Converting Volvo EC 210 from Standard Boom to Long Reach

[MikePhua]

Introduction
Excavators are among the most versatile machines in the construction and heavy equipment industries, known for their ability to perform a wide range of tasks such as digging, lifting, and grading. The Volvo EC 210 is a mid-sized hydraulic excavator, popular for its efficiency and reliability in standard applications. However, certain projects may require the machine to handle tasks that necessitate a longer reach, such as deep trenching or high-elevation digging. In such cases, converting the Volvo EC 210 from a standard boom configuration to a long reach boom can significantly enhance its performance. This article explores the process, benefits, and considerations of such a conversion.
Why Convert to a Long Reach Boom?
A long reach boom increases the operational range of an excavator, allowing it to extend further from its base. This modification is especially useful in applications such as:

1. Deep Excavations: Long reach booms enable excavators to reach deeper into trenches, foundations, and other excavation sites without the need to move the machine as frequently.
   
2. High Reach Tasks: For tasks like demolitions, dredging, or clearing high ground, a long reach boom allows the excavator to extend its reach to elevated areas that would otherwise be difficult to access.
   
3. Improved Safety and Efficiency: By reaching further distances, a long reach boom reduces the need for repositioning the machine, improving overall site efficiency and reducing the chances of accidents or mishaps caused by machine movement.
   

Components of the Volvo EC 210 Excavator
The Volvo EC 210 is known for its durability, fuel efficiency, and ease of operation. It is equipped with a standard boom, stick, and bucket configuration, and comes with various attachments suited for digging, lifting, and trenching. The base machine is powered by a Volvo D6D engine, providing solid power and torque for standard applications.
Key specifications include:

• Operating Weight: Approximately 21,500 kg (47,400 lbs)
  
• Engine Power: Around 121 kW (163 hp)
  
• Bucket Capacity: Up to 1.0 m³ (depending on the bucket used)
  
• Maximum Digging Depth: Approximately 6.5 meters (21 feet)
  

These specifications make the EC 210 highly effective in standard applications. However, the machine's standard boom limits its reach, making it less suitable for projects requiring extended digging distances.
Steps to Convert to a Long Reach Boom
Converting a Volvo EC 210 excavator to a long reach configuration involves several key modifications to enhance the machine’s reach and overall functionality. Below are the general steps involved in the process:

1. Selecting the Long Reach Boom Kit
   The first step is to select the appropriate long reach boom kit that is compatible with the Volvo EC 210. These kits typically include a longer boom, a matching longer stick, and necessary hydraulic components. The right kit should be selected based on the required reach, the machine’s operating conditions, and the tasks at hand.
   
2. Disassembling the Standard Boom
   The existing standard boom needs to be removed before installing the long reach components. This process involves disconnecting the hydraulic lines and removing the boom, stick, and bucket assembly. It is important to ensure all components are carefully labeled and stored for possible reuse.
   
3. Installing the Long Reach Boom
   The new long reach boom is mounted to the excavator’s frame. This is typically a bolt-on procedure, where the new boom is attached to the existing structure. The hydraulic lines must then be reconnected to ensure that the long reach boom operates efficiently with the machine’s existing hydraulic system.
   
4. Replacing the Stick and Bucket
   Along with the boom, the stick (or arm) and bucket are also replaced with extended versions that are designed for the long reach configuration. The longer stick allows the operator to reach further distances, while the extended bucket can handle larger volumes of material. Depending on the task, different buckets (such as grapple buckets or mud buckets) may be used.
   
5. Recalibrating the Hydraulic System
   With the longer boom and arm installed, the hydraulic system must be recalibrated. The increased reach requires adjustments to the machine’s hydraulic flow to ensure optimal performance. It may involve tweaking the hydraulic pressure settings or upgrading certain hydraulic components to accommodate the increased demands.
   
6. Testing the Machine
   Once all parts are installed and the system is recalibrated, the excavator should undergo a series of tests to ensure the conversion has been successful. Operators will test the reach, lifting capacity, and overall performance of the long reach setup to ensure it meets the required specifications.
   

Benefits of a Long Reach Conversion

1. Increased Reach and Efficiency
   The primary benefit of converting to a long reach boom is the increased working radius. With a longer boom, the Volvo EC 210 can reach areas that would otherwise require additional equipment or repositioning. This increases efficiency, especially on large sites where the machine must cover a wide area.
   
2. Enhanced Versatility
   A long reach boom expands the types of tasks an excavator can handle. It makes the machine more versatile, allowing it to perform applications such as dredging, deep trenching, demolition, and clearing operations that require significant reach.
   
3. Cost-Effective Solution
   Instead of purchasing a new long reach excavator, converting an existing EC 210 can be a cost-effective solution. This conversion allows operators to use the same machine for a wider range of tasks, saving on capital expenditure and maintenance costs associated with purchasing additional equipment.
   
4. Improved Productivity
   With the increased reach, the excavator can cover more ground without the need for frequent repositioning. This results in faster operation, increased productivity, and reduced downtime on jobsites.
   

Considerations and Potential Drawbacks
While converting to a long reach configuration offers many advantages, there are a few important considerations to keep in mind:

1. Reduced Lifting Capacity
   One of the trade-offs of extending the boom is a reduction in lifting capacity. The further the boom extends, the less weight it can safely lift. Operators should ensure that the tasks performed with the long reach boom do not exceed the machine’s new lifting limits.
   
2. Increased Wear on Components
   The longer reach puts additional strain on the hydraulic system and structural components of the excavator. This can lead to increased wear and tear, requiring more frequent maintenance. Operators must ensure the machine is regularly serviced and properly maintained to extend its lifespan.
   
3. Stability Concerns
   The increased boom length can affect the machine’s stability, especially when working on uneven ground or in situations where the excavator is extended to its maximum reach. Careful operation and awareness of the machine’s limits are essential to prevent tipping or accidents.
   

Conclusion
Converting a Volvo EC 210 from a standard boom to a long reach boom is a highly effective way to extend the machine’s capabilities and make it suitable for a broader range of tasks. Whether for deep trenching, high-elevation digging, or demolition work, the long reach conversion allows operators to enhance productivity, improve safety, and increase overall machine versatility. However, it is important to be mindful of the potential trade-offs, such as reduced lifting capacity and increased wear on components, and to ensure that the conversion is done correctly to maintain the machine’s performance and longevity.
By investing in a long reach conversion, companies can maximize the utility of their existing equipment, saving on costs while expanding the types of jobs their excavators can perform.