Volvo EW160C Excavator Workshop Service Repair Manual PDF Electrical Wiring Diagrams Download - MVLVCONEW160C.zip

This is a full service and repair guide, complete with Electrical Wiring Diagrams, for the Volvo EW160C Excavator — offering every technical detail needed to service, troubleshoot, fix, and rebuild the machine the way professional technicians do.

The workshop service and repair documentation for Volvo Construction Equipment's EW160C Excavator contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Volvo EW160C Excavators Service Repair Manual.pdf

PRODUCT DETAILS:

Total Pages: 2,979 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

MAIN SECTIONS

0 - Foreword......2

0 - GENERAL......3

00 - DESCRIPTION; COMPLETE MACHINE......4

Description; complete machine......5

Component locations ......6

Product plates......8

03 - SPECIFICATIONS......9

Tightening torques......13

Conversion tables......19

Engine; specifications ......27

Engine; weights ......28

Valve system specifications ......29

Flywheel; weight ......31

Lubrication system; specifications ......33

Fuel pressure; specifications ......34

Fuel tank; specifications ......36

Injectors; specifications ......37

Cooling system; specifications ......38

Coolant pump; thermostat; specifications ......39

Engine speed control switch; specifications ......41

Electrical system; specifications ......42

Engine control unit E-ECU; specifications ......44

Electronic climate control unit ECC; specification ......46

Wireless control unit W-ECU; specification......48

Keypad; specification......50

Alternator; specifications ......53

Starter motor; specifications ......55

Electric horn; specifications ......56

Rotating beacon; specifications ......58

Travel alarm; specifications ......59

Wiper controller; specifications ......61

Windscreen flusher pump; specifications ......63

Start switch; specifications ......65

Control lockout lever switch; specifications......67

Emergency engine speed control switch; specifications_{06-43}......69

Emergency engine speed control switch; specifications_{06-25}......70

Auto_Manual pump control switch; specifications ......72

Relay; specifications......73

Circuit breaker; specification......75

Hour counter; specifications......77

Audio remote controller; specifications_{04-35}......79

Audio remote controller; specifications_{04-16}......82

Capacities......84

Specifications; weight......85

Engine; oil and filter; change. ......86

Radio with tape or CD player; specifications......89

DC–DC converter; specifications......92

Travel motor; specifications......93

Slew motor; specifications......95

Centre passage; specification......96

Propeller shaft; specifications......97

Front axle; specification......98

Rear axle; specification......99

Slew ring gear; specifications......100

Steering axle; specifications......101

Counterweight; specifications_{58-41}......102

Counterweight; specifications_{58-19}......103

Engine; volume ......104

Air cleaner; specification-5734......105

Air cleaner; specification ......106

Fuel filler pump; specifications ......107

Engine control; specifications ......108

Instrument control unit I-ECU; specifications ......109

Vehicle control unit V-ECU; specifications ......111

Battery; specifications ......116

Preheating; specifications ......117

Lighting; specifications ......118

Lower wiper motor; specifications ......119

Battery disconnect switch; specifications ......120

Multi-function lever switch; specifications ......121

Control levers; specifications ......122

Manual travel control switch; specifications ......129

Control lockout solenoid valve; specifications ......130

Stabiliser solenoid valve; specifications ......131

Electric center passage; specification ......132

Power outlet; specifications ......133

Flasher relay; specifications......134

Hydraulic oil filter pressure switch; specifications......135

Auto idle pressure switch; specifications......136

Slew position sensor; specfications......137

Rear view camera; specifications......138

Travel gearbox; specifications_{48-43}......139

Travel gearbox; specifications_{48-24}......140

Wheels; specifications......141

Cab; specifications......142

Cab; weight......145

Air conditioning unit; specifications......147

Diesel coolant heater (5kw); specifications......148

Automatic lubrication system; specifications......150

Brake pump; specifications......152

Steering pump; specifications......153

Control valve (steering unit); specification......154

Hydraulic pressure; specifications......155

X1; Specifications......157

Cruise control; specifications......161

Hydraulic tank; specifications......162

Working pump; specifications......163

Servo pump; specifications......164

Digging equipment bearings; specifications......165

Cylinder data......167

Hydraulic oil cooling system; specifications......168

05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION......171

Lifting instructions......172

07 - STANDARD TIME......174

Operation numbers for additional work......175

08 - TOOL......177

E-tool; 1802 Extractor for pressure limiting valve......178

E-tool; 3500 Support plate for travel gearbox and motor......179

E-tool; 3501 Puller for gear wheel fan pump......181

E-tool; 3502 Plate for turning crankshaft......182

E-tool; 3506 Flange......184

E-tool; 3507 Plug......185

Infrared Thermometer......186

09 - MISCELLANEOUS......188

Service positions ......189

Welding on the machine......192

Hydraulic cylinders; dieseling......195

Control units; changing......197

1 - STANDARD PARTS; SERVICE......199

16 - LUBRICANT; FUEL; OTHER FLUID......200

Coolant with freezing and corrosion protection......201

Recommended lubricants......202

Coolant......205

Alternative fuels......210

17 - SERVICE......213

Bearings......216

Elimination of trapped hydraulic pressure......220

Replacement parts......222

Service......226

Service methods......227

Pressure testing......231

Hoses and tubes......235

Cleaning prior to repair......239

Arrival Inspection; according to Inspection Programme......240

Delivery Inspection; according to Inspection Programme......245

Maintenance of Stored Machines; according to Inspection Programme......247

Warranty inspection 100 hours......249

Warranty inspection 1000 hours......250

Periodic maintenance......251

Maintenance service; daily......253

Maintenance service; every 50 hours......254

Maintenance service; every 250 hours......255

Maintenance service; first 500 hours......256

Maintenance service; every 500 hours......257

Maintenance service; every 1000 hours......258

Maintenance service; every 2000 hours......259

Maintenance service; every 4000 hours......260

Maintenance service; every 6000 hours......261

Tyres; wear and air pressure; checking......262

Checking for cracks and leaks......264

Check engine oil level......265

Test-run and check......266

Grease points on dipper arm; lubrication......267

Grease points on booms; lubrication......270

Grease points on undercarriage; lubrication......272

Grease points on superstructure; lubrication_{16-18}......274

Grease points on superstructure; lubrication_{15-57}......275

Hydraulic system; checking oil level......276

Water separator; drain......278

Coolant level; check......280

Axles; checking oil level......281

Axle hubs; checking oil level......283

Travel gearbox oil level; checking......285

Fuel tank water and sediment; drain......287

Battery condition; check......289

Door hinges; lubricate with grease......292

Cab; prefilter; clean......294

Axles; changing oil......296

Hub reduction gear; changing oil......298

Engine; oil and filter; change.......300

Fuel filters; primary and secondary filter; replace_{03-47}......303

Fuel filters; primary and secondary filter; replace_{03-25}......305

Radiator and coolers; cleaning......307

Condenser; clean (with compressed air) (optional equipment)......310

Cab; main filter; clean......312

Belts and belt tension; check; replace when needed.......314

Service journal (included in Operator's manual); fill in......317

Wheel nuts; check torque......318

Brake system; checking function......319

Air cleaner primary filter; change......320

Air conditioning unit; maintenance......323

MATRIS; reading; export reading......324

VCADS Pro; logged errors; read off......326

Swing bath grease; check......328

Travel gearbox; changing oil......331

Brake discs; checking wear......333

Air cleaner secondary filter; change......336

Cab; prefilter; replace......338

Cab main filter; replacing......340

Fuel tank breather filter; replacing......342

Hydraulic oil return filter; changing......344

Hydraulic tank breather filter; changing......346

Hydraulic oil servo filter; change......348

Coolant's freezing point; check......350

Valve clearance and IEGR; check......352

Hydraulic system; changing oil......353

Hydraulic oil suction strainer; change......357

Turbocharger inclusive inlet and exhaust systems; leakage; check......360

Coolant; change......362

CareTrack backup battery; replacing......366

Creeping of hydraulic cylinder......369

Emergency operation; description......373

Towing......376

Secondary lowering of digging equipment......378

Starting engine with booster cables......380

19 - GENERAL......382

Safety concerns everybody!......383

Service positions......385

CE marking and declaration of conformity......388

Safety when handling the machine......390

Safety rules when servicing......394

Checklist after a fire or heat exposure ......396

Fire prevention measures......397

Health hazards with paint; plastics and rubber......400

Checklist after a fire or heat exposure......405

Some simple rules regarding tyre handling......409

Safety when using lifting equipment......411

Safety when handling oils and fuel......415

Safety when working with batteries......419

Starting with booster batteries......424

Safety when working with air conditioning refrigerant......428

Safety when working with hydraulic systems......433

Environmental handling for the future......435

Environmentally safe handling......439

Environmentally hazardous fluids......442

Working in environmentally contaminated areas......446

Decontamination......450

Waste handling......454

2 - ENGINE WITH MOUNTING AND EQUIPMENT......458

20 - GENERAL......459

Engine; description......460

E-ECU MID 128 pre-programmed; replacing......462

E-ECU MID 128 non-programmed; replacing......464

Engine; identification......466

Engine; volume......467

Engine; tightening torques......468

Component locations......471

Engine; weights ......473

21 - ENGINE......474

Engine; specifications......476

Cylinder compression; PC test......477

Engine characteristic curve......478

Basic check; Engine......480

Troubleshooting......482

Camshaft and flywheel signals; checking with Tech Tool and oscilloscope......485

Engine and transmission; installing......491

Engine; weights......501

Cylinder head; description......502

Cylinder head gasket; description......504

Cylinder; description......506

Pistons; description......508

Piston rings; description......510

Piston cooling......512

Valve system specifications......514

Valves; description......517

Internal Exhaust Gas Recirculation (IEGR); description......519

Valves; adjusting......525

Engine timing gear; description......538

Camshaft; description......541

Timing gear case new gasket; installing......544

Flywheel; weight......561

Crankshaft; description......563

Vibration damper; description......566

Connecting rod; description......569

Crankshaft front oil seal; replacing......572

Crankshaft rear oil seal; replacing......581

Oil sump; description......592

Oil sump; replacing......594

Oil level sensor; replacing......599

Engine mounting......603

Engine mount front; replacing......606

Engine mounting rear; changing......610

22 - LUBRICATING SYSTEM......613

Lubricating system; description......614

Lubrication system; specifications......618

Lubrication system; principle of operation......619

Oil pump; replacing......623

Lubrication oil pressure; checking with pressure gauge......635

Oil cooler; replacing......637

Oil cooler; description......640

23 - FUEL SYSTEM......641

Fuel system; description......643

Fuel pressure; specifications......645

Instructions for working with electronic fuel injection......647