Volvo EC160C Excavator Workshop Service Repair Manual PDF Download - MVLVCONEC160C.zip
A full workshop repair guide, complete with electrical wiring diagrams, for the Volvo EC160C Excavator—packed with every technical detail needed to service, troubleshoot, overhaul, and rebuild it the way a professional technician would.
Volvo Construction's EC160C Excavator workshop service and repair manual 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 EC160C Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,095 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL...2
00 - DESCRIPTION; COMPLETE MACHINE...3
Machine view...4
Product plates...6
03 - SPECIFICATIONS...8
Tightening torques...11
Measurement conversion tables...22
Engine; specifications...31
Engine; weights...32
Valve system specifications...33
Flywheel; weight...35
Lubrication system; specifications...37
Fuel system; tightening torques...40
Fuel tank; specifications...44
Fuel filler pump; specifications...45
Cooling system; specifications...47
Coolant pump; thermostat; specifications...48
Engine - Pump control; specification...50
Engine speed control switch; specifications...52
Electrical system; specifications...54
Engine control unit E-ECU; specifications...56
Electronic climate control unit ECC; specification...58
Wireless control unit W-ECU; specification...60
Keypad; specification...62
Battery; specifications...65
Alternator; specifications...66
Starter motor; specifications...68
Preheating; specifications...69
Work lights and extra lights; specifications...71
Electric horn; specifications...73
Rotating beacon; specifications...75
Travel alarm; specifications...77
Wiper controller; specifications...79
Upper wiper motor; specifications...81
Lower wiper motor; specifications...83
Windscreen flusher pump; specifications...85
Start switch; specifications...87
Control lockout lever switch; specifications...89
Auto_Manual pump control switch; specifications...91
Relay; specifications...93
Fuse; specifications_{29-22}...95
Fuse; specifications_{29-00}...97
Circuit breaker; specification...99
Hour counter; specifications...101
Audio remote controller; specifications_{27-46}...103
Audio remote controller; specifications_{27-25}...106
Vehicle control unit V-ECU; specifications...108
Radio with tape or CD player; specifications...114
Radio with CD and MP3 player; specifications...117
Track gearbox; specifications...120
Swing gearbox; specifications...121
Track motor; specifications...122
Swing motor; specifications...123
Tightening torque; specifications_{24-01}...124
Tightening torque; specifications_{23-40}...126
Swing ring gear; specifications...128
Frame and track unit; specifications...129
Counterweight; tightening torques...130
Counterweight; specifications...132
Cab; weight...133
Diesel coolant heater (5kw); specifications...135
Recommended hydraulic oil; specifications...136
Hydraulic pressure; specifications...139
Hydraulic tank; specifications...140
Hydraulic oil cooling system; specifications...141
Main control valve; specifications...142
Line rupture valve (boom); specifications...144
Line rupture valve (arm); specifications...146
Hydraulic pump; specifications...148
Proportional solenoid valve; specifications ...149
Current_pressure; specifications...152
Servo pump; specifications...153
Pressure accumulator; specifications...154
Remote control valve (Lever); specifications...156
Remote control valve (pedal); specifications...158
Solenoid valve; specifications ...160
Hammer return filter; specifications...162
Proportional solenoid valve; specifications...163
Solenoid valve; specifications...165
Logic valve; specifications...167
Adjustable boom and cylinder; specifications...168
Control pattern selector valve; specifications...170
Rotator valve; specifications_{12-54}...172
Rotator pump; specifications_{12-33}...173
Attachment quick coupler solenoid valve; specification...174
Dozer blade cylinder; specifications...175
Boom; specifications...177
Boom lifting cylinder; specifications...178
Dipper arm; specifications...180
Dipper arm cylinder; specifications...181
Bucket cylinder; specifications...183
Automatic lubrication system; specifications...185
07 - STANDARD TIME...187
Operation numbers for additional work...188
08 - TOOL...190
NET 8940-00200 Replace tool for the remote control valve joint...191
E-tools; NET 8940-00270 Replace tool for the swing ring gear...193
E-tools; NET 8940-00300 Swing ring gear guide pin...195
NET 8940-00290 Track motor guide pin...197
09 - MISCELLANEOUS...199
Service positions...200
Welding on the machine...203
Hydraulic cylinders; dieseling...206
Control units; changing...210
1 - STANDARD PARTS; SERVICE...212
16 - LUBRICANT; FUEL; OTHER FLUID...213
Recommended lubricants...214
Coolant with freezing and corrosion protection...217
Alternative fuels...221
17 - SERVICE...224
Bearings...226
Replacement parts...230
Safety when servicing...234
Service...238
Service methods...240
Pressure testing...244
Hoses and tubes...248
Cleaning prior to repair...252
Arrival Inspection; according to Inspection Programme...256
Delivery Inspection; according to Inspection Programme...261
Maintenance of Stored Machines; according to Inspection Programme...265
Maintenance service; according to display message...269
Maintenance service; daily...272
Maintenance service; every 50 hours...275
Maintenance service; every 100 hours...280
Maintenance service; every 250 hours...286
Maintenance service; every 500 hours...295
Maintenance service; every 1000 hours...310
Maintenance service; every 2000 hours...327
Maintenance service; every 4000 hours...346
Maintenance service; every 6000 hours...366
Track motor gearbox; changing oil...388
Swing motor gearbox; changing oil...390
Coolant anti-freeze resistance; checking...392
Engine oil and filter; changing...396
CareTrack backup battery; replacing...399
Hydraulic oil; changing...402
Hydraulic oil return filter; replacing...404
Hydraulic oil tank breather filter; replacing...407
Measuring condition...409
Cylinder speed...411
Creeping of hydraulic cylinder...414
Swing speed...416
Coasting left and right swing...417
Measuring of swing bearing clearance...419
Travel Speed...422
Track running speed...424
Straight traveling performance...426
Starting engine with booster cables...428
19 - GENERAL...432
Safety concerns everybody!...433
CE-marking; EMC-directive...437
Safety when handling the machine...440
Safety rules when servicing...447
Fire prevention measures...451
Health hazards with paint; plastics and rubber...457
Checklist after a fire or heat exposure...462
Safety when using lifting equipment...466
Safety when handling oils and fuel...470
Safety when working with batteries...474
Starting with booster batteries...479
Safety when working with air conditioning refrigerant...483
Safety when working with hydraulic systems...488
Environmental handling for the future...492
Environmentally safe handling...496
Environmentally hazardous fluids...499
Working in environmentally contaminated areas...503
Decontamination...507
Waste handling...511
2 - ENGINE WITH MOUNTING AND EQUIPMENT...515
20 - GENERAL...516
Engine; description...517
E-ECU MID 128 pre-programmed; replacing...518
E-ECU MID 128 non-programmed; replacing...521
Engine; identification...524
Engine; tightening torques...525
Component locations...529
Engine; weights ...531
Fuel system; tightening torques ...532
21 - ENGINE...536
Engine; specifications...537
Engine characteristic curve...538
Basic check; Engine...540
Troubleshooting ...542
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...545
Engine; weights...551
Cylinder head; description...552
Cylinder head gasket; description...554
Cylinder block; description...556
Cylinder; description ...558
Pistons; description...559
Piston rings; description...561
Piston cooling...563
Valve system specifications...565
Valves; description...568
Internal Exhaust Gas Recirculation (IEGR); description...570
Engine timing gear; description...576
Camshaft; description...579
Flywheel; weight...582
Crankshaft; description...584
Vibration damper; description...587
Connecting rod; description...590
Oil sump; description...593
Engine mounting...595
22 - LUBRICATING SYSTEM...597
Lubricating system; description...598
Lubrication system; specifications...602
Lubrication system; principle of operation...605
23 - FUEL SYSTEM...609
Fuel system; description...610
Fuel system; tightening torques...615
Instructions for working with electronic fuel injection...619
Carbon dioxide in fuel system; checking...622
Fuel system; bleeding...625
Feed pump; replacing...627
Fuel filters; replacing...630
Fuel filter extra; replacing...632
Fuel tank; specifications...634
Fuel filler pump; specifications...635
Fuel tank; description...637
Fuel filler pump; description...638
Fuel filling pump; removing...640
Fuel filling pump; installing...642
Injectors; description...644
Injector; replacing one...648
Fuel rail pressure; checking...652
Fuel control valve (FCV); description...656
Fuel control valve (FCV); replacing...658
25 - INLET & EXHAUST SYSTEM...664
Inlet system; description...665
Exhaust system; description...666
Silencer; replacing...667
Exhaust pipe flexible tube; replacing...670
Turbocharger; description...673
Turbocharger; inspecting...676
Turbocharger; replacing...678
Preheating coil; replacing...682
Charge air cooler; description...684
Charge air cooler; replacing...686
Charge air cooler connection (hose; tube); replacing...698
26 - COOLING SYSTEM...700
Cooling system; description...701
Cooling system; specifications...703
Coolant anti-freeze resistance; checking...704
Coolant; changing...709
Radiator; replacing...712
Radiator hose upper; replacing...715
Radiator hoses lower; replacing...717
Expansion tank; replacing...720
Coolant pump; thermostat; specifications...722
Thermostat; checking...724
Reversible cooling fan; description...728
Fan belt and_or alternator belt; replacing...731
Fan...734
Engine block heater; description...737
27 - ENGINE CONTROL...738
Engine - Pump control; specification ...739
Engine speed control switch; specifications...741
Engine speed control switch; description...743
Engine speed control switch; inspection...746
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...748
30 - GENERAL...749
Electrical system; special instructions for servicing; general...754
Electrical system; special instructions for servicing; electronic components...757
Electrical system; special instructions for servicing; electrical components; batteries...759
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator...762
Electrical system; special instructions for servicing; action when working on machine...764
Electrical system; description...766
Electronic control system; description...768
Communication with data buses...771
Auxiliary start...774
Data buses; function...777
Service connection and programming connection...783
Electrical system; specifications...786
Power Boost control; description...788
Engine Protection...790
Emergency operation; description...793
Start lock; description...796
X1 control; description...798
X1 pressure control; description...803
X3 control; description...805
Electro hydraulic pump control; description...808
Quick fit control; description...810
Engine - Pump control; specification...812