Volvo EC160D Excavator Workshop Repair Service Manual with Wiring Diagrams PDF - MVLVCONEC160D.zip
A full workshop service and repair manual for the Volvo EC160D Excavator, featuring Electrical Wiring Diagrams and every technical detail needed to service, troubleshoot, fix, and overhaul the machine just like an expert technician.
The Volvo Construction Equipment EC160D 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 EC160D Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,432 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....9
Measurement conversion tables....20
Engine; software specifications....29
Alternator; specifications....32
Starter motor; specifications....33
Preheating; specifications....34
Engine limp home switch; specifications....35
Relay; specifications....37
Undercarriage; tightening torque_{14-25}....39
Undercarriage; tightening torque_{14-04}....40
Undercarriage; tightening torque_{13-42}....41
Counterweight; tightening torques....43
Lubrication system; specifications....45
Engine; tightening torques_{12-03}....47
Engine; tightening torques_{11-38}....50
07 - STANDARD TIME....52
Operation numbers for additional work....53
08 - TOOL....55
E-tools; NET 8940-00290 Swing motor guide pin....56
E-tools; NET 8940-00420 Replace tool for the swing ring gear....57
E-tools; NET 8940-00320 Swing motor guide pin and swing ring gear....59
09 - MISCELLANEOUS....61
Service positions....62
Welding on the machine....65
Hydraulic cylinders; dieseling....68
Control units; changing....72
1 - STANDARD PARTS; SERVICE....74
16 - LUBRICANT; FUEL; OTHER FLUID....75
Engine oil....76
Fuel....78
Hydraulic oil....81
Recommended lubricants....86
Coolant_{02-34}....89
Coolant_{02-12}....94
Coolant with freezing and corrosion protection....98
Grease....102
Alternative fuels....106
Specification; filling capacities....109
17 - SERVICE....110
Bearings....113
Replacement parts....117
Safety when servicing....121
Service....125
Service methods....128
Pressure testing....132
Hoses and tubes....136
Cleaning prior to repair....140
VCADS Pro; Operations....144
Arrival Inspection; according to Inspection Programme....146
Delivery Inspection; according to Inspection Programme....151
Maintenance of Stored Machines; according to Inspection Programme....155
Maintenance service; first 500 hours....159
Maintenance service; daily....160
Maintenance service; every 50 hours....161
Maintenance service; every 250 hours....162
Maintenance service; every 500 hours....163
Maintenance service; every 1000 hours....165
Maintenance service; every 2000 hours....167
Maintenance service; every 3000 hours....169
Maintenance service; every 4000 hours....171
Maintenance service; every 4500 hours....173
Maintenance service; every 6000 hours_{51-00}....174
Maintenance service; every 6000 hours_{50-39}....175
Test-run and check....176
MATRIS; reading; export reading....179
VCADS Pro; logged errors; read off....182
The machine; check for external damages; cracks and wear damages....185
Washer fluid level; check....188
Engine; oil level; check....189
Coolant level; check....190
Hydraulic oil level; check....191
Fuel filter; change....193
Water separator; check_drain....195
Water separator filter element; change....196
Fuel tank sediment; drain....198
Fuel tank air ventilation filter; change....200
Hydraulic oil servo filter; change....203
Air cleaner; cleaning filter element....204
Air cleaner; primary filter replacing....206
Air cleaner; secondary filter replacing....208
Battery condition; check....211
Air conditioner compressor belt; check....213
Fan belt and belt tension; check....215
Radiator outside_hydraulic oil cooler outside; cleaning....216
Hydraulic oil drain filter; change....218
Hydraulic oil suction strainer; clean....220
Valves; adjusting....222
Coolant anti-freeze resistance; checking....230
Coolant; changing....234
DPF (Diesel particulate filter); checking and cleaning....236
Spark plug; replacing....241
Air conditioner main filter; clean....243
Air conditioner main filter; change....247
Cab; prefilter; clean....251
Cab prefilter; replacing....253
Lubrication; see lubrication chart....255
Swing gearbox oil level; check....257
Swing motor gearbox; changing oil....259
Swing ring gear bearing; lubricate....261
Swing bath grease; check....264
Cab; door; covers; hinges; joints and locks; lubricate....266
Track shoe bolts; check....268
Track tension_condition; check....270
Track gearbox oil level; check....272
Track motor gearbox; changing oil....274
Loose and loss of bolts; check....276
X1 return filter (optional equipment); change....279
Service history (included in the respective Operator's manual); fill in.....281
Engine oil and filter; changing....284
CareTrack backup battery; replacing_{28-02}....287
CareTrack backup battery; replacing_{27-37}....290
Hydraulic oil; changing....295
Hydraulic oil return filter; replacing....298
Hydraulic oil tank breather filter; replacing....301
Measuring condition....304
Cylinder speed....307
Creeping of hydraulic cylinder....310
Swing speed....313
Coasting left and right swing....314
Measuring of swing bearing clearance....316
Travel Speed....319
Track running speed....321
Straight traveling performance....323
Starting engine with booster cables....325
19 - GENERAL....329
Safety concerns everybody!....330
CE-marking; EMC-directive....334
Cautions during operation....338
Safety when handling the machine....345
Safety rules when servicing....352
Move and operate machine safely....357
Fire prevention measures....360
Health hazards with paint; plastics and rubber....366
Checklist after a fire or heat exposure....371
Safety when using lifting equipment....375
Safety when handling oils and fuel....379
Safety when working with batteries....383
Starting with booster batteries....388
Safety when working with air conditioning refrigerant....392
Safety when working with hydraulic systems....397
Environmental handling for the future....401
Environmentally safe handling....405
Environmentally hazardous fluids....409
Working in environmentally contaminated areas....413
Decontamination....417
Waste handling....421
2 - ENGINE WITH MOUNTING AND EQUIPMENT....425
20 - GENERAL....426
Engine; description....427
Engine; software specifications....431
Component locations....434
VCADS Pro; Operations....437
E-ECU MID 128 pre-programmed; replacing....439
E-ECU MID 128 non-programmed; replacing....441
21 - ENGINE....443
Engine; specifications....444
Engine characteristic curve....445
Engine; removing....447
Engine; tightening torques_{03-55}....458
Engine; tightening torques_{03-33}....461
Crankcase ventilation; description....463
Valve system specifications....467
Valves; adjusting....468
Oil level sensor; replacing....476
22 - LUBRICATING SYSTEM....479
Lubricating system; description....480
Lubrication system; specifications....485
Lubrication system; tightening torques....487
Lubrication system; component locations....489
Lubrication oil pressure; checking with pressure gauge....491
23 - FUEL SYSTEM....494
Fuel system; description....495
Fuel system; specifications....501
Fuel system; tightening torques....503
Carbon dioxide in fuel system; checking....505
Fuel system; component location....511
Feed pump pressure; checking....513
Fuel system; bleeding....516
Fuel tank; volume....518
Fuel filler pump; specifications....519
Fuel tank; description....520
Fuel filling pump; removing....522
Fuel filling pump; installing....525
Injectors; replacing....527
High pressure fuel pump; checking....537
Injector sleeves; replacing_{48-50}....543
Injector sleeves; replacing_{48-26}....553
Fuel rail; replacing....561
Fuel rail pressure; checking....568
Fuel rail pressure sensor; replacing....573
High pressure fuel pump; replacing....576
Fuel control valve (FCV); checking....579
Fuel control valve (FCV); replacing....584
Pressure relief valve (PRV); replacing....588
High pressure fuel system pressure; relieving....591
25 - INLET & EXHAUST SYSTEM....595
Inlet and exhaust system; description....596
Inlet and exhaust system; component location....601
Inlet and exhaust system; tightening torques_{42-50}....603
Inlet and exhaust system; tightening torques_{42-29}....605
Exhaust pipe flexible tube; replacing....607
Exhaust Aftertreatment System; description....610
Exhaust Aftertreatment System; component location....622
Regeneration process; description....624
Exhaust aftertreatment system; specifications....629
DPF (Diesel particulate filter); checking and cleaning....632
Spark plug control unit; replacing....637
Air pump safety valve; replacing....639
ACM (Aftertreatment control module) non-programmed; replacing....642
ACM (Aftertreatment control module) pre-programmed; replacing....645
Spark plug; inspecting....648
Spark plug; replacing....650
Spark plug cable; replacing....652
Air pump; replacing....654
Burner function; checking....658
Burner; replacing....664
DOC (Diesel oxidation catalyst); replacing....670
Turbocharger; description....673
Turbocharger; replacing....676
Preheating coil; replacing....679
Air cleaner; cleaning filter element....684
Air cleaner; primary filter replacing....686
Air cleaner; secondary filter replacing....688
Charge air cooler; replacing....691
26 - COOLING SYSTEM....701
Cooling system; description....702
Carbon dioxide in coolant system; checking....705
Cooling system; component location....711
Cooling system; tightening torques....713
Cooling system pressure; checking....715
Radiator; description....717
Coolant anti-freeze resistance; checking....719
Coolant; changing....724
Radiator; replacing....726
Radiator hoses all; replacing....728
Expansion tank; replacing....730
Thermostat; replacing....733
Thermostat; checking....737
Thermostat; specifications....741
Cooling fan control....743
Fan belt and_or alternator belt; replacing....746
Fan belt and_or alternator-; compressor belt; replacing all belts....749
Cooling fan clutch; description....752
27 - ENGINE CONTROL....755
Engine - Pump control; specification....756
29 - MISCELLANEOUS....758
EGR actuator; replacing....759
Exhaust Gas Recirculation (EGR); description....762
Exhaust gas recirculation (EGR); component location....767
EGR system; tightening torques....769
EGR reed valve; replacing....772
EGR cooler; replacing....776
EGR valve; replacing....783
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....786
30 - GENERAL....787
Electrical system; special instructions for servicing; general....793
Electrical system; special instructions for servicing; electronic components....797
Electrical system; special instructions for servicing; electrical components; batteries....800
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator....804
Electrical system; special instructions for servicing; action when working on machine....807
Electrical system; description....810
Electronic control system; description....812
Communication with data buses....815
Auxiliary start....818
Data buses; function....822
Service connection and programming connection....827
VCADS Pro; Operations_{12-08}....830
VCADS Pro; Operations_{11-45}....833
Electrical system; specifications....835
Power Boost control; description....838
Emergency operation; description....841
Anti-theft system....843
CareTrack with anti-theft....846
Start lock; description....855
Safe start and stop; description....857
X1 control; description....860
X1 pressure control; description....865
X3 control; description....867
Response mode....870