VOLVO EXCAVATORS

PERFORMANCE MANUAL
Contents

Introduction 4

Cycle time estimation 5

Production estimation 8

Cost calculation 10

Appendix-Material property 13

Appendix-Bucket capacity rating 17

Appendix-Digging force calculation 18

3
 Introduction
Preface
This manual is intended as an aid for planners,
estimators and machine owners in forecasting the
cycle time, production and cost for performing bulk
movement of materials with Volvo excavators.
The results gained by using the manual can be
regarded as fully reliable, provided that the nature of
the ground and other factors are correctly evaluated
and that the operator is of normal competence.
4
Since working conditions vary so widely between
different operating sites, it has not been possible to
take into account all the factors affecting performance
and cost; therefore, we cannot accept responsibility for
any differences that may arise between calculations
and actual results.
To make proper use of this manual, a certain
amount of experience in the planning of bulk movement
of materials, time studies and technical terms occurring
in the business are necessary.
Metric units of measure are in normal type, followed by
U.S. units of measure in bold type face.
Cycle time estimation

Cycle time estimation

The excavator cycle time is the total time required
to fill a bucket, swing loaded, dump bucket and
swing empty to the digging position. The cycle time
is mainly dependent on the excavation class
(material to be moved) and the loading position to
the hauling equipment.

Excavation Classes
Clearly, the performance of an excavator will
depend on the kinds of material to be excavated.
The harder or tougher the material, the longer it
takes to fill the bucket and the longer it takes to
perform the cycle. Categorizing different ground
conditions is not easy, and everyone will have their
own opinions on the matter. Nevertheless, it is
useful to communicate the degree of difficulty in
filling the bucket. Excavation classes are therefore
a way of categorizing ground conditions (see table
below). Problems such as underground services,
trench support systems and men working close to
the bucket can slow the bucket filling operation
regardless of the nature of the excavated material,
and therefore affect cycle times. The following table
may be used as a guide.

Excavation Classes Examples of Materials

Class 1: Easy digging Unpacked earth, sand-gravel, ditch cleaning
Class 2: Medium digging Packed earth, tough dry clay, soil with less 25% rock content
Class 3: Medium to hard digging Hard packed soil with up to 50% rock content
Class 4: Hard digging Shot rock or tough soil with up to 75% rock content

Loading position
Can be represented by 4 positions.
- Hauler is below the excavator and swings 45° to load hauler
- Hauler is below the excavator and swings 90° to load hauler
- Hauler and excavator are on the same level and swing 90° to load hauler
- Hauler and excavator are on the same level and swing 180° to load hauler

5
 Cycle time estimation

Assumptions
- The power mode set: G mode ~ H mode
- Digging depth or the bench height: 40% ~ 70% of max. digging depth
- A competent operator
- No obstacles interfering with loading of the hauler

Cycle time with hauler below the excavator and swing angle at 45 degrees unit: sec
Excavation material class
Model
1 2 3 4
EC140B 6.9 ~ 9.4 7.9 ~ 10.4 9.4 ~ 11.9 10.4 ~ 13.3
EC160B 7.7 ~ 10.2 8.7 ~ 11.2 10.2 ~ 13.0 11.4 ~ 14.7
EC180B 7.7 ~ 10.2 8.7 ~ 11.2 10.2 ~ 13.0 11.4 ~ 14.7
EC210B 9.5 ~ 12.0 10.5 ~ 13.0 12.0 ~ 15.5 13.5 ~ 17.5
EC240B 9.5 ~ 12.5 11.0 ~ 13.5 12.5 ~ 16.0 14.0 ~ 18.0
EC290B 9.5 ~ 12.5 11.0 ~ 14.0 12.5 ~ 16.0 14.0 ~ 18.0
EC330B 9.7 ~ 12.6 11.2 ~ 14.6 12.6 ~ 16.0 14.1 ~ 18.0
EC360B 9.7 ~ 12.6 11.2 ~ 14.6 12.6 ~ 16.0 14.1 ~ 18.0
EC460B 10.2 ~ 13.5 11.6 ~ 14.9 13.0 ~ 17.2 14.9 ~ 19.6

Cycle time with hauler below the excavator and swing angle at 90 degrees unit: sec
Excavation material class
Model
1 2 3 4
EC140B 7.9 ~ 10.4 8.9 ~ 11.4 9.9 ~ 12.9 11.4 ~ 14.3
EC160B 8.6 ~ 11.4 9.7 ~ 12.5 10.7 ~ 14.0 12.4 ~ 15.8
EC180B 8.6 ~ 11.4 9.7 ~ 12.5 10.7 ~ 14.0 12.4 ~ 15.8
EC210B 10.0 ~ 13.5 11.5 ~ 15.0 12.5 ~ 16.5 14.5 ~ 19.0
EC240B 11.5 ~ 14.5 13.0 ~ 16.0 14.0 ~ 18.0 16.0 ~ 20.0
EC290B 12.0 ~ 15.0 13.5 ~ 16.5 14.0 ~ 18.0 16.0 ~ 20.5
EC330B 12.1 ~ 15.5 13.6 ~ 17.5 15.1 ~ 18.9 17.0 ~ 21.9
EC360B 12.1 ~ 15.5 13.6 ~ 17.5 15.1 ~ 18.9 17.0 ~ 21.9
EC460B 13.0 ~ 16.8 14.9 ~ 18.6 16.3 ~ 20.5 18.6 ~ 23.3

6
Cycle time estimation

Cycle time with hauler and excavator on same level and swing angle at 90 degrees unit: sec
Excavation material class
Model
1 2 3 4
EC140B 8.9 ~ 12.4 9.4 ~ 13.3 9.9 ~ 13.8 11.4 ~ 15.8
EC160B 9.7 ~ 13.4 10.2 ~ 14.4 10.9 ~ 14.9 12.4 ~ 17.0
EC180B 9.7 ~ 13.4 10.2 ~ 14.4 10.9 ~ 14.9 12.4 ~ 17.0
EC210B 11.5 ~ 15.5 12.0 ~ 16.5 13.0 ~ 17.0 14.5 ~ 19.5
EC240B 12.0 ~ 15.5 12.5 ~ 16.5 13.5 ~ 17.0 15.5 ~ 19.5
EC290B 12.5 ~ 16.0 13.0 ~ 17.0 14.0 ~ 17.5 16.0 ~ 20.0
EC330B 13.1 ~ 17.5 14.1 ~ 18.5 14.6 ~ 18.9 17.0 ~ 21.9
EC360B 13.1 ~ 17.5 14.1 ~ 18.5 14.6 ~ 18.9 17.0 ~ 21.9
EC460B 14.4 ~ 17.7 14.9 ~ 18.6 15.8 ~ 19.6 18.2 ~ 22.3

Cycle time with hauler and excavator on same level and swing angle at 180 degrees unit: sec
Excavation material class
Model
1 2 3 4
EC140B 10.9 ~ 14.3 11.4 ~ 15.3 12.4 ~ 15.8 13.3 ~ 17.3
EC160B 11.9 ~ 15.7 12.4 ~ 16.7 13.4 ~ 17.3 14.5 ~ 19.0
EC180B 11.9 ~ 15.7 12.4 ~ 16.7 13.4 ~ 17.3 14.5 ~ 19.0
EC210B 14.0 ~ 18.5 14.5 ~ 19.5 15.5 ~ 20.5 17.0 ~ 22.5
EC240B 15.0 ~ 19.0 15.5 ~ 20.0 16.5 ~ 21.5 18.0 ~ 23.5
EC290B 15.5 ~ 19.5 16.0 ~ 20.5 17.0 ~ 22.0 18.5 ~ 24.0
EC330B 16.0 ~ 20.4 17.0 ~ 21.4 18.0 ~ 22.3 19.4 ~ 24.8
EC360B 16.0 ~ 20.4 17.0 ~ 21.4 18.0 ~ 22.3 19.4 ~ 24.8
EC460B 15.8 ~ 20.9 16.8 ~ 21.9 17.7 ~ 23.3 19.6 ~ 25.1

7
 Production estimation

Production estimation
The producted volume per hour can be detemined by the following formula.
Hourly production (m3/h) =3.6 x Bucket volume (l) x Bucket fill factor x Job efficiency / Cycle time (sec)
(yd3 /h) =3,600 x Bucket volume (yd3 ) x Bucket fill factor x Job efficiency / Cycle time (sec)

Bucket fill factor

is detemined by the excavation class which was mentioned above.

Excavation Classes Bucket fill factor

Class 1: Easy digging 1.2
Class 2: Medium digging 1.0
Class 3: Medium to hard digging 0.8
Class 4: Hard digging 0.6

Job efficiency
is the actual working time rate per 1 hour.

Work time / hour Efficiency

60 min 1.0
55 min 0.91
50 min 0.83
45 min 0.75
40 min 0.67

Example
How much is the production per hour for EC210B with 920 l, 1.20 yd3 K-Bucket?
Excavation class is 2 and the loading position is above the hauler and 90° swing.

Get the average cycle time from the table: 13.3 sec
Bucket fill factor is 1.0 and assume the actual working time as 50 min. per hour.

The production per hour will be 3.6 x 920 x 1.0 x 0.83 / 13.3 = 207 m3/h
3,600 x 1.20 x 1.0 x 0.83 / 13.3 = 270 yd3 /h

8
Production estimation

Maxmizing production with

an excavator
Right bucket selection _ can take the advan-
tage of the digging forces fully and contributes to
maximizing production that match to soil conditions.
The bigger bucket does not always ensure more
production. Important bucket measurements that Tip radius
affect performance, include the tip radius and the
bucket width. A short tip radius bucket provides
more digging forces than long tip radius buckets,
making it easier to load harder material.
Bucket width is also a critical measurement that
impacts digging forces. Wide buckets are typically
Bucket width
used in easily dug soil, while narrow buckets are
used for harder material. Because the digging
forces are spread over a larger area, there is less
penetration force per width of bucket cutting edge
with a wider bucket. Wider buckets are also more
prone to twisting when an obstacle is encountered,
which can cause some serious damage all the way
up to the arm. Another feature of the bucket which
affect performence is the bucket profile that is
related with the ease of filling the bucket and its
self-cleaning capabilities.

Ideal bench height and truck distance _

Bench height should be about equal to arm length
for stable or consolidated materials. It should be
less for unstable materials. The most useful truck
position is when the inside truck body rail is below
the boom arm hinge pin.

Optimum work zone and swing angle _

The work zone should be limited to 15° either side
of the machine center or about equal to the under-
carriage width for maximum production. Trucks
should be positioned as close as possible to
machine centerline. Two alternatives are shown
here.

Best distance from the edge _ The machine

should be positioned so that the arm is vertical
when the bucket reaches full-load. Digging force is
reduced if the unit is farther back. Undercutting may
occur and time is wasted bringing the arm back out
if it is closer to the edge. Also, the operator should
begin with the boom-up when the bucket is 75% of
the way through the curl cycle. This should be as
the arm nears the vertical position.

9
 Cost calculation

Calculating hourly cost

Hourly cost includes all costs for owning and
operating a machine. In this example, the costs for
management, administration, profit, etc., are not
included.
Costs will vary in different markets and in different
applications.
To make an estimate of hourly cost, the information
below must be collected:

Cost input
Input valves for hourly cost estimation Formula

a. Purchase price price

b. Depreciation time years

c. Residual value price

d. Depreciation cost per year (a - c)/b

e. Interest rate %

f. Interest cost per year e x (a+c)/2

100
g. Machine tax per year

h. Insurance per year

i. Fuel cost per l (US gal)

j. Fuel consumption l/h (US gal) Table

k. Oil cost l/h (US gal)

l. Oil consumption l/h (US gal)

m. Repairs and maintenance per year

n. Operator cost per year

o. Operating time hours per year

10
Cost calculation

Cost calculation

Machine
A. Owning cost per hour Formula

Depreciation d
__
o

Interest f
__
o
g
__
Machine tax o

Insurance h
__
o

Total fixed cost Sum A

B. Operating cost per hour

Fuel ixj

Oil kxl

Repair and maintenance m

__
o

Total of variable cost Sum B

C. Operator cost per hour n

__
o

D Total costs per hour Sum A+B+C

11
 Cost calculation

Fuel consumption
The power mode set: G mode ~ H mode
The hourly fuel consumption is estimated in the
table below using three different working conditions.

unit: liter/h / US gal/h

Working Conditions
Model
Light Medium Heavy
EC140B 6 ~ 7 / 1.5 ~ 1.9 7 ~ 10 / 1.9 ~ 2.6 9 ~ 12 / 2.4 ~ 3.2
EC160B 7 ~ 9 / 1.9 ~ 2.4 9 ~ 12 / 2.4 ~ 3.2 11 ~ 16 / 3.0 ~ 4.1
EC180B 8 ~ 10 / 2.0 ~ 2.5 10 ~ 13 / 2.5 ~ 3.4 12 ~ 16 / 3.2 ~ 4.3
EC210B 10 ~ 13 / 2.6 ~ 3.4 13 ~ 17 / 3.3 ~ 4.4 16 ~ 20 / 4.3 ~ 5.3
EC240B 11 ~ 15 / 3.0 ~ 4.1 14 ~ 19 / 3.7 ~ 5.1 19 ~ 23 / 4.9 ~ 6.2
EC290B 13 ~ 17 / 3.4 ~ 4.5 16 ~ 21 / 4.2 ~ 5.6 21 ~ 26 / 5.5 ~ 6.9
EC330B 14 ~ 19 / 3.8 ~ 5.1 18 ~ 24 / 4.8 ~ 6.2 23 ~ 29 / 6.2 ~ 7.6
EC360B 15 ~ 21 / 4.0 ~ 5.5 19 ~ 25 / 5.1 ~ 6.6 25 ~ 31 / 6.6 ~ 8.1
EC460B 18 ~ 23 / 4.7 ~ 6.2 22 ~ 28 / 5.9 ~ 7.5 28 ~ 35 / 7.5 ~ 9.2

Working conditions:
- Light work: Easy digging conditions with 40% digging of the daily working hour.
- Medium work: Medium digging conditions with 60% digging of the daily working hour.
- Heavy work: Hard digging conditions with 90% digging of the daily working hour.

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Appendix-Material property

Bank, loose and compacted volumes

In the earthmoving industry, volumes can be
expressed in different ways, depending on which
stage of excavation the material is. In this chapter,
the most common ones, bank, loose and
compacted volume will be explained:

Bank volume Loose volume

Compacted volume

Fig. 1

Bank volume (Bm3, Byd3 ) is the undisturbed
material in the ground, before excavation. Note that
the volume that is actually excavated often is some-
what larger than the one calculated from drawings.
Loose volume (Lm3, Lyd3 ) is the volume of the
material when it is loaded on the transport machine.
The loose volume is larger than the bank volume
since the material expands when excavated, this
difference is called swell.
Compacted volume (Cm3, Cyd3 ) is the
volume of the materials after leveling and compaction
on the site. This volume is smaller than the loose,
and can be either larger or smaller than the bank
volume depending on the material properties. As for
bank volumes, it is important to note that the actual
filled volume often is larger than the volume calcu-
lated from drawings.
The graph below shows an example of how the
volume of material can vary during excavation and
transport (Fig. 2).

Volume Transport

Leveling and compaction

Swell Compacted
Bank Loading

Blasting

Fig. 2 Volume variation during excavation and transport

13
 Appendix-Material property

Density
The relationship of the weight of a material to its Density and swell of a material vary with grain size
volume is called density. and moisture content. To make an accurate
determination of density and swell, measurements
WEIGHT have to be made on the site, but rough estimates
DENSITY = __________
VOLUME can be made from table 1-4.

Density is expressed in kg/m3, lb/yd3 . The graph below shows an example of how the
Density of the same material may be different density of a material can vary during excavation and
depending on whether it is in the bank, loose or transport (Fig. 3.)
compacted form. The difference is noted by using
the same abbreviations as for volumes, e.g. 1,700
kg/L3, lb/Lyd3 means that one loose cubic yard
(meter) of the material weight 1,700 kg, 2,870 lb.

Density

Blasting

Bank Loading

Compacted

Loose

Leveling and compaction

Fig. 3 Density variation during excavation and transport

14
Appendix-Material property

Swell
When soil and rock materials are loaded into a Volume changes:
dumper, the volume increases due to expansion of LOOSE VOLUME = BANK VOLUME x SWELL
the material. This increase is called swell. This is
usually expressed as a swell-factor which is the LOOSE VOLUME
loose volume divided by the bank volume, see BANK VOLUME = _________________
SWELL
below, but it can also be expressed as a percent-
age. For conversions between bank and loose Density changes:
BANK DENSITY
forms, the following formulas are used. LOOSE DENSITY = _________________
SWELL
LOOSE VOLUME BANK DENSITY = LOOSE DENSITY x SWELL
SWELL = _________________
BANK VOLUME

Example:

Dry clay has a bank density of 1,700 kg/Bm3, 2,870 lb/Byd3 and the swell-factor 1.3
(it swells 30%)

What is the weight of 1 Lm3, Lyd3 ?

1,700
LOOSE DENSITY = ________ = 1,308 kg/Lm3, 2,208 lb/Lyd3
1.3

What is the weight of a full load in a 16.5 m3, 21.6 yd3 dumper-body:

LOAD WEIGHT = LOAD VOLUME x LOOSE DENSITY

= 16.5 Lm3 x 1,308 kg/Lm3 = 21,600 kg
= 21.6 Lyd3 x 2,208 lb/Lyd3 = 47,726 lb

If 75,000 Bm3, 98,100 Byd3 are to be excavated, how many Lm3, Lyd3 are to be transported?

LOOSE VOLUME = 75,000 Bm3 x 1.3 = 97,500 Lm3, 98,100 Byd3 x 1.3 = 127,530 Lyd3

15
 Appendix-Material property

Material density
Bank volume Loose volume Swell-
Material kg/m3 lb/yd3 kg/m3 lb/yd3 factor
Clay
dry 1,640 2,750 1,170 1,950 1.4
moist 2,100 3,550 1,500 2,550 1.4
dry with gravel 1,660 2,800 1,424 2,400 1.2
wet with gravel 1,840 3,100 1,660 2,750 1.2
compact 2,017 3,400 1,660 2,750 1.2
Soil
dry 1,100 1,850 960 1,600 1.2
moist 2,100 3,550 1,680 2,850 1.3
mixed with sand/gravel 1,660 2,800 1,420 2,400 1.2
stony (25% stones) 1,960 3,300 1,570 2,650 1.3
Sand
dry 1,600 2,700 1,420 2,400 1.1
moist 2,070 3,500 1,840 3,100 1.1
dry with gravel 1,930 3,250 1,720 2,900 1.1
wet with gravel 2,230 3,750 2,020 3,400 1.1
Gravel
dry 1,470 2,500 1,330 2,250 1.1
wet 2,340 3,950 2,130 3,600 1.1
Rocks and minerals
granite 2,970 5,000 1,980 3,350 1.5
limestone 2,640 4,450 1,590 2,700 1.7
sandstone 2,400 4,050 1,440 2,450 1.7
crushed stone 2,670 4,500 1,620 2,750 1.7
gypsum 2,580 4,350 1,980 _ 1.3
Ores
iron ore 2,760 4,650 2,340 3,950 1.2
copper ore 2,600 4,400 2,200 3,700 1.2
zinc ore 3,000 5,050 2,500 4,200 1.2
Other material
slag 1,700 2,850 1,020 1,700 1.7
cement 1,540 2,600 1,400 2,350 1.1

These weights are only approximate, the densities vary with moisture content, grain size, etc.
Test must be carried out to detemine exact material characteristics.

16
Appendix-Bucket capacity rating

Bucket capacity rating

VOLVO bucket rating complies with ISO standard
7451, SAE standard J296 and PCSA standard
No.3. Buckets are rated on both their struck and
heaped capacities as follows:

Struck capacity
Volume actually enclosed inside the outline of the
sideplates and rear and front bucket enclosures
without any consideration for any material supported
or carried by the spillplate or bucket teeth.

1 1
1 1
1 1
1 1

Strike
Heaped off
plane Struck
capacity
capacity

Excavator bucket rating

Heaped capacity
Volume in the bucket under the strike off plane plus
the volume of the heaped material above the strike
off plane, having an angle of repose of 1:1 without
any consideration for any material supported or
carried by the spillplate or bucket teeth.
The Committee on European Construction
Equipment (CECE) rates heaped bucket pay loads
on a 2:1 angle of repose for material above the
strike off plane.

17
 Appendix-Digging force calculation

Digging force calculation FB = Radial tooth force due to bucket cylinder

Bucket cylinder force Length A x Length C
Bucket penetration into a material is achived by the = __________________ __________________
( )
Length D Length B
bucket digging force (FB) and arm digging force (FA).
Cylinder force =
According to the estimated position where the
(Pressure) x (End area of cylinder head)
digging force is exerted, there are 2 kind of rating
Length D = Bucket tip radius
methods.
Maximum radial tooth force due to bucket
cylinder (bucket digging force) is the digging
90o force generated by the bucket cylinder and
tangential to the arc of radius D1. The bucket
90
E o
shall be positioned to obtain maximum output
A moment FB occurs when the factor _ length A
times length C divided by length B _ becomes
the maximum.

FA = Radial tooth force due to arm cylinder

(Arm cylinder force) x (Length E)
90 o
= ____________________________
(Length F)
B F
Length F = Bucket tip radius + Arm length

Maximum radial tooth force due to arm cylinder

D FB (arm digging force) is the digging force
generated by the arm cylinder and tangential
to the arc of radius F. The arm shall be positioned
D1 to obtain the maximum output moment from the
90 o
90 o FA arm cylinder and the bucket force rating.
o
90 When calculating, maximum FA occurs when the
C axis in the arm cylinder working direction is at a
Bucket lip right angle to the line connecting the arm cylinder
pin and the boom nose pin.

Rating by SAE standard J1179 and Rating by ISO standard 6015

PCSA standard No.3
Rated digging forces are the digging forces that
can be exerted at the outermost cutting point.
These forces can be calculated by applying working
relief hydraulics pressure to the cylinders providing
the digging force.
Rated digging forces are the digging forces that
can be exerted at the bucket lip. Therefore, the
digging forces calculated by ISO are bigger than
those by SAE and PCSA due to the shorter length
D and length F.

18
Note

19
All products are not available in all markets. Under our policy of continuous improvement, we reserve the right to change specifications
and designs without prior notice. The illustrations do not necessarily show the standard version of the machine.

Ref. No. 22 A 100 1003 American English

Volvo Construction Equipment Printed in USA 2003.11-1 KOR
Volvo, Asheville
North America Inc.
One Volvo Drive, Asheville, N.C. 28803-3447
www.volvoce.com