How Volvo Excavator Work Modes Boost Productivity and Reduce Costs

When it comes to excavator operation, it’s all about work modes. Today’s excavators come with a variety of excavator controls to match engine speed and pump flow to the application. Selecting the proper mode ensures operators have the appropriate power and controllability for the task at hand — without burning more fuel than necessary.

Too often, however, operators tend to jump directly into the highest mode, regardless of task. The presumption can be that higher rpm equates to more productivity — but that’s not always the case. Constantly running at the highest mode not only burns unnecessary fuel, it can result in speeds that only the most skilled operators are equipped to handle effectively.

With some simple tips and changes to operator behavior, you can see a positive impact to your operation’s bottom line.

1. Hot turbo shutdowns

It’s recommended that operators let their machine idle for 2 to 3 minutes prior to shutting down. If an operator repeatedly shuts down the machine without properly idling, it can eventually lead to turbocharger damage or eventual failure — typically a $1,000 to $5,000 repair, depending on the machine. Using your ActiveCare Direct online dashboard, you can identify which machines are experiencing hot turbo shutdowns and how often. This gives you the opportunity to train operators and avoid costly repairs.

2. High-speed shifts on wheel loaders

Operators should always bring the machine to a complete stop before shifting from reverse to forward (or vice versa). Shifting at high speeds over a long period of time can lead to eventual driveline failure. ActiveCare Direct flags instances of high-speed shifts on individual machines, giving you an opportunity to train operators before this bad habit leads to a potential transmission replacement costing upwards of $20,000.

3. Misuse of excavator work modes

Many operators have a tendency to run in the highest work mode because they assume it gives them the highest productivity. Often, however, they could be achieving the same level of productivity in a lower work mode and burning 50 percent less fuel. We designed ActiveCare Direct to automatically flag any excavator that runs in Heavy (H) Mode more than 80 percent of the time. By switching to a lower work mode, you could be saving upwards of $10,000 per year, per excavator in fuel costs, assuming 1,500-hour-per-year usage.

4. Cycles with overloaded haulers

Overloading haul trucks has a number of downsides that can outweigh the increased amount of material moved, from dragline fatigue, damage to the haul road and shortening of tire life (which can be one of the most expensive replacement parts on a truck) to increased fuel consumption. Your ActiveCare Direct dashboard lets you know how many cycles your fleet has run with overloaded haulers — you can also see a breakout by machine to know which operators might need some additional training.

5. Excavator travel time

Excessive excavator travel time can cost you a lot of money, as it’s the number one cause of undercarriage wear. It puts a lot of stress on the tracks, sprockets and idlers, and these repairs can represent more than half of your machine maintenance costs. This wear can also lead to reduced resale values or extra charges at the end of your lease. Too much travel time could also indicate a problem with your site’s setup. ActiveCare Direct monitors excavator travel time across the entire fleet and by individual machine. It can help you determine if you need a higher number of smaller excavators to manage the workload or if your excavating/loading locations and/or haul routes aren’t configured efficiently.

Learn more about ActiveCare Direct and see how these online dashboards can help you easily spot and correct machine misuses to lower your costs.

By Jim Bretz

Volvo excavators feature nine total settings within four work modes — Idle (I), Fine (F), General (G) and Heavy (H). Selection of the mode during operation — perhaps more so than any other feature — offers the greatest potential for saved fuel, saved time and gained productivity, when used properly.

So, what are the four work modes your operators should be using when operating Volvo excavators? Let’s take a look:

1. Idle (I) minimizes fuel consumption
What is it?
The “I” mode has two settings that allow the engine to run at low rpms when the machine isn’t actively working.

When should I use it?
The lower of the two settings runs at 800 rpm, offering the best possible fuel consumption short of the machine being off, which should be used as often as possible when not actively working. The higher “I” setting runs at 1,000 rpm, which still offers excellent fuel efficiency, but allows for quicker warmup times as compared to the lowest setting.

What’s my benefit?
The lower the rpm, the lower the fuel consumption and the greater cost savings. Volvo excavators also offer an auto-idle function which can be set to automatically switch to “I” mode after a predetermined amount of time, simplifying cost-saving potential for the operator.

2. Fine (F) provides precise control
What is it?
The “F” mode has two settings — each providing a lower pump flow for increased controllability, while still providing high boost pressure and full power.

When should I use it?
The lower of the two settings is ideal for fine finish work such as grading, whereas the higher setting provides full power and slightly higher pump flow for the perfect balance between speed and controllability. The higher setting is ideal for scenarios that require speed, precision and power, such as setting large pipes or culverts in a trench.

What’s my benefit?
When used properly, the “F” mode ensures higher productivity and quality of work through increased precision.

3. General (G) dials in exact power
What is it?
With four settings ranging from 1,400 rpm to 1,700 rpm, the “G” mode allows the operator to choose a setting that achieves the task at hand with the least amount of fuel consumption.

When should I use it?
The “G” mode is excellent for general digging and excavation, and it allows the operator to find the perfect balance between power and fuel efficiency.

What’s my benefit?
It’s estimated that going down even two settings within “G” mode can reduce fuel consumption by up to 10% during excavator operation. Training operators to scale back will not only save on operating cost but will also reduce stress on the engine and lead to longer machine life.

4. Heavy (H) boasts brute force
What is it?
The “H” mode offers one setting in which the engine runs at 1,900 rpm.

When should I use it?
The “H” mode is strictly for tasks that require maximum machine power and speed such as heavy truck loading and digging in extremely hard terrain at maximum depths. Fuel consumption is higher than any other mode and should only be used when necessary to accomplish the task at hand.

What’s my benefit?
Your operators have access to extremely impressive power as needed but can scale back to save on fuel during normal operations.

To see Volvo excavator work modes firsthand, watch this short video — and make sure your operators understand which mode to use for the task at hand. With more efficient excavator operation, you should see better performance and an improved bottom line.