Service Information

Document Title: Function Group: Information Type: Date:

General precautions 191 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]

General precautions
WARNING
For safety, observe the following rules.

Safety precautions

Figure 1
Keep the safety rules

 Do not operate the machine if you are under the influence of alcohol, medicine or other drugs.
 When carrying out any operation or maintenance, have trained and experienced personnel carry out the work.
 When carrying out any operation or maintenance, carefully read the Operator’s manual.
Read all the precautions given on the decals which are fixed to the machine.

Safety device

 Make sure that all guards and covers are mounted in their proper position. Repair or replace if damaged.
 Pay attention to the method of using any safety locking device or safety belt.
 Fasten the safety belt for all operations.

Safety clothes and hard hat

Figure 2
Wear clothes suitable for welding work
  Wear the specified work clothes in the correct manner.
 Use the specified protective gear (hard hat, safety glasses, safety shoes, mask, gloves).
Guard against injury from flying pieces of metal or debris, wear goggles, gloves and helmet.
Always have a trained and experienced welder carry out any welding work.
When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suitable for
welding work.

Prepare for emergencies

Figure 3
Prepare for emergencies

 Know where fire extinguishers are located and how to use them.
 Keep a first aid kit and an eye wash kit near the work area.
 Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Handle fluids safely-avoid fires

Figure 4
Avoid fires

 Handle fuel with care. It is highly flammable.

 Do not refuel the machine while smoking or when near open flame or sparks.
Always stop the engine before refuelling machine.
Fill the fuel tank outdoors.
 Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized containers.

Dispose of fluids properly

Figure 5
Do not pour oil into the ground

 Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the
proper way to dispose of waste from your local environmental agency.
 Catch draining fuel, oil, or other fluids in suitable containers.
Do not use food or beverage containers that may mislead someone into drinking from them. Wipe up spills at once.
 Do not pour oil into the ground, down a drain, or into a stream, pond, or lake.
Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, filters, batteries, and
other harmful waste.

Working in contaminated environment

Figure 6
Avoid breathing dust

 Used cab and engine air filters from machines which operate in environments containing asbestos or other
dangerous dust must be placed in the tight-fitting bag, before they are deposited in a designated place.
 The machine must be equipped for work within an environment which is contaminated or constitutes a health
hazard before the work is initiated. Besides, special local regulations apply for such operations and for servicing a
machine which has been used in such environment.

Crystalline silica (quartz) dust

Because crystalline silica is a basis component of sand and granite, many activities at construction sites produce dust
containing crystalline silica. Trenching, sawing and boring of material containing crystalline silica can produce dust
containing crystalline silica.
If dust which contains crystalline silica is present there are guidelines which should be followed.

1. Be aware of the health effects of crystalline silica and that smoking adds to the damage.
2. Be aware of and follows OSHA (or other) guidelines for exposure to airborne crystalline silica.
3. Know the work operations where exposure to crystalline silica may occur.
4. Participate in air monitoring or training programs offered by the employer.
5. Be aware of and use optional equipment controls such as water sprays, local exhaust ventilation, and enclosed cabs
with positive pressure air conditioning.
6. Where respirators are required, wear a respirator approved for protection against crystalline silica -containing dust.
Do not alter the respirator in any way. Workers who use tight-fitting respirators cannot have beards/mustaches
which interfere with the respirator seal to the face.
7. If possible, change into disposable or washable work clothes at the work site ; shower and change into clean
clothing before leaving the work site.
8. Do not eat, drink use tobacco products, or apply cosmetics in areas where there is dust containing crystalline silica.
9. Store food, drink and personal belongings away from the work area.
10. Wash hands and face before eating, drinking, smoking, or applying cosmetics after leaving the exposure area.
 Service Information

Document Title: Function Group: Information Type: Date:

Cautions during operation 191 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]

Cautions during operation

Service cooling system safely

Figure 1
Hot coolant can burn you

 At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to the heaters
and engine contain hot coolant. Any contact can cause severe burns.
 Hot coolant can cause personal injury.
 Check the coolant level only after the engine has been stopped and the radiator pressure cap is cool enough to
remove with your bare hand.
 Remove the radiator pressure cap slowly to release pressure.
 Cooling system additive contains alkali that can cause personal injury. Avoid contact with the skin, eyes and mouth.
 Allow cooling system components to cool before draining.

Avoid high-pressure fluids

Figure 2
Avoid high pressure fluids

 Escaping fluid under pressure can penetrate the skin causing serious injury.
 Avoid the hazard by releasing pressure before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
 Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not use your
bare hand.
Protect hands and body from high pressure fluids.
 Be careful not to break, twist or damage the high pressure pipes.
A jet spray of high pressure oil can cause electrical fires.
Handling of heavy objects

Figure 3
Support the equipment safety

 When raising heavy components, use a hoist or crane.

 Ensure that wire ropes, chains and hooks are free from damage.
 Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places.
 Use a hoist or crane and operate slowly to prevent the component hitting any other part.
 When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
Never use concrete blocks for supports. They can collapse under even light loads.
 Before starting work, lower the blade, ripper, bucket or any other work equipment to the ground.
 Do not work under the equipment when the equipment is not sufficiently supported.

Electrical system

Figure 4
ALWAYS turn the master switch OFF when welding on the machine.

 When working on the electrical system, ALWAYS turn the master switch OFF or remove the lead from the battery
negative (–) terminal.
 The battery master switch is installed inside the tool box located on the right side of machine.
 When removing components, be careful not to break or damage the wiring.
Damaged wiring can cause electrical fires.

 ON position (1)
Turn the key clockwise to supply power to the electrical system.
 OFF position (2)
Turn the key counter-clockwise to cut off electric power to the machine.

Electric welding

 Before electric welding is carried out on the machine or any attachment installed to the machine, the current must
be turned OFF at the battery master switch.
 Figure 5
When working on the battery, pay attention
 Before carrying out any electric welding on the machine, the battery cables should be disconnected and the
connectors pulled out of the electronic control units.
 When disconnecting and reconnecting, the leads should be without current (the battery master switch turned off).
 Connect the earth (ground) lead of the welding equipment as close to the welding point as possible.
 Before welding, remove all paint from an area of at least 10 cm (4 inch) around the point of welding. Paint which is
heated gives off unhealthy gases.
 All paint decomposes when heated and forms a great number of compounds, which may cause irritation and be
dangerous to ones health after repeated or prolonged exposure.
 In addition to the health hazard, the weld will be of inferior quality and strength, which, in the future, may cause the
weld to break. Therefore, never weld directly on a painted surface.

 When working on the battery, wear goggles or safety glasses.

 Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin and eat holes in clothing and cause blindness if splashed into the eyes.
If you spill acid on your clothes or skin, immediately flush with large quantities of clean water, then get medical
attention.
 If splashed into the eyes, flush with water and get medical attention immediately.
 Keep sparks, lighted matches, and open flame away from the top of battery. Battery (hydrogen) gas can explode.

Figure 6
Battery posts and cables can burn you

 Battery posts and cables touched by metal objects can short circuit and burn you.
 Keep tools away from posts, wires and terminals.
 Tighten the battery terminals to ensure good contact.
 When disassembling and assembling the battery, make sure that the battery terminals are correctly connected.
Figure 7
Do not use water or steam in the cab

 If water gets to the electrical system, abnormal operation or failure can result.
Do not use water or steam on sensors, connectors and instruments in the cab.

Cautions during operation

Figure 8
Be careful when opening the grease valve

 When removing covers which are under internal pressure or under pressure from a spring, always leave two screws
in position on opposite sides.
Slowly release the pressure, then slowly loosen the screws.
 High pressure grease in the spring package of the undercarriage can explode and injure you.
Be careful when opening the grease valve.
Do not loosen the grease valve more than 1 turn until the pressure is released.
 When assembling or installing parts, always use the specified tightening torque.
 When installing protective parts such as guards, or parts which rotate at high speed, be particularly careful to check
if they are installed correctly.

Figure 9
Do not contact rotating parts
 Be sure that your clothes or hair do not contact any rotating components.

Figure 10
Be careful of your finger (1)

 When aligning two holes, never insert your fingers or hand.

Be careful not to get your fingers pinched in a hole, or between parts or tools.

Figure 11
Be careful of your finger (2)
Figure 12
Never touch rotating parts

 Never touch rotating parts such as the fan blades or fan belt.

Figure 13
Pay attention when removing or installing the tracks

 Pay attention when removing or installing the tracks of track type machines. When removing the track pin, the track
separates suddenly, so never let anyone stand at either end of the track.
Always block both ends of the track to prevent any sudden uncontrolled movement.
 Service Information

Document Title: Function Group: Information Type: Date:

Preparations for work 191 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]

Preparations for work

Warn others of service work

Figure 1
Attach a warning tag

 Unexpected machine movement can cause serious injury.

 Before performing any work on the machine, attach a warning tag on the remote control lever.
 When carrying out any operation with two or more workers, always agree on the operating procedure before
starting.

Figure 2
Sound the travel alarm

 Turn on the travel alarm off switch when you start to move the machine.. Sound the horn and let other workers and
bystanders know you are starting the machine.

Figure 3
Hot filament of a broken bulb can ignite spilled fuel or oil

 Illuminate your work area adequately but safely.

Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
Use tools properly

Figure 4
Use tools safely

 Use a tool only for its designed application.

 Keep all tools in good condition and know the correct way to use them.
 Decide on a place in the repair workshop to keep tools and removed parts.
 Always keep the work area clean and make sure that there is no dirt or oil on the floor.
 Before adding oil or making any repairs, park the machine on hard, level ground and put blocks under the wheels
or tracks to prevent the machine from moving.
 Before starting work, lower the blade, ripper, bucket or any other work equipment to the ground.
If that is not possible, insert the safety pin or use blocks to prevent the work equipment from falling.

Control lockout system

WARNING
Place the control lockout lever securely to "Locked" position to lock out the control hydraulics before starting the
engine or leaving the operator's seat. Unless the control lockout lever is in the "Locked" position, control levers can
be operated by careless touch, which could cause serious injury.

Figure 5
Control lockout system

A. Unlocked position (When this lever is put at this position the engine can not be started)
B. Locked position (When this lever is put at this position the engine can be started)

1. control lockout lever

2. Control lever (left)
3. Left control console
4. Backrest
  This system is used to LOCK OUT the attachment, slew and the travel unit. Place the control lockout lever equipped
on the left control console to "Locked" (B) position to lock out the hydraulic operating levers.

Use handholds and steps

Figure 6
Never jump on/off the machine

 Never jump on or off the machine.

Figure 7
Always maintain a three point contact with the steps and handrails

 When you get on and off the machine, always maintain a three point contact (two feet and one hand or one foot
and two hands) with the steps and handrails and face the machine.
Do not use any controls as handholds, when entering or leaving the operator’s station.
Do not try to climb on or off the machine when carrying tools or supplies. Use a hand line to pull equipment up
onto the platform.

Figure 8
Remove all mud and oil from the steps

 Remove all mud and oil from the steps of other places used to get on and off the machine.
 Service Information

Document Title: Function Group: Information Type: Date:

Move and operate machine 191 Service Information 2014/6/11
safely
Profile:
EXC, EC210B LC [GB]

Move and operate machine safely

 Only allow the operator on the machine. Keep all riders off.
Know the location of bystanders before moving, slewing or operating the machine.

Figure 2
Don’t contact electric power lines
 Always keep the travel alarm in working condition.
 Use a signal person when moving, slew or operating the machine in a congested area.
 Before traveling check the traveling direction.
Particularly, for reverse traveling, check that no person is in the area after slew to the rear side.
Use the travel alarm before traveling.
 Serious injury or death can result from contact with electric power lines.
Never move any part of the machine or load closer to the electric power line than the minimum established safe
distance.

 Refer to the Operator’s manual for further details.

Transporting the machine

NOTE!
Loading, positioning, slinging and securing for transporting the machine on a trailer or other vehicle should be comply with
the local or national laws and regulations.

NOTE!
The operator performing any work for transportation must be familiar with and be understood both operating information
and related laws.

NOTE!
Please contact authorized personnel or Volvo CE dealer for any information that you may require.

Refer to the Operator’s manual for further details (Transporting the machine).
 Service Information

Document Title: Function Group: Information Type: Date:

Safety regulations, forestry 191 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]

Safety regulations, forestry

Forestry

WARNING
Please pay attention to the safety instructions in the Operator's and Service Manuals concerned.

All mechanical equipment can be hazardous if operated without due care or correct maintenance. Most accidents involving
machine operation and maintenance are caused by failure to observe basic safety rules or precautions.
An accidents can often be avoided by recognizing potentially hazardous situations before an accident occurs.
Since it is impossible to anticipate every possible circumstance that might involve a potential hazard, the warnings in this
guide and on the machine are not all inclusive. If a procedure, tool, working method or operating technique not specifically
recommended by the manufacturer is used, you must satisfy yourself that it is safe for you and others. Also ensure that the
machine will not be damaged or made unsafe by the method of operation or maintenance procedures you choose.
Safety is not just a matter of responding to the warnings. When working with the machine, always pay attention to what
hazards there might be and how to avoid them.
Do not work with this machine until you are sure that you control it. Do not start any job until you are sure that you and
those around you will be safe.
Manuals
Read and understand this appendix to the Service Manual.
The operator must be thoroughly familiar with how to operate and maintain the machine and should preferably undergo
required training on the machine.
The operator must follow the rules and recommendations given in the Service Manual and in this appendix, but also pay
attention to any statutory and national regulations or specific requirements or risks that apply to the work site.
Care and alertness
At all times when working with the machine, take great care and be aware of any hazards.
The machine operator must be thoroughly rested and must never operate the machine under the influence of alcohol,
medicine or other drugs.
Clothing
Suitable clothing for safe handling should be worn.
Use a hard hat, safety glasses, protective shoes and gloves and an approved respirator (dust mask) or other protective
articles when required.
Regulations and lows
Obey all laws, work site and local regulations which affect you and your equipment.
Communications
Bad communications can cause accidents. Keep persons around you informed of what you will be doing. If you will be
working with other persons make sure they understand any signals you will be doing.
Work sites can be noisy. Do not rely only on spoken commands. See the signalling diagram in the Service Manual.
Hydraulic fluid
Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leak.
Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the
cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin seek medical help immediately.
Equipment condition
Defective equipment can injure you and others. Do not operate equipment which is defective or has missing parts.
Make sure the maintenance procedures in the Service Manual and this appendix are completed before using the product.
Make sure that all clamps, guards and heat shields are installed correctly. This will help to prevent vibration, rubbing against
other parts and excessive heat.
Repairs and maintenance
Do not try to do repairs or any other maintenance work you do not understand.
Modifications
Adjustment or modifications to the equipment by unauthorized persons will invalidate any warranty given. If any problem
with the equipment arises, which cannot be rectified by the instructions in the appendix, please contact a workshop
authorized by Volvo CE.
Work site
Work sites can be hazardous. Inspect the site before working on it. Check for potholes, weak ground, hidden rocks etc.
The machine operator must be in charge of the working area of the machine.
NOTE!
Prevent persons from staying in the risk zone. There can be chips from woods or optional equipments. In this cases, operator
should give more consideration and other persons never enter in the risk zone.

Cautions in maintenance
When working in a dusty circumstance, check the following,

 Check often the air cleaner clogging control lamp. Clean the air cleaner element often even before the control lamp
lights.
 Clean often the radiator and oil cooler to prevent it from being clogged.
 Clean the electronic parts, especially start motor and alternator to protect from dust.
 Thank you for your purchase.
Have a nice day.

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