Service Information

Document Title: Function Group: Information Type: Date:

Safety concerns everybody! 191 Service Information 2014/5/5 0
Profile:
EXC, EW180B [GB]

Safety concerns everybody!

Always follow the instructions in the machine's operator's manual.
The operator's manual should always be kept in the cab for easy reference.
We have spent many hours engineering and producing a machine with a high level of safety and efficiency. All this time may
be wasted if an individual who is about to perform service on any of our machines does not read through the safety
instructions or does not follow them: for example, does not replace guards, climbs on slippery machine parts instead of
using a ladder, grabs on to hoses instead of the provided handles or uses the wrong tools for the job.
Always use genuine (intended and adapted) spare parts to maintain safe and efficient machine function.
Machines seldom cause accidents. Instead, people do.
A safety-conscious person and a well-maintained machine constitute a safe, efficient and profitable combination.
Any person who does not follow the safety instructions and who ignores the warnings in this manual must make
sure that their work method is safe. Otherwise, there is a great risk of serious accidents and injuries, perhaps even
fatalities.

WARNING
WARNING SYMBOL

This symbol is shown at various points throughout the manual. The appearance of it means "Warning, stay alert! Your safety
is involved!"
Get to know the capacities and limitations of your machine!
 Service Information

Document Title: Function Group: Information Type: Date:

CE marking and declaration 191 Service Information 2014/5/5 0
of conformity
Profile:
EXC, EW180B [GB]

CE marking and declaration of conformity

(Only applies to machines marketed within the EU/EEA).
This machine is CE-marked. This means that, when delivered, the machine meets the applicable "Essential Health and Safety
Requirements", which are given in the EU Machine Safety Directive. If changes are made that affect the safety of the
machine, the person making the changes is responsible for the same.
As proof that the requirements are met an EU Declaration of Conformity, issued by Volvo Construction Equipment , is
supplied with each separate 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.
If the machine is used for other purposes or with other attachments than indicated in this instruction, safety must be
maintained at all times and in each separate case. The person carrying out such action is also responsible for the action
which, in some cases, may require a new CE-marking and the issue of a new EU Declaration of Conformity.
EU's EMC Directive
In some cases, the machine's electronic equipment may cause interference with other electronic equipment or may itself
may be adversely affected by external electromagnetic interference, which may result in safety risks.
The EU EMC directive on "Electromagnetic conformity" provides a general description of what requirements can be made on
the machine from a safety perspective, where limit values have been determined in international standards.
A machine or device that meets the requirements should be CE-marked. Our machines have been specifically tested for
electromagnetic interference. The machine's CE-marking and the declaration of conformity also include the EMC directive.
If other electronic equipment is installed on this machine, the equipment must be CE-marked and tested on the machine
with regards to electromagnetic interference.
Unauthorized modifications of the cab
The cab is tested and approved according to the FOPS standard, if equipped with roof window grating, according to ISO
3449, SAE J231.
All planned modifications must be reviewed in advance by our engineering department in order to determine if the
modification can be performed without affecting the certification.
It's important that all employees at your company, including the management, is aware of these rules governing ROPS.
If someone in your company discovers that a certain machine has been modified in a way that is not approved, your
company must inform the customer and the manufacturer in writing about the machine in question as well as in
which way it has been altered.
NOTE!
Modifications or removal of material which affects sound, for example, noise-insulating, noise-dampening or noise-
absorbing materials, are not allowed. Also, it is not permitted to make openings/holes in the cab or engine compartment as
this may increase the noise level in the cab.
 Service Information

Document Title: Function Group: Information Type: Date:

Environment 191 Service Information 2014/5/5 0
Profile:
EXC, EW180B [GB]

Environment
Today, our global environment is exposed to great stress due to the increasing industrialization of the world. Nature, animals
and humans all over the world are exposed daily to great risks in connection with handling of various chemicals.
At this time, there are no oils, coolants, etc. available on the market which are completely unharmful. Therefore, all who
operate, perform service on or repair vehicles must use the assistive devices and methods that are necessary to perform
their work in an environmentally friendly manner. Follow the local governing regulations regarding recycling.
If you also follow the simple rules below, you will contribute to caring for our environment:
Recycling

 Contribute to careful use of natural resources by depositing discarded materials with companies that specialize in
recycling or incineration.

Batteries, etc.

 Components such as batteries, electronics, plastics and other material that may be environmentally hazardous
waste may not simply be discarded just anywhere. Such waste should be handled in an environmentally sound
manner. Follow the national governing legislation applicable to environmentally hazardous waste.

Environmentally hazardous fluids

 Environmentally hazardous fluids freely released into the environment can cause environmental damage and may
also cause fires. When draining/emptying oils or fuel, take appropriate actions to avoid unnecessary spills.
 Waste oil/fluids must always be taken care of by an authorized company.
 Watch for leaks of oil and other fluids! Repair/seal leaks immediately!

Filters

 Thoroughly drain all fluids from used filters before discarding them as waste. Follow the local regulations applicable
to discarded filters.

Air conditioning

 The refrigerant in the air conditioning for the cab adds to the greenhouse effect and must therefore never be
intentionally released into the open air. Special training is required for all service work on the air conditioning unit.
Many countries also require certification by an authority for such work. See also “Safety when working with
refrigerant”.

Operating in a contaminated area

 Used cab and engine air filters from machines operating in environments with asbestos or other hazardous dust
must be placed in the tight-sealing plastic bag supplied with the new filter before being deposited in the
designated waste area.
 The machine must be equipped for operation in contaminated areas (polluted environment or areas hazardous to
health) before work is started. In addition, special local regulations apply for such operation and when servicing
such a machine.
 Service Information

Document Title: Function Group: Information Type: Date:

Safety rules for service 191 Service Information 2014/5/5 0
Profile:
EXC, EW180B [GB]

Safety rules for service

This section is intended to serve as a guide for the correct and safe handling of the machine. Study these instructions and
the Operator's Manual carefully before using or servicing the machine. Keep the Operator's Manual in the cab for easy
reference.
We have spent many working hours designing and manufacturing a machine with a high level of safety and efficiency. All
this time and work may be wasted if an individual who is about to service the machines does not through the safety
instructions, or does not bother to follow tem; for example, does not replace protective covers, climbs on the machine
instead of using a ladder, grabs a hold of hoses instead of using handles or uses the wrong tools for the job.
Machines seldom cause accidents, instead accidents are caused by incorrect handling of machines.
Anyone who fails to follow the safety instructions and fails to observe the warnings given in this manual must take
responsibility for making sure that their work method is safe. Otherwise, there is a great risk of serious accidents or injuries,
perhaps even fatal accidents.

Volvo Construction Equipment Group disclaims all warranty liability if:

 The machine has not been used correctly, or has not been maintained according to what is prescribed in the
Operator's Manual.
 Specified service and prescribed inspections have not been conducted at the specified intervals.
 Lubrication recommendations in the manual have not been followed.
 Seals have been broken by unauthorized persons.
 Modifications and repairs have not been performed as prescribed by Volvo.
 Service and repair work has not been performed according to methods prescribed by Volvo.
 Non-genuine spare parts/accessories from Volvo, or parts/accessories that do not meet Volvo's requirements
have been used.

WARNING
This warning symbol means risk of fatalities or personal injury if the instructions are not followed.

Know the capacity and limitations of the machine!

The rules in the Operator's Manual apply to all operation of the machine.
Therefore, carefully read and consider what has to be done before operating the machine.

Figure 1
Read the Operator's Manual
Read the instructions in the Service Manual and in the Operator's Manual, as well as the signs on the machine and about
their meaning which are described in the Operator's Manual, before starting to work on the machine. Each of these contains
important information for handling and service.

 Always use a hard hat, safety glasses, work gloves and work shoes and other protective items when the work
requires it. Before starting the diesel engine indoors - make sure that adequate ventilation is provided.

Figure 2
Protective equipment
 Perform all recommended checks.
 Perform a control light test before the diesel engine is started by turning the ignition key to position 1, see the
Operator's Manual. If the alarm light flashes, the machine must not be started until the problem has been
resolved.
 The machine must under no circumstances be operated by persons under the influence of alcohol, medicine or
other drugs.
 When climbing up or down from the machine, always face the machine and use the available access routes. Always
use both hands and one foot, or both feet and one hand. Do not jump!
 No work must be performed on the machine until you have sufficient knowledge of the machine to do the work.
 Service not performed correctly can be dangerous. Make sure that you have sufficient knowledge and the right
information, tools and equipment to perform service work correctly.
 Always stop the diesel engine before performing service unless the instructions from Volvo indicate otherwise.
 When changing oil in the diesel engine, hydraulic system or transmission; beware that the oil may be hot and can
cause severe burn injuries.
 Make sure that there is no oil, dirt or ice on stepping surfaces or handrails.
 Never wear jewellery or other items that can get caught in machine parts when working on the machine.
 Make sure that the machine cannot start to roll.
 During service work, the digging equipment shall be lowered with the bucket resting on solid ground, unless
Volvo's instructions indicate otherwise.
 If the undercarriage is raised with the digging equipment, the raised part should first be supported securely before
anyone enters the dangerous area.
 Do not stand under raised digging equipment.
 Do not drive out the digging equipment without first supporting underneath or connecting approved and
adequately dimensioned lifting equipment.
 When lifting or supporting machine parts - use equipment with a capacity that is intended at least for the load
caused by the part in question.
 All lifting devices such as slings, straps and ratchet blocks, etc. must comply with the national governing regulations
for lifting devices.
 Stop the diesel engine and remove the ignition key before opening service doors and covers. Make sure that no
tools or other objects that can cause damage are forgotten in the machine.
 Make sure that all covers and doors on the machine are closed before the diesel engine is started and the machine
is operated.
 Open pressurized tanks/vessels carefully.
 Be careful during leak detection. An invisible oil jet from a leak can easily penetrate the skin and cause severe tissue
damage. If an injury occurs - seek immediate medical attention.
 Never adjust a pressure limiting valve to a higher pressure than that recommended by the manufacturer.
 Keep out of the machine's work area when it is working.

Before leaving the operator's seat to perform service with the engine running, take the following precautions:

1. Lower the digging equipment with the bucket resting on solid ground.
2. Lower the safety bar (no servo pressure to control levers and pedals).
3. Check that there's no servo pressure to the left control lever by trying to activate the dipper arm or slew movement.
 This must not result in a drop of the diesel engine speed. If the speed drops, stop the engine before leaving the
cab.
4. Make sure that the machine cannot start to move.
5. Make sure that no unauthorized persons can gain access to the operator's cab.

NOTE!
The diesel engine must be stopped and the ignition key must be removed if the machine is to be left unattended.
 Service Information

Document Title: Function Group: Information Type: Date:

Fire prevention measures 191 Service Information 2014/5/5 0
Profile:
EXC, EW180B [GB]

Fire prevention measures

General

 There is always a risk of fire. Find out which type of fire extinguisher you should use, where it's located and learn
how to use it.
 Fire-fighting equipment installed in or on the machine should be kept in working order. These shall be considered a
complement to the operator's own actions in case of a fire.
The equipment may not be considered a substitute for the operator's own fire-fighting efforts.
 A fire extinguisher that is installed on the machine or is used when working must meet certain standards. See the
machine's Operator's Manual.
 At the slightest sign of fire, considering your own safety and if the situation allows it, take the following actions:

 drive the machine away from the fire-hazardous area.

 lower the lift arms to the bottom position so that the attachment rests on the ground.
 stop the engine by turning the ignition key to position 0.
 leave the cab.
 turn off the electric power with the battery disconnector.
 start fighting the fire and call the fire department if necessary.

Figure 1
Smoking or open flames are absolutely forbidden during refuelling and when the diesel fuel is in contact
with the air.
 Smoking or open flames are absolutely forbidden near the machine during refuelling or when the fuel system is
open to contact with the air.
 Diesel fuel is flammable and may not be used as a cleaning agent. Use an approved solvent with cleaning.
 Keep in mind that certain solvents may cause skin rashes and may be a fire hazard. Avoid inhaling vapours from
solvents.
 Engine starting gases, etc. may constitute a fire hazard. Store these in cool and well ventilated spaces.
Remember that such starting gases, etc. may not be used in combination with electric preheating of the induction
air.

Cleanliness

 Cleanliness is of decisive importance for reliability of the machine's systems. Keep the service work area clean. Oil
and water make floors and footsteps slippery, and are also dangerous in combination with electrical systems and
electric power tools. Oily or greasy clothes are a serious fire hazard.
 Check daily that the machine and equipment, i.e. belly plates, are free from dirt and oil. This reduces the fire hazard
 and makes it easier to detect defective components and loose parts.

NOTICE
If a high-pressure washer is used when cleaning, work carefully since damage may be caused to electrical
components and insulation of the electrical cabling even at relatively moderate water pressure and
temperature. Protect electrical cabling in a suitable manner.

 Keep the machine extra clean when operating in flammable environments such as saw mills, garbage dumps,
landfill sites and similar. In such environments, the machine should be fitted with special equipment (i.e. muffler
guard, radiator grating, heavy-duty cyclone pre-cleaner, etc.) that reduce the risk of accumulation and spontaneous
combustion of flammable materials.

Electrical system

 Check electric wiring for chafing damage. Also make sure that the wiring cannot be subjected to chafing. This
applies especially to the red unfused leads.
For example, leads between:

 Batteries
 Batteries–starter motor
 Alternator–starter motor
 Electric cable to engine's preheating coil.

 In cases where unfused electric leads are disconnected, it is important that they are routed and clamped in such a
way that there is no risk of chafing. Unfused leads must not rest against oil or fuel hoses.
 When installing any optional equipment, make sure that all electric wiring is connected across fuses and that it is
routed and clamped in such a way that there is no risk of chafing.

Fuel, hydraulic and brake system

 Check that there's no chafing on fuel, hydraulic and brake hoses.

Welding and grinding work

 Welding and grinding may only be performed on a clean area and where there are no flammable liquids, i.e. tanks,
hydraulic pipes and similar.
Be extra careful when welding and grinding near such places.

NOTICE
A fire extinguisher should be easily accessible during all welding work.

 Never weld on a painted surface without first removing the paint. In addition to the health-hazardous gases,
welding on a painted surface results in a technically inferior weld that may lead to future failures and subsequent
accidents.

Actions after a fire, see “Checklist after a fire or exposure to other extreme heat”.
 Service Information

Document Title: Function Group: Information Type: Date:

Health hazards with paint, 191 Service Information 2014/5/5 0
plastics and rubber
Profile:
EXC, EW180B [GB]

Health hazards with paint, plastics and rubber

Work on painted surfaces
No welding or torch-cutting is allowed on painted surfaces.
All paint is broken down when heated and forms a wide variety of substances that may be irritating and very hazardous to
health after prolonged or repeated exposure.
The following safety instructions must be followed:

 Remove all paint by sand-blasting at least 10 cm (4 in.) around the welding or cutting point (use suitable breathing
protection).
If the work area cannot be sand-blasted, remove the paint in another way, for example, with a paint remover
(solvent).
NOTE!
When using paint removers (solvents), use an air extractor, breathing protection and protective gloves.

 High-speed grinding machines and grinding discs also heat the paint and must only be used if there's an air
extractor on the grinding machine. Use breathing protection as well.

Rubber and plastics

WARNING
When heated, rubber and plastics can give off substances that are hazardous to personal health and the
environment.

The following safety instructions must be followed:

 Do not weld or cut near polymer materials (rubber and plastics) without first protecting them from the heat.
 Never burn polymer materials when scrapping them.
 Be careful when handling machines that have been exposed to fire or other intense heat. Also, refer to “Checklist
after a fire or other heat exposure”.
 Always use protective gloves, protective glasses/goggles and breathing protection.

Fluor rubber

WARNING
Risk of serious corrosive injuries!

WARNING
When hydrogen fluoride rubber is heated, there is a risk of hydrogen fluoride gas build-up already at approx. 320 °C
(610 °F). When inhaled, the gas is extremely corrosive to respiratory tracts.

Certain seals designed to withstand high operating temperatures (for example, in engines, transmissions, axles, brakes,
hydraulic motors and pumps) may be made of fluor rubber, which will form hydrogen fluoride and hydrofluoric acid when
exposed to intense heat.
This acid is highly acidic and corrosive. It cannot be rinsed or washed off the skin, and causes very severe burn and corrosive
injuries that take a very long time to heal. As a rule, injured tissue must be removed surgically.
The acid may remain on machine parts for a very long time (several years) after a fire.
NOTE!
It may take several hours after contact with the acid before any symptoms become apparent.
If swelling, redness or burning sensations appear and contact with heated fluor rubber is suspected, contact a physician
immediately. If a machine or a component for a machine has been exposed to fire or other intense heat, it shall be handled
by specially trained personnel.
Thick protective neoprene rubber gloves and tight-fitting protective goggles must be used during all handling of machines
after a fire.

WARNING
Burning of painted parts, plastic or rubber parts constitutes a health hazard.

Decontamination
The area around a heated part that is suspected of being made of fluor rubber must be decontaminated by thorough and
ample washing with lime water (a solution or suspension of calcium hydroxide, that is, slaked lime in water). After the work
has been completed, wash the protective gloves in lime water and discard them.

The safety instructions in the following checklist must be followed under all circumstances if a machine has been exposed to
a fire or other intense heat:
 Service Information

Document Title: Function Group: Information Type: Date:

Checklist after a fire or heat 191 Service Information 2014/5/5 0
exposure
Profile:
EXC, EW180B [GB]

Checklist after a fire or heat exposure

 As a precaution, seal rings (O-rings or axle/shaft seals) should always be handled as if they were made of fluor
rubber, see also section “Fluor rubber”.

WARNING
Avoid splashing when washing a machine damaged by fire. For this reason, never use high-pressure washing
equipment.

 Never touch burned components or parts with your bare hands when there is a risk that you may be exposed to
contact with melted polymers. First, wash thoroughly with plenty of lime water (a solution or a suspension of
calcium hydroxide, i.e. slaked lime).
Use thick, protective gloves made of rubber and wear goggles that are certain to protect your eyes.
 Seek medical attention if your skin may have come in contact with burnt fluor rubber. The skin should be treated
with Hydrofluoric Acid Burn Jelly or similar.
Symptoms may not appear until several hours after contact with burnt fluor rubber.
 Discard protective gloves, rags and other items that may have come into contact with burnt fluor rubber.
 Service Information

Document Title: Function Group: Information Type: Date:

Safety when lifting and 191 Service Information 2014/5/5 0
supporting the machine
Profile:
EXC, EW180B [GB]

Safety when lifting and supporting the machine

 When lifting or supporting machine parts, use equipment with a lifting capacity that equals at least the weight of
the part in question.
 All lifting devices, such as straps, slings, ratchet blocks, must comply with governing national regulations for lifting
devices. We will not accept any responsibility if any lifting devices, tools or work methods are used other than those
described in this publication.
 If a jack is to be used, make sure that the ground or floor is even and is sufficiently firm or strong to support the
expected load.
 Prevent the machine from rolling by applying the parking brake and placing suitable wedges on both sides of the
wheels which are not to be raised off the ground.
 Always use a jack with sufficient lifting capacity and position the jack according to instructions for the work that is
to be done.
Make sure that the jack is correctly positioned and is at the correct angle to the lifting point on the machine.
 Take care to position supports under the machine in a safe way.
 Service Information

Document Title: Function Group: Information Type: Date:

Safety when handling oils 191 Service Information 2014/5/5 0
and fuel
Profile:
EXC, EW180B [GB]

Safety when handling oils and fuel

 When changing oil in the engine, hydraulic system or transmission: Remember that the oil may be hot and can
cause burns.
 Engine, hydraulic and transmission oils as well as diesel fuel have a corrosive effect on mucous membranes, for
example, in eyes and throat and on skin. Therefore, take special care to keep such oils away from these sensitive
body parts.
 When emptying/draining oils or fuel, steps must be taken to avoid unnecessary spills. In places where a container
for collecting the liquid cannot be used, use a pump or connect a hose to ensure safe handling. Oil released or
spilled on the ground will harm the environment and could also cause a fire.
Waste oil/fluids must always be taken care of by a company authorized for such work.
 Remember the fire hazard!
 Service Information

Document Title: Function Group: Information Type: Date:

Safety when working with 191 Service Information 2014/5/5 0
batteries
Profile:
EXC, EW180B [GB]

Safety when working with batteries

Figure 1
Battery charging

Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. In addition, batteries
give off hydrogen gas when they are loaded (supplying electricity) or being charged.
Together with the oxygen in the air, hydrogen gas forms a very explosive mixture.
This combination, corrosive acid and explosive gas, means a high risk of accidents during all work with batteries used in
vehicles.
Therefore, it is very important that you take great care and follow the rules below when you are working with batteries.
Follow these instructions when charging batteries:

 Batteries give off explosive gases. Never smoke near batteries.

Figure 2
Do not smoke near batteries!
 Begin by disconnecting the ground lead when removing a battery. In order to reduce the risk of sparks that can
cause fire, always connect the ground lead last when fitting a battery.
 Never tilt a battery to any great extent in any direction. Battery electrolyte may leak out.
 Do not connect a discharged battery in series with a fully charged battery. The current surge can cause the batteries
to explode.
 Do not allow metal objects (such as tools, rings, wristwatches) to come in contact with battery terminals. Risk of fire
and personal injury.
 Always cover the top of the battery with a rag or other non-conducting material when you work close to the
batteries.
 Always refit the terminal caps on the batteries.
 Batteries contain substances dangerous to health and the environment. Discarded batteries must therefore be
 disposed of according to local and/or national regulations.

Charging batteries
Explosion hazard
When a battery is being charged, an explosive mixture of oxygen and hydrogen is formed. A short circuit, open flame or
spark near the battery can cause a powerful explosion. Always turn off the charging current before disconnecting the
charging clamps. Ventilate well, especially if the battery is charged in a confined space.
Corrosive sulphuric acid
The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately.
Wash with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately
with plenty of water and seek immediate medical attention.
 Service Information

Document Title: Function Group: Information Type: Date:

Safety when working with 191 Service Information 2014/5/5 0
air conditioning refrigerant
Profile:
EXC, EW180B [GB]

Safety when working with air conditioning refrigerant

General
Special competence is required for service work and more involved work which requires opening of the air conditioning
system.
Many countries also require special training and official authority approval. Find out about governing regulations for your
country and follow them!
Refrigerant R134a is used in the air conditioning unit, see also Section 8.
The type of refrigerant and the amount to be filled are shown on the type plate.
NOTE!
R134a adds to the greenhouse effect and should never be intentionally released into the open air.

Personal protective equipment

Figure 1
Protective goggles and gloves should be worn when there is a risk of contact with refrigerant.

When there is a risk of skin contact with refrigerant, use:

Tight-fitting protective goggles and protective gloves, and protect other bare skin (risk of frostbite).
Risks

WARNING
The gases have no smell and may cause serious damage to the lungs already at low concentrations.

Refrigerant R134a may, if incorrectly handled, cause serious personal injuries as well as damage to the environment.
Therefore, great care must be taken in all work with air conditioning units! The rules given below may be a great help to
avoid injuries to all who come into contact with refrigerants.

 In liquid form the refrigerant may cause:

Frostbite.
 When in the form of a gas and at low concentration, the gas may:
Have some effect, especially on the nervous system.
 When in the form of a gas and at high concentration it may:
Have an anaesthetic effect.
 The air conditioning unit is pressurized and the refrigerant can unintentionally leak out. Never disconnect hoses or
remove the filler plug on the compressor.
If you suspect a leak, certified and trained personnel at a licensed workshop should be contacted for
troubleshooting and repair.
 The refrigerant gas is heavier than air and will sink to the floor. Therefore, make sure that any escaped gas is
 ventilated before work is started in any low-lying areas.

Smoking, welding or other open flames are not allowed in a workplace where work with refrigerant is in progress. The
refrigerant gas will then burn and form a toxic gas which is very dangerous to inhale. The gases formed when heating the
refrigerant have a pungent smell at high concentrations.
The symptoms may appear several hours (perhaps up to 24 hours) after exposure to the gases.
Action in case of accidents
Inhalation
If escape of gas is suspected, leave the area, try to find fresh air and move affected persons out of the danger area. Small
amounts of vapour from refrigerant R134a may have some effect especially on the nervous system. In large amounts, the
gas may have an anaesthetic effect. In serious cases, seek immediate medical attention.
Skin contact
In case of frostbite, flush with lukewarm water for a long time. If a large amount of liquid refrigerant comes into contact with
unprotected skin, the injured area should be carefully warmed with lukewarm water or warm clothes.
Seek medical attention immediately if symptoms persist.
Splash in eyes
Flush with warm water until the irritation ceases. Seek immediate medical attention.
 Service Information

Document Title: Function Group: Information Type: Date:

Some simple rules 191 Service Information 2014/5/5 0
regarding tyre handling
Profile:
EXC, EW180B [GB]

Some simple rules regarding tyre handling

WARNING
Tires installed on a split rim may explode and cause very severe injuries.

Inflating

 Never stand to the side of the tyre while inflating which is fitted on a split rim. Use a self-locking outlet with a hose
long enough to allow you to stand outside of the hazard zone during inflation, see the illustration.
 Make sure that the hazard zone is clear when the tyre is inflated.
 The machine must be unladen when checking tyre pressure.
 Spare tyres should only be filled with enough air to allow the rim parts to be held in place.
 Secure a loose wheel with an inflation cage, cable or chains before inflating. Before removing the inflation cage,
check that the tyre is properly fitted to the rim. Adjustments should be made before the wheel is inflated.
 Do not attempt to adjust side rings or lock rings when the tyre is inflated.
 Tyres used at less than 80% of normal pressure and rims or tyres suspected of being damaged should not be
inflated with the wheel attached to the machine.

Fitting of tyres and rims

 Handling of tyres should be performed by authorised personnel only.

 The tyre should be deflated before removal from the machine.
 Never install a tyre on a rim that has not been recommended for that tyre.
 Never assemble rim parts for different dimensions or use damaged or faulty parts.
 Exercise caution if using reconditioned wheel details. Welding errors, faulty heating or soldering may have
weakened the parts and may cause the detail to break.
 Make sure the lock ring groove in the rim is cleaned from foreign matter and rust before fitting the lock ring.
 Use a lubricant recommended by the tyre manufacturer when fitting onto the rim.

Repairing tyres and rims

 Never cut, weld nor heat the wheel parts in any manner.
 Exercise caution when using bead breakers and hydraulic jacks. Remain outside the hazard zone when removing
foreign objects from the tyres. A bead breaker that releases can cause severe personal injury and may result in
death.
 Service Information

Document Title: Function Group: Information Type: Date:

Safety when working with 191 Service Information 2014/5/5 0
hydraulic systems
Profile:
EXC, EW180B [GB]

Safety when working with hydraulic systems

Setting pressure and checking for leaks

WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

Make sure that nobody can operate the machine when setting pressure or checking for leaks.
The following safety rules must be followed:

 Control levers and pedals should be activated slowly to avoid sudden and unexpected machine movements as well
as abnormally high pressures.
 When the intended pressure has been reached, stop the pressure-increase immediately.
 Only make changes in small increments when setting pressure adjusting devices if their sensitivity is unknown. This
is especially important for the servo circuit, where the pressure is obtained directly after start of the diesel engine.
 Check and calibrate pressure checking equipment at regular intervals, and replace damaged components.

Elimination of trapped pressure

WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

The hydraulic system may contain high trapped pressures even if the diesel engine is off. Be extra careful when
working on the system between valves and hydraulic cylinders or between valves and hydraulic motors.
Before working on the hydraulic system, the system should be depressurized as follows:

1. Park the machine on solid ground. The most suitable position for the attachment may vary depending on which
type of bucket or other attachment that the machine is equipped with. It's important that the digging equipment is
positioned in such a way that no pressure can build up in the hydraulic cylinders due to the weight of the digging
equipment and attachment. The bucket cylinder should be in one of the end positions when the attachment is
placed in resting position. Support the attachment if needed. A suitable position for most equipment is service
position C, see 091 Service positions.
2. Stop the diesel engine.
3. Check that the safety bar is raised.
4. Turn the ignition key to position 1.
5. Move the right control lever forward (=boom down) and to the left and right (=bucket in and out) using full
strokes.
6. Move the left control lever back and forth (=dipper arm in and out) and to the left and right (=slew left and right)
using full strokes.
7. Move all pedals back and forth using full strokes.

NOTE!
It's important that the pressure is released for all movements immediately after stopping the diesel engine. If the
accumulated servo pressure should be insufficient, charge the accumulator by starting the diesel engine and
repeating steps 3 - 7. This is to ensure that the hydraulic system has been depressurized and is pressureless.

Elimination of pressure in accumulator for servo circuit

The machine is equipped with an accumulator for servo pressure. Before working on the hydraulic system, the servo pressure
should be eliminated as follows:
 1. Park the machine in any service position, see 091 Service positions.
2. Stop the diesel engine.
3. Turn the ignition key to position 1.
4. Check that the safety bar is raised.
5. Move one of the levers at least 15 times using full strokes.
6. Turn the ignition key to position 0.
7. Lower the safety bar.

Elimination of pressure in accumulators for brake circuits

The machine is equipped with two accumulators for the brake circuits (one for each circuit). Before working on the brake
system, the brake pressure should be eliminated as follows:

1. Park the machine in any service position, see 091 Service positions.
2. Stop the diesel engine.
3. Make sure that the brake pedal's catch is released.
4. Press down the brake pedal completely and hold down for at least 3 seconds in each end position - repeat at least
20 times.
5. Lower the safety bar.

Elimination of pressure in accumulator for parking brake

The machine is equipped with an accumulator for the parking brake. It's a negative disc brake mounted on the transmission.
The brake is applied by spring force and released hydraulically. Before working on the hydraulic circuit for the parking brake,
the accumulator pressure should be eliminated as follows:

1. Park the machine in any service position, see 091 Service positions.
2. Stop the diesel engine.
3. Turn the ignition key to position 1.
4. Check that the safety bar is raised.
5. Activate high travel speed (rabbit).
6. Wait for at least 7 seconds.
7. Activate low travel speed (turtle).
8. Wait for at least 7 seconds.
9. Repeat steps 5 - 8 another two times.
10. Turn the ignition key to position 0.
11. Lower the safety bar.
 Many thanks for your purchase.
Happy every day.

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