productive work environments for operators. Interior lighting, illumination on the steps and handholds ensure maximum ease and safety as you enter or exit.

Expansive windows, a sloped rear wall and the cowling design provide exceptional visibility to all areas of the grader, while a unique package of six optimally placed interior and exterior mirrors allow a commanding view to the rear and sides.

Fresh, clean double-filtered air is ducted in throughout the cab, with vents built into the rear posts for improved circulation. Side and front windows also open for passive ventilation.

Quiet Volvo engines combined with a sound suppression package provide lowest interior sound levels.

Additional features include built-in coat hooks, smart storage areas, convenient mounting brackets for communications gear and an optional air-suspension seat for the best in operating comfort.

Electrical system The battery disconnect switch is connected to the negative (-) cable of the batteries. When the switch is turned to the OFF position, electrical power is disconnected from the machine. The battery disconnect switch should be turned off whenever the machine is not in use.

The electrical system is a 24 volt, negative ground system. Battery charging is accomplished using a standard 80 amp alternator or an optional alternator with increased charging ability.

The machine has three electronic control units (ECUs). The instrumentation electronic control unit (I-ECU) is integrated with the display unit, warning lamps and instruments, and provides the operator with information. The vehicle electronic control unit (VECU) receives signals from sensors on the machine and these are passed on to the I-ECU and E-ECU. The V-ECU is placed in the electrical distribution box on the back wall of the cab. The EECU controls the engine. For D7 engines, the E-ECU is installed

Presentation

10 in the cooling module. For D9 engines, the E-ECU is installed on the engine.

Joystick ECU, description Valid for option / configuration Option Steering

Configuration Dual joystick

The joystick steering major components consist of two joysticks, a display, a master controller, multiple slave controllers, and a steering valve. The joysticks are mounted on the seat armrests to provide comfortable, ergonomic operation and replace the shift lever used in conventional steering. The steering wheel is still included and will take control if used by the operator. Besides steering, some of the major functions controlled include gear shifting, mouldboard tilt, mouldboard shift circle turning, articulation, wheel lean, and auxiliary hydraulics.

Transmission All machine models are equipped with the standard HTE840 powershift transmission, which has 8 forward speeds and 4 reverse speeds. All machine models can be equipped with the optional HTE1160 powershift transmission, which has 11 forward speeds and 6 reverse speeds. Both transmissions are direct drive, fully sequential units using a countershaft design.

Brake system Hydraulically actuated oil disc service brakes are located at the four tandem drive wheels. The crossover dual braking circuits provide even braking on both sides of the machine. During normal operation, a brake charge system maintains pressure in a bank of accumulators. If the engine stalls or hydraulic pump failure occurs, hydraulic pressure stored in the accumulators supplies the power required to bring the machine to a safe stop.

Parking brake The parking brake is a spring applied, hydraulically released, wet multiple disc brake. The brake assembly is installed inside the rear axle housing. In the event of transmission system pressure loss, an accumulator in the circuit stores system pressure and allows the parking brake to remain released for approximately 20 minutes.

Rear axle and tandem Models G930, G940, G946 and G960 are equipped with the APR70A rear axle. Models G970, G976 and G990 are equipped with the APR90A rear axle. Each has an operator-controlled differential lock/unlock. Tandem wheels are chain-driven.

Description, All Wheel Drive system Applies to models: G946, G976

G946 and G976 are all wheel drive (AWD) models. The AWD system is powered by two electronically controlled, variable displacement hydraulic pumps in separate closed loop systems.

Each pump supplies one front wheel motor. Front wheel motors are two-speed, high torque, radial piston, cam lobe type. Each wheel motor has a separate speed sensor.

Presentation

11 Cab The cab is approved as a protective structure according to falling object protective structure (FOPS) and rollover protective structure (ROPS) standards, see page 11.

If any part of the cab's protective structure is affected by plastic deformation or cracks, the cab shall be replaced immediately.

Never carry out any unauthorised alterations to the cab, e.g., lowering the roof height, drilling, welding on brackets for fire extinguisher, radio aerial or other equipment, without first, via a dealer, having discussed the alteration with personnel at Volvo Construction Equipment. The manufacturer will decide whether the alteration may void the warranty.

A mounting plate option is available for the mounting of two-way radios, etc.

Cab's emergency exits On machines equipped with an enclosed cab, in case of emergency and a blockage of the normal cab exit occurs, exit the cab through the window identified with the “Emergency Exit” label, located at the right side of the cab. Exit through the front or rear window if blockage occurs at the normal and emergency exits.

FOPS and ROPS

WARNING Risk of serious injury or death.

Structural damage caused by unauthorised modification, or the machine rolling over, weakens the rollover protective structure (ROPS) / falling objects protective structure (FOPS) and can result in serious injury or death from falling objects or machine rollover.

Do not repair, modify, drill, weld on or add attachments to the ROPS/FOPS unless authorised in writing by the manufacturer.

Use only genuine original equipment manufacturer replacement parts. Do not operate this machine if the ROPS/FOPS is structurally damaged, shows cracks, is not properly secured as originally installed, or has been involved in a rollover.

The manufacturer provides rollover protective structure (ROPS), falling object protective structure (FOPS) and a seat belt as standard equipment on the machine. The ROPS and FOPS, used in conjunction with a seat belt, will lessen the possibility of death or serious injury in the event of a rollover.

Check the seat belt regularly for wear or damage. Inspect belt hardware and fabric. Replace if hardware is damaged or if strap is nicked, frayed or if loose stitching is found. Seat belt assemblies should be replaced every 3 years regardless of appearance. Seat belt strength degrades over time and use due to exposure to weather, ultraviolet (UV) radiation and abrasives (dirt). Ensure mounting hardware is tight.

Hydraulic system The closed-centre hydraulic system uses a pressure and flow compensated (load sensing) variable displacement piston pump.

The pump supplies oil to the implements and the steering. The cooling fan is driven by a hydraulic motor. Fan speed is variable

Presentation

12 and is determined by various cooling requirements. The fan operates between pre-determined minimum and maximum speeds. The fan remains at its minimum speed until there is a demand for cooling. Fan speed will automatically increase with the demand for cooling. Lock valves are incorporated in the blade lift, moldboard tilt, circle shift, wheel lean and articulation hydraulic circuits to prevent cylinder drift. The control levers are short throw, feathering type and are located on a fully adjustable steering pedestal.

Equipment The machine can be equipped with different types of optional equipment, depending on the requirements of different markets.

Examples of such equipment are lever steering (CDC), Boom Suspension System (BSS), secondary steering, separate attachment lock, automatic engine shutdown, and automatic greasing system (standard on certain markets).

Anti-theft device (optional equipment) An installed anti-theft device makes it more difficult to steal the machine. Volvo Construction Equipment can supply an anti-theft device as optional equipment. If your machine is not equipped with such a device, look into the possibility of having one installed by your dealer.

Modifications Modifications to the machine, including use of unauthorised accessories and spare parts, may affect the machine's condition and its ability to function as it was designed. No changes of any kind may be performed without first obtaining written approval from Volvo Construction Equipment. Volvo Construction Equipment reserves the right to refuse all warranty claims that have resulted due to or can be attributed to unauthorised modifications.

The person who performs unauthorised modifications assumes all responsibility for consequences that arise due to the modification or can be attributed to the modification, including damage to the machine.

Modifications may be considered to be officially approved, if at least one of the following conditions has been met: 1 The attachment, the accessory, or the spare part has been made or distributed by Volvo Construction Equipment and has been installed according to approved method described in a publication available from Volvo Construction Equipment; or 2 The modification has been approved in writing by the Engineering Department at each product company within Volvo Construction Equipment.

Attachments The circle, drawbar and moldboard equipment is fully manoeuvrable using hydraulic cylinders. Blade mobility permits steep ditch cutting angles and back sloping outside of overall machine width. The circle is held in place by adjustable clamp plates and guide shoes. Bearing surfaces are faced with Duramide™ for maximum service life. Hardened teeth are cut on the outside of the circle. The moldboard has a replaceable cutting edge and end bits. The drawbar is a narrow “T” design for optimum visibility to the work area. Five common attachments include:

Presentation

13 1 2 3 4 5

Mid-mounted scarifier Front-mounted scarifier Rear-mounted ripper Front-mounted dozer blade Front-mounted push block

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 authorised workshops in the product development process and for possible malfunction detection.

Questions regarding this information can be directed to your dealer.

CareTrack The machine can be equipped with optional 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, operating hours, fuel consumption, alarms, etc. (may vary by machine model and/or subscription). CareTrack is available in different versions, depending on the required information level.

CareTrack makes it easier to plan for service and reduces costly downtime. Productivity is improved by knowing if machines are being operated correctly and how much fuel is being consumed.

It also allows the customer to restrict the operating area of the machine, by using virtual fences. This helps eliminate unauthorised machine usage and theft. For further information, contact a Volvo Construction Equipment dealer.

Additional Icons NOTE! Some symbols shown in this section may not appear on your machine.

Machine specific symbols Symbol

Description

Symbol

Tie-down points and tow points

Description Caution

International symbols Symbol

Description

Symbol

Description

On/start

Seat (lap) belt

Off/stop

Linear

Presentation

14 Symbol

Description

Symbol

Description

On/Off

Rotational

Plus (positive)

Volume empty

Minus (negative)

Volume half full

Horn

Volume full

Battery condition

Grease

Hourmeter

Oil lubrication point

Lift point

Engine oil temperature

Jack or support point

Engine coolant

Filling or emptying

Engine coolant level

Read Operator's Manual

Coolant temperature

Engine oil

Engine rotations (rpm)

Engine oil pressure

Gas inject (cold start)

Engine oil pressure – failure

Engine air filter

Presentation

15 Symbol

Description

Symbol

Description

Engine oil level

Engine air filter – failure

Engine oil filter

Fan belt – failure

Emergency engine stop

Reverse direction

Engine start

Parking brake

Engine on/run

Brake on

Start switch

Brake off

Transmission

Primer (start aid)

Transmission oil level

Hydraulic oil

High gear

Hydraulic oil pressure

Low gear

Hydraulic oil level

Forward direction

Hydraulic oil filter

Hydraulic oil temperature

Control lever – multi-direction

Diesel fuel

Clockwise rotation

Presentation

16 Symbol

Description

Symbol

Description

Fuel level

Counterclockwise rotation

Fuel filter

Engine electrical preheat

Work light

Fast speed

Flashing beacon

Slow speed

Control lever – dual direction

Presentation

Machine view

17

Machine view Directional terms The terms left and right, when used in this manual, indicate the sides of the machine as seen from the operator seat facing the front of the machine.

1 Front 2 Rear 3 Left 4 Right

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18

Machine view Machine description

1

Operator's cab

12

Battery disconnect switch

2

Operators seat

13

Frame articulation hinge and lock pin

3

Power transmission

14

Moldboard tilt cylinder

4

Hydraulic tank

15

Moldboard

5

Engine and hydraulic pumps

16

Circle

6

Cooling package

17

Drawbar

7

Fuel tank

18

Circle turning cylinders

8

Tie-down points

19

Circle lift cylinders

9

Lift points

20

Circle shift cylinder

10

Battery

21

Molboard shift cylinders

11

Axle and tandems

Presentation

CE-marking, EMC-directive

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CE-marking, EMC-directive CE-marking If 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 Directive, 2006/42/EC. 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, an EU Declaration of Conformity and a sound certificate regarding sound level in dB (A) are supplied with the machine. The sound certificate includes both measured external values and guaranteed sound level. These declarations are issued by Volvo Construction Equipment for each individual machine. This EU declaration also covers attachments manufactured by Volvo Construction Equipment.

The documentation is a valuable document, which should be kept safe and retained for at least 10 years. The document should always accompany the machine when it is sold.

EU's 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’s EMC-directive about “Electromagnetic Compatibility,” 2004/108/EC, provides a general description of what demands can be made on the machine from 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 CEmarked. Our machines have been tested particularly for electromagnetic interference. The CE-marking of the machine and the declaration of conformity also cover the EMC-directive.

If other electronic equipment is fitted to this machine, the equipment must be CE-marked and tested on the machine with regard to electromagnetic interference.

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CE-marking, EMC-directive Declaration of Conformity The following is a generic version of the EC declaration of conformity. A signed and dated version is included with the shipment of the machine.

EC Declaration of Conformity for Machinery (IIA) Volvo Construction Equipment Inc, Shippensburg, PA, USA, hereby declares that the product: Make: Volvo Construction Equipment Type: Motor Grader *Gxxx* Product Identification Number (PIN): VCEXXXXXXXXXXXXXXXXX to which this declaration relates, is in conformity with the relevant provisions of Essential Health and Safety requirements of the: Council Directive 2006/42/EC relating to Machinery.

Council Directive 2000/14/EC relating to Noise Emission in the Environment by equipment for use out doors.

Council Directive 2004/108/EC on electromagnetic compatibility, and their Amendments relating to machinery, and other applicable Directives.

Harmonized standards applied: EN 474-1:2006+A1:2009 Earth Moving machinery – Safety General Requirements, EN 474-6:2006+A1:2009 Earth Moving machinery- Safety Requirements for Dumpers.

This declaration relates exclusively to the machinery in the state in which it was placed on the market, and excludes components which are added and/or operations carried out subsequently by the final user.

Signature of the issuer of this declaration: _____________________________________ _____________________________________ Director, Road and Utility Product Platforms Signature _____________________________________ Date of issue Signature of the person, established in the Community, authorised to compile the technical file: _____________________________________ _____________________________________ Global Director Laws and Regulations Signature _____________________________________ _____________________________________ _____________________________________ Date of issue _____________________________________ Address This declaration may include attachments developed, designed/approved, marked and marketed by abovementioned manufacturer.

Presentation

Communication equipment, installation

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Communication equipment, installation NOTICE All installation of optional electronic communication equipment must be performed by trained professionals and in accordance with the Volvo Construction Equipment instructions.

Protection against electromagnetic interference This machine has been tested in accordance with EU directive 2004/108/EC 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.

Guidelines for installation of mobile telephone 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.

Guidelines for installing antenna The guidelines given below must be followed during installation: The aerial placement must be chosen to give good adaptation to the surroundings.

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.

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.

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.

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Product plates

Product plates The machine and its components can be identified using the identification numbers on the machine's product plates. State these numbers when ordering spare parts or for any enquiries.

Enter the numbers in the table on page 3.

Product identification 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. The component identification number (CIN) indicates the serial number of the component.

When ordering spare parts, and in all telephone inquiries or correspondence, the PIN and CIN must always be quoted.

Product identification plates

Presentation

Product plates 1 Engine The engine model designation, serial number and power rating (plate attached on the engine).

2 Cab ROPS / FOPS number and ROPS / FOPS certificate number (plate attached on the R.H. door post).

3 Product plate The manufacturer’s name and address, machine model designation, machine PIN, machine weight, engine output, year of manufacture, year of delivery and position of CE mark (EU / EEA countries only).

4 CE mark Separate self-adhesive decal attached to the product plate (EU / EAA countries only).

23

5 Product plate for TUV (Germany) Machine model designation, PIN, max. machine weight, max. charge weight on front axle, max. charge weight on rear axle, year of manufacture.

6 Transmission The manufacturer’s name and address and transmission CIN (plate attached to the housing).

7 Rear axle The manufacturer’s name and address and rear axle CIN (plate attached to the housing).

Product identification number V C E E C 3 5 C C 0 0 0 1 2 3 4 5 A

B

C

PIN plate detail A World manufacturer code B Machine descriptor section C Check letter section D Machine serial number

D V1085475

When ordering spare parts and in all telephone enquiries or correspondence, the product identification number (PIN), which includes the machine model, must always be quoted.

The PIN is located on the PIN product plate. The PIN identifies the world manufacturer code, the machine model and the machine serial number.

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24

Information and warning decals

Information and warning decals The operator should read, understand and follow the information and warning decals which are positioned on the machine.

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 decals and in the Parts Catalogue. Contact your manufacturer’s local authorised dealer or distributor for additional information or assistance as required.

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Information and warning decals

25

Decal locations Applies to models: G970, G976, G990

Item Decal

Quantity Location

1

Warning! Rotating components, hot surfaces, high pressure

1

Engine compartment

2

Warning! Jumper cables alert

1

Battery box

3

Warning! Battery information, corrosion and explosion hazards

1

Battery box

4

Warning! Read Operator's Manual first

3

Cab

5

Warning! Articulation crush zone. Stay clear when engine is running

2

Both sides of frame articulation hinge joint

6

Warning! Crush zone. Keep clear of moldboard

4

Both sides of circle

7

Warning! Pressurized accumulators

4

Over the circle area

8

Warning! Rotating components

1

Rear cooling grille

9

Warning! Reversing machine

1

Rear bumper

10

Lifting points

5

Main frames

11

Tie down points

8

Main frames

12

Battery disconnect switch

1

Engine compartment

13

Warning! Rotating components

2

Both sides articulation hinge joint

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26

Information and warning decals Decal locations Applies to models: G930, G940, G946, G960

Item Decal

Quantity Location

1

Warning! Rotating components, hot surfaces, high pressure

1

Engine compartment

2

Warning! Jumper cables alert

1

Battery box

3

Warning! Battery information, corrosion and explosion hazards

1

Battery box

4

Warning! Read Operator's Manual first

3

Cab

5

Warning! Articulation crush zone. Stay clear when engine is running

2

Both sides of frame articulation hinge joint

6

Warning! Crush zone. Keep clear of moldboard

4

Both sides of circle

7

Warning! Pressurized accumulators

4

Over the circle area

8

Warning! Rotating components

1

Rear cooling grille

9

Warning! Reversing machine

1

Rear bumper

10

Lifting points

5

Main frames

11

Tie down points

8

Main frames

12

Battery disconnect switch

1

Engine compartment

13

Warning! Rotating components

2

Both sides articulation hinge joint

Presentation

Information and warning decals

27

North American decals

1 WARNING! Rotating components, hot surfaces, high pressure. Read Operator's Manual.

2 WARNING! Jumper cables alert. Read Operator's Manual.

3 WARNING! Battery information, corrosion and explosion hazards. Read Operator's Manual.

4 WARNING! Read Operator's Manual first.

Presentation

28

Information and warning decals 5 WARNING! Articulation crush zone. Stay clear when engine is running.

6 WARNING! Crush zone. Keep clear of moldboard.

7 WARNING! Pressurized accumulators. Read Operator's Manual.

8 WARNING! Rotating components. Keep clear.

9 WARNING! Reversing machine. Keep clear.

10 Lift points

11 Tie down points

12 Battery disconnect switch

Presentation

Information and warning decals 13 WARNING! Rotating components

29

Presentation

30

USA federal clean air act

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 EPAcertified non-road engine to a non certified configuration.

The Federal regulations implementing the Clean Air Act for nonroad engines, 40 CFR 89.1003(a)(3)(i), reads as follows: The following acts and the causing thereof are prohibited: For a person to remove or render inoperative a device or element of design installed on or in a non-road engine vehicle or equipment in compliance with the regulations under this part prior to its sale and delivery to the ultimate purchaser or for a person knowingly to remove or render inoperative such a device or element of design after the sale and delivery to the ultimate purchaser.

The law prescribes a fine of up to $2,750 USD for each violation.

An example of a prohibited modifications is the recalibration of the fuel system so that the engine will exceed the certified horsepower or torque.

You should not make a change to an EPA-certified non-road engine that would result in an engine that does not match the engine configuration certified to meet the Federal Standards.

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

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.

Presentation

USA federal clean air act

31

Non-road engine maintenance This is a non-road engine of conventional design and any local dealer may perform the necessary non-road emission control maintenance as defined in this manual.

Volvo recommends that the purchaser use the service program for the non-road engine, known as preventative maintenance, including the recommended engine emission control maintenance.

In order to document that the proper regular maintenance has been performed on the non-road engine, Volvo recommends that the owner keep all records and receipts of such maintenance.

These records or receipts should be transferred to each subsequent purchaser of the non-road engine.

Service performed by your local dealer Your local dealer is best suited to give you good, dependable service since he has trained service technicians and is equipped with genuine original manufacturer's parts and special tools and the latest technical publications. Discuss your servicing and maintenance requirements with your local dealer. He can tailor a maintenance program for your needs.

For scheduled service or maintenance, it is advisable to contact your local dealer in advance to arrange for an appointment to ensure availability of the correct equipment and service technician to work on your machine. In this way you will assist your local dealer in reducing the time required to do service on your machine.

Preventive maintenance program In order for the conventional non-road engine to retain the reliability and performance parameters such as noise level and emission levels it had when delivered, it is essential that it receives regularly scheduled service, inspections, adjustments, and maintenance.