Volvo EC160E L EC160EL Excavator Workshop Repair Service Manual PDF Electrical Wiring Diagrams - MVLVCONEC160E.zip
A full-service repair guide, complete with Electrical Wiring Diagrams, for the EC160E L Volvo Excavator — containing every technical detail needed to service, troubleshoot, fix, and rebuild the machine just like an expert technician.
The workshop service and repair manual for Volvo Constructions EC160EL Excavators covers:
* 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.
EC160E L Volvo Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,061 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
000 - Foreword.........2
000 - GENERAL.........3
00 - DESCRIPTION; COMPLETE MACHINE.........4
Machine View.........5
Product plates.........7
03 - SPECIFICATIONS.........9
Tightening torques.........10
Measurement conversion tables.........21
Undercarriage; tightening torque_{02-46-38}.........30
Undercarriage; tightening torque_{02-46-18}.........31
Undercarriage; tightening torque_{02-45-59}.........32
07 - STANDARD TIME.........34
Operation numbers for additional work.........35
08 - TOOL.........37
Infrared Thermometer.........38
09 - MISCELLANEOUS.........42
Service positions.........43
Welding on the machine.........45
Hydraulic cylinders; dieseling.........48
001 - STANDARD PARTS; SERVICE.........52
17 - SERVICE.........53
Bearings.........56
Replacement parts.........60
Safety when servicing.........64
Service.........68
Service methods.........71
Pressure testing.........75
Hoses and tubes.........79
Cleaning prior to repair.........83
Tech Tool; operations .........87
Arrival Inspection; according to Inspection Programme.........89
Delivery Inspection; according to Inspection Programme.........94
Maintenance of Stored Machines; according to Inspection Programme.........98
Maintenance service; first 500 hours.........102
Maintenance service; every 10 hours.........103
Maintenance service; every 50 hours.........104
Maintenance service; every 250 hours.........105
Maintenance service; every 500 hours_{02-29-05}.........106
Maintenance service; every 500 hours_{02-28-46}.........108
Maintenance service; every 1000 hours_{02-28-15}.........110
Maintenance service; every 1000 hours_{02-27-55}.........112
Maintenance service; every 2000 hours_{02-27-24}.........114
Maintenance service; every 2000 hours_{02-27-04}.........116
Maintenance service; every 4000 hours_{02-26-34}.........118
Maintenance service; every 4000 hours_{02-26-14}.........120
Maintenance service; every 6000 hours_{02-25-43}.........122
Maintenance service; every 6000 hours_{02-25-24}.........123
Maintenance service; every 8000 hours_{02-24-46}.........124
Maintenance service; every 8000 hours_{02-24-27}.........125
Service position.........126
Lubrication; every 50 hours.........129
Test running and checking.........131
Valves; adjusting .........133
Engine oil and filter; changing.........138
Fuel filter; replacing.........141
Water separator filter; replacing.........143
Fuel tank breather filter; replacing.........145
Diesel particulate filter; regenerating.........148
Diesel particulate filter; checking and cleaning.........150
AdBlue®_DEF pump unit filter; replacing.........156
AdBlue®_DEF tank breather filter; replacing.........160
Engine air cleaner primary filter; replacing.........162
Engine air cleaner secondary filter; replacing.........164
Coolant; changing-.........166
Coolant freezing point; checking.........169
Fan_alternator belt; checking.........172
Radiator and hydraulic oil cooler; cleaning.........174
MATRIS and Tech Tool; reading.........176
Software update; checking.........179
Battery; checking_{02-13-54}.........183
Battery; checking_{02-13-32}.........185
CareTrack backup battery; replacing_{02-12-57}.........187
CareTrack backup battery; replacing_{02-12-35}.........190
Track gearbox oil level; checking.........195
Track gearbox oil; changing.........197
Swing gearbox oil level; checking.........199
Swing gearbox oil; changing.........201
Swing ring gear bearing; lubricating.........203
Swing bath grease; checking.........205
Track shoe bolts; checking.........206
Track tension and condition; checking.........208
Cab door; covers; hinges; joints and locks; lubricating.........210
Air conditioner main filter; cleaning.........212
Air conditioner main filter; replacing.........215
Cab prefilter; cleaning.........218
Cab prefilter; replacing.........220
Air conditioner compressor belt; checking.........222
Hydraulic oil level; checking.........224
Hydraulic oil; changing.........226
Hydraulic oil suction strainer; cleaning.........229
Hydraulic oil drain filter; replacing.........231
Hydraulic oil servo filter; replacing.........233
Hydraulic oil return filter; replacing.........234
Hydraulic return filter on X1 option circuit; replacing.........237
Hydraulic oil tank breather filter; replacing.........239
Measuring condition.........241
Cylinder speed.........244
Creeping of hydraulic cylinder.........247
Swing speed.........249
Coasting left and right swing.........250
Measuring of swing bearing clearance.........252
Travel Speed.........255
Track running speed.........257
Straight traveling performance.........259
19 - GENERAL.........261
Safety concerns everybody!.........262
CE-marking; EMC-directive.........266
Cautions during operation.........270
Safety when handling the machine.........277
Safety rules when servicing.........283
Move and operate machine safely.........288
Fire prevention measures.........291
Health hazards with paint; plastics and rubber.........297
Checklist after a fire or heat exposure.........302
Safety when using lifting equipment.........306
Safety when handling oils and fuel.........310
Safety when working with batteries.........314
Starting with booster batteries.........319
Safety when working with air conditioning refrigerant.........323
Safety when working with hydraulic systems.........328
Environmental handling for the future.........332
Environmentally safe handling.........336
Environmentally hazardous fluids.........340
Working in environmentally contaminated areas.........344
Decontamination.........348
Waste handling.........352
002 - ENGINE WITH MOUNTING AND EQUIPMENT.........356
20 - GENERAL.........357
Engine; description_{01-38-08}.........358
Engine; description_{01-37-46}.........365
Component locations.........371
Tech Tool; operations_{01-36-33}.........374
Tech Tool; operations_{01-36-14}.........376
Engine control module (ECM); replacing pre-programmed.........379
Engine control module (ECM); replacing non-programmed.........381
Engine; reference values.........384
Engine belts; replacing.........387
21 - ENGINE.........390
Engine; specifications.........391
Engine rotation speed sensor (crank shaft); replacing.........392
Engine rotation speed sensor (camshaft); replacing.........394
Engine; removing.........396
Engine; installing.........406
Engine; replacing_{01-30-56}.........415
Engine; replacing_{01-30-37}.........419
Engine; tightening torques.........422
Cylinder compression; testing.........429
Crankcase ventilation; description.........432
Valves; adjusting.........436
Valve cover; removing.........441
Valve cover; installing.........444
Oil level sensor; replacing.........447
22 - LUBRICATING SYSTEM.........450
Lubrication system; description.........451
Lubrication system; specifications.........456
Lubrication system; component locations.........458
Lubrication system; tightening torques.........460
Lubrication oil pressure; checking with pressure gauge.........463
Oil cooler; replacing.........466
23 - FUEL SYSTEM.........468
Fuel system; description.........469
Fuel system; specifications.........477
Fuel system; tightening torques.........479
Carbon dioxide in fuel system; checking.........487
Fuel system basics; checking.........493
Fuel system; component location.........496
Feed pump pressure; checking.........498
Fuel system; bleeding.........500
Water separator; specifications.........502
Injectors; replacing.........504
Injector sleeves; replacing.........510
Fuel rail; replacing.........518
Fuel rail pressure sensor; replacing.........521
High pressure fuel pump; replacing.........523
High pressure fuel pipes; replacing.........526
Fuel control valve (FCV); replacing.........528
Pressure relief valve (PRV); replacing.........533
25 - INLET & EXHAUST SYSTEM.........536
Inlet and exhaust system; description.........538
Inlet and exhaust system; specification.........544
Inlet and exhaust system; component location.........546
Inlet and exhaust system; tightening torques.........548
Exhaust pipe flexible tube; replacing.........554
Exhaust Aftertreatment System; description.........557
Exhaust Aftertreatment System; component location.........570
Regeneration process; description.........572
AdBlue®_DEF dosing injector; replacing.........579
AdBlue®_DEF mixing tube; replacing.........582
AdBlue®_DEF tank; replacing.........586
AdBlue®_DEF; draining.........588
Coolant valve; replacing.........591
SCR (Selective catalytic reduction) muffler; replacing.........594
AdBlue®_DEF quality; checking.........599
SCR (Selective catalytic reduction) dosing system; checking.........602
AdBlue®_DEF pump unit diagnostics; description.........605
DPF (Diesel particulate filter); checking and cleaning.........609
ACM (Aftertreatment control module) non-programmed; replacing.........615
ACM (Aftertreatment control module) pre-programmed; replacing.........618
Inlet throttle; replacing.........620
DOC (Diesel oxidation catalyst); replacing.........622
AdBlue®_DEF pump unit; replacing.........625
AdBlue®_DEF tank armature; replacing.........628
AdBlue®_DEF tank armature; cleaning.........633
AdBlue®_DEF tank armature suction filter; replacing.........636
AdBlue®_DEF hoses; replacing.........638
AdBlue®_DEF.........642
Crystallization of AdBlue®_DEF; checking.........648
AdBlue®_DEF pump unit; filter; replacing.........653
AdBlue®_DEF pump unit; flushing.........656
AdBlue®_DEF pump unit; inlet nipple; replacing.........659
Regeneration log; checking.........662
AdBlue®_DEF tank; cleaning.........674
Turbocharger; replacing.........677
Charge air cooler; replacing.........681
26 - COOLING SYSTEM.........688
Cooling system; description.........689
Cooling system; specifications.........693
Carbon dioxide in coolant system; checking.........695
Cooling system; component location.........701
Cooling system; tightening torques.........703
Coolant with anti-freeze and corrosion protection; recommendation.........706
Cooling system pressure; checking.........709
Coolant; changing.........711
Radiator; replacing.........714
Expansion tank; replacing.........716
Coolant pump; replacing.........719
Thermostat; replacing.........722
Cooling fan control.........725
Cooling fan rpm; specifications.........729
Cooling fan clutch; description.........730
27 - ENGINE CONTROL.........733
Engine - Pump control; specification.........734
29 - MISCELLANEOUS.........736
EGR venturi tube; cleaning.........737
Exhaust Gas Recirculation (EGR); description.........739
Exhaust gas recirculation (EGR); component location.........745
EGR system; tightening torques.........747
EGR reed valve; replacing.........749
EGR cooler; replacing.........755
EGR actuator; replacing.........760
EGR venturi tube; replacing.........762
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.........766
30 - GENERAL.........767
Electrical system; special instructions for servicing; general.........773
Electrical system; special instructions for servicing; electronic components.........777
Electrical system; special instructions for servicing; electrical components; batteries.........780
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator.........784
Electrical system; special instructions for servicing; action when working on machine.........787
Electrical system; description.........790
Electronic control system; description.........792
Auxiliary start.........799
System voltage.........803
Electrical system; specifications.........806
Tech Tool; operations-.........809
Power Boost control; description.........811
Engine stops.........814
CareTrack with anti-theft.........816
Start lock; description.........827
X1 control; description.........829
X3 control; description.........833
Electro hydraulic pump control; description.........835
Power supply; description.........840
Mode selection; description.........845
Boom float position; description.........849
Limp home.........851
Travel speed; description.........854
Overload warning.........856
Seat belt.........859
Auto Idle.........861
Attachment quick coupler.........863
Intermittent wiper and washer.........865
Grading and lifting control; description.........869
ECO mode; description.........873
Software parameters; description.........875
Automatic engine shut-down.........887
General fault diagnosis information.........890
Troubleshooting strategy.........892
Collection of basic data.........894
Information display; check.........898
Error code information; general.........901
Error codes; build-up.........912
Conditions when checking.........914
Lead and connector checks.........919
Special tools for troubleshooting.........925