Volvo EW160B Excavator D6D Engine Workshop Service Repair Manual PDF - MVLVCONEW160B.zip

A full factory-level service and repair guide featuring Electrical Wiring Diagrams for the Volvo EW160B Excavator, packed with every technical detail you need to service, troubleshoot, fix, and rebuild your machine the way trained technicians do.

This workshop manual for the Volvo Construction EW160B Excavator covers:

- General instructions and safety precautions

- Engine

- Electrical system

- Hydraulic system

- Working equipment

* 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 EW160B Excavators Service Repair Manual.pdf

PRODUCT DETAILS:

Total Pages: 1,932 pages

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

Language: English

TABLE OF CONTENTS

0 - Foreword.....2

0 - GENERAL.....3

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

Machine EW160B; description.....5

Component locations.....6

Product plates.....8

03 - SPECIFICATIONS.....9

Tightening torques.....11

Conversion tables.....19

Dimensions.....27

Engine; weights .....29

Digging diagram.....30

Cylinder head; specifications .....33

Servo pump; installing .....34

Cylinder liner; specifications .....35

Pistons; specifications .....37

Piston rings; specifications .....38

Camshaft; specifications .....40

Crankshaft; specifications .....42

Capacities.....43

Flywheel; specifications .....44

Flywheel; weight- .....45

Lubrication system; specifications .....46

Fuel feed pump; specifications .....47

Fuel filter; specifications .....48

Unit pumps; specifications .....49

Injectors; specifications-.....50

Turbocharger; specifications-.....51

Cooling system; specifications-.....52

Coolant pump; thermostat; specifications-.....53

Electrical system; specifications-.....54

Battery; specifications-.....55

Alternator; specifications.....56

Starter motor; specifications-.....57

Preheating; specifications-.....58

Travel motor; specifications-.....59

Slew motor; specifications-.....60

Steering axle; specifications .....61

Lighting; specifications-.....62

Electric horn; specifications-.....63

Upper wiper motor; specifications-.....64

Lower wiper motor; specifications-.....65

Preheating; specifications .....66

Upper wiper motor; specifications .....67

Lower wiper motor; specifications- .....68

Undercarriage; specifications-.....69

Slew system for superstructure; specifications-.....70

Brake discs; specifications-.....71

Hydraulic oil; specifications-.....72

Hydraulic pressure; specifications .....73

Working pump; specifications-.....75

Servo _ fan and brake _ steering pump; specifications-.....76

Cylinder data .....77

Hydraulic pressure; specifications-.....78

Digging equipment bearings; specifications-.....80

Cylinder data- .....81

05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION.....82

Lifting instructions.....83

07 - STANDARD TIME.....85

Operation numbers for additional work.....86

08 - TOOL.....88

E-tools; NET 00024 Guide pin for slew ring.....89

E-tool; NET 00025 Lifting eye for superstructure.....90

E-tool; 1802 Extractor for pressure limiting valve.....92

09 - MISCELLANEOUS.....93

Service positions.....94

Welding on the machine.....96

Hydraulic cylinders; dieseling.....98

1 - STANDARD PARTS; SERVICE.....100

16 - LUBRICANT; FUEL; OTHER FLUID.....101

Recommended lubricants.....102

Alternative fuels.....105

17 - SERVICE.....108

Elimination of trapped hydraulic pressure.....109

Arrival Inspection; according to Inspection Programme.....111

Delivery Inspection; according to Inspection Programme.....116

Maintenance of Stored Machines; according to Inspection Programme.....118

Warranty inspection 1000 hours.....120

Maintenance service; daily.....148

Maintenance service; every 50 hours.....152

Maintenance service; every 250 hours.....159

Maintenance service; every 500 hours.....170

Maintenance service; every 1000 hours.....187

Maintenance service; every 2000 hours.....209

Maintenance service; every 4000 hours.....237

CareTrack backup battery; replacing.....267

Towing.....270

Secondary lowering of digging equipment.....272

Starting engine with booster cables.....275

19 - GENERAL.....277

Safety concerns everybody!.....278

CE marking and declaration of conformity.....280

Environment.....282

Safety rules for service.....284

Fire prevention measures.....287

Health hazards with paint; plastics and rubber.....290

Checklist after a fire or heat exposure.....292

Safety when lifting and supporting the machine.....293

Safety when handling oils and fuel.....294

Safety when working with batteries.....295

Safety when working with air conditioning refrigerant.....297

Some simple rules regarding tyre handling.....299

Safety when working with hydraulic systems.....301

2 - ENGINE WITH MOUNTING AND EQUIPMENT.....303

20 - GENERAL.....304

E-ECU MID 128 pre-programmed; replacing.....305

E-ECU MID 128 non-programmed; replacing.....308

Description D6D.....311

Component position; engine D6D.....312

Engine; weights-.....315

21 - ENGINE.....316

Engine; specifications.....317

Engine; removal.....318

Engine; installation.....327

Engine; weights.....337

Cylinder head; description.....338

Cylinder head; specifications.....339

Cylinder block; specifications.....340

Cylinder liner; specifications.....341

Pistons; specifications.....342

Pistons; description.....343

Piston rings; specifications.....345

Valve mechanism; description.....346

Valve mechanism; specifications.....347

Valve mechanism; tightening torques.....349

Valves; adjusting.....350

Engine timing gear; description.....356

Camshaft; description.....357

Camshaft; specifications.....359

Flywheel; weight.....360

Crankshaft; description.....361

Vibration damper; description.....364

Crankshaft; specifications.....367

Connecting rod; description.....369

Connecting rods; specifications.....372

Flywheel; specifications.....374

Crankshaft front oil seal; replacing.....375

Crankshaft rear oil seal; replacing.....384

Oil sump; replacing.....390

Engine mount front; replacement.....396

Engine mount rear; replacement.....399

22 - LUBRICATING SYSTEM.....402

Lubrication system; description.....403

Lubrication system; specifications.....405

Oil pump; description.....406

Oil pump; specifications.....407

Oil pump; replacing.....408

Lubrication oil pressure; checking.....424

Oil pressure relief valve; replacing.....426

23 - FUEL SYSTEM.....431

Fuel system; specifications.....432

Fuel system; description.....433

Fuel feed pump; description.....435

Fuel feed pump; specifications.....436

Feed pump pressure; checking.....437

Feed pump; replacing.....439

Fuel filter; description.....442

Fuel filter; specifications.....443

Fuel system; bleeding.....444

Fuel tank; removal.....446

Fuel tank; installation.....450

Fuel filling pump; replacement.....455

Injectors; description.....457

Injectors; specifications.....458

Injector; replacing.....459

Unit pump; description.....465

Unit pumps; specifications.....470

Pump unit; replacing.....471

25 - INLET & EXHAUST SYSTEM.....477

Silencer; replacing.....478

Turbocharger; description.....481

Turbocharger; specifications.....484

26 - COOLING SYSTEM.....485

Cooling system; specifications.....486

Radiator; removal.....487

Radiator; installation.....492

Expansion tank; replacement.....498

Coolant pump; thermostat; specifications.....501

Coolant pump; replacing.....502

Thermostat; replacing.....505

Fan belt; replacement.....507

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....512

30 - GENERAL.....513

Electrical system; special instructions for servicing.....517

Electrical system; description.....519

Electronic control system; description.....520

Communication with data buses.....522

Data buses; function.....524

Service connection and programming connection.....528

Component location; sensors; solenoid valves and proportional valves.....530

Data links; fault tracing with Oscilloscope.....533

Electrical system; specifications.....543

Troubleshooting strategy.....544

Troubleshooting; general.....546

Collection of basic data.....548

Electrical cables and connectors; checking.....550

Troubleshooting tools.....555

Special tools for troubleshooting.....556

VCADS Pro service tool.....557

Troubleshooting using alarm and error codes.....561

128 PID110.....562

187 SID231.....564

999 8699 Multi-pin breaker box.....566

999 0062 Extension cable.....567

999 3894 Template.....568

999 3893 Adapter cable.....569

11 666 140 Multimeter.....570

951 1355 Adapter cable.....571

999 8505 Adapter cable.....572

999 3721 Service display unit.....573

11 668 006 Extension cable.....574

Error texts and troubleshooting information; general.....575

SAE error codes; translation to error messages; general.....576

Error codes; overview.....577

128 PID45.....580

128 PID91.....582

128 PID100.....583

128 PID102.....585

128 PID105.....587

128 PID106.....589

128 PID107.....591

128 PID108.....593

128 PID111.....594

128 PID172.....596

128 PID174.....598

128 SID1 - 6.....600

128 SID21.....602

128 SID22.....604

128 SID70.....606

128 SID231.....608

128 SID240.....610

128 SID250.....612

128 SID251.....614

128 SID253.....616

128 SID254.....618

130 PID84.....620

130 PID190.....621

130 PPID1092.....623

130 PPID1193.....625

130 PPID1194.....627

130 PPID1283.....629

130 PPID1284.....631

130 PPID1285.....633

130 PPID1286.....635

130 PPID1287.....637

130 PPID1288.....639

130 PPID1289.....641

130 PPID1290.....643

130 PPID1291.....645

130 PPID1292.....647

130 PPID1293.....649

130 PPID1294.....651

130 PPID1295.....653

130 PPID1310.....655

130 SID231.....657

130 SID240.....659

130 SID250.....661

130 SID251.....663

130 SID253.....665

130 SID254.....667

140 SID231.....669

140 SID240.....670

140 SID250.....671

140 SID253.....672

140 SID254.....673

187 PID96.....674

187 PPID1110_3.....676

187 PPID1110_4.....678

187 PPID1110_7.....680

187 PPID1114.....682

187 PPID1116.....684

187 PPID1117.....686

187 PPID1121.....688

187 PPID1127.....690

187 PPID1128.....691

187 PPID1129.....693

187 PPID1130.....695

187 PPID1131.....697

187 PPID1132.....699

187 PPID1150_1.....701

187 PPID1156.....703