Volvo EW160E Excavator Workshop Repair Service Manual with Wiring Diagrams PDF Download - MVLVCONEW160E.zip

This is the full factory service and repair guide for Volvo EW160E Excavators, complete with Electrical Wiring Diagrams and every technical detail needed to service, troubleshoot, fix, and rebuild the machine to professional shop standards.

The Volvo Construction EW160E Excavators workshop service and repair manual 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.

PRODUCT DETAILS:

Total Pages: 4,261 pages

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

Language: English

Volvo EW160E Excavators Service Repair Manual.pdf

MAIN SECTIONS

000 - Foreword.......2

000 - GENERAL.......3

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

Description, complete machine.......5

Machine view.......7

Product plates.......9

03 - SPECIFICATIONS.......10

Conversion tables.......11

Machine weights.......19

Specifications, weight.......20

Tightening torques.......21

05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION.......27

Lifting instructions.......28

Measurements before transporting machine.......30

Tying down machine.......31

07 - STANDARD TIME.......33

Operation numbers for additional work.......34

08 - TOOL.......36

88830268 User Instruction.......37

88830540 User Instruction.......40

E-3508.......43

E-3509.......45

E-tool, 3500 Support plate for travel gearbox and motor.......47

E-tool, 3502 Plate for turning crankshaft.......49

Infrared Thermometer.......51

09 - MISCELLANEOUS.......53

Control units, changing.......54

Hydraulic cylinders, dieseling.......55

Service positions.......57

Welding on the machine.......58

001 - STANDARD PARTS, SERVICE.......59

16 - LUBRICANT; FUEL; OTHER FLUID.......60

AdBlue_DEF-[3727].......61

Alternative fuels.......67

Coolant with freezing and corrosion protection.......70

Fuel, lubricant and filling capacities.......72

Fuel.......74

Recommended lubricants.......75

17 - SERVICE.......78

AdBlue_DEF pump unit filter, replacing.......81

AdBlue_DEF tank breather filter, replacing.......85

Air conditioner compressor belt, checking.......88

Arrival Inspection, according to Inspection Programme.......90

Battery, checking.......95

Bearings.......97

Boom suspension accumulator, checking.......98

Brake disc wear, measuring.......103

Brake pressure and function, checking.......106

Cab main filter, cleaning.......110

Cab main filter, replacing.......113

Cab prefilter, cleaning.......116

Cab prefilter, replacing.......118

Cleaning prior to repair.......120

Coasting left and right swing.......121

Coolant freezing point, checking.......123

Coolant level, checking.......126

Coolant, changing.......128

Creeping of hydraulic cylinder.......132

Cylinder speed.......135

Delivery Inspection, according to Inspection Programme.......138

Diesel particulate filter, checking and cleaning.......140

Diesel particulate filter, regenerating.......148

Drive axles and hubs oil level, checking.......149

Drive axles and hubs oil, changing.......152

Elimination of trapped hydraulic pressure.......156

Engine air cleaner primary filter, replacing.......159

Engine air cleaner secondary filter, replacing.......161

Engine belt tension, checking.......163

Engine oil and filter, changing.......165

Engine oil level, checking.......168

Fuel filters, replacing.......169

Fuel tank breather filter, replacing.......171

Fuel tank sediment, draining.......173

Hoses and tubes.......175

Hydraulic oil drain filter, replacing.......176

Hydraulic oil level, checking.......178

Hydraulic oil return filter, replacing.......180

Hydraulic oil servo filter, replacing.......182

Hydraulic oil tank breather filter, replacing.......185

Hydraulic oil, changing.......187

In-line hydraulic oil filter, cleaning.......192

Leakage, checking.......195

Lubrication, every 100 hours.......196

Lubrication, every 50 hours_{09-30-10}.......200

Lubrication, every 50 hours_{09-30-24}.......205

Lubrication, every 500 hours.......210

MATRIS and Tech Tool, reading.......211

Maintenance of Stored Machines, according to Inspection Programme.......213

Maintenance service, every 10 hours.......215

Maintenance service, every 100 hours.......216

Maintenance service, every 1000 hours.......217

Maintenance service, every 2000 hours.......219

Maintenance service, every 250 hours.......222

Maintenance service, every 4000 hours.......223

Maintenance service, every 50 hours.......226

Maintenance service, every 500 hours.......227

Maintenance service, every 5000 hours.......229

Maintenance service, every 6000 hours.......230

Maintenance service, every 8000 hours.......231

Maintenance service, first 500 hours.......232

Measuring condition.......233

Measuring of swing bearing clearance.......234

Pressure testing.......235

Radiator, cleaning.......236

Replacement parts.......238

Secondary lowering of digging equipment.......239

Service methods.......241

Service position-[3041].......242

Service.......245

Software update, checking.......246

Starting engine with booster cables.......250

Swing ring gear lubrication, checking.......252

Swing speed.......254

Tech Tool, operations-[3419].......256

Test running and checking.......257

Towing.......259

Trailer hitch, checking_{09-15-07}.......262

Trailer hitch, checking_{09-15-31}.......265

Travel Speed.......270

Travel gearbox oil level, checking.......271

Travel gearbox oil, changing.......273

Tyre wear and air pressure, checking.......275

Universal quick coupler, checking.......277

Valves, adjusting-[2750].......279

Water separator, checking.......287

Wheel nuts torque, checking.......288

19 - GENERAL.......289

CE-marking, EMC-directive.......290

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

Decontamination.......293

Environmental handling for the future.......294

Environmentally hazardous fluids.......295

Environmentally safe handling.......296

Fire prevention measures.......298

Health hazards with paint, plastics and rubber.......301

Safety concerns everybody!.......303

Safety rules when servicing.......305

Safety when handling oils and fuel.......307

Safety when handling the machine_{09-09-53}.......308

Safety when handling the machine_{09-10-09}.......312

Safety when using lifting equipment.......315

Safety when working with air conditioning refrigerant.......316

Safety when working with batteries.......318

Safety when working with hydraulic systems.......320

Service position.......322

Some simple rules regarding tyre handling.......325

Starting with booster batteries.......327

Waste handling.......328

Working in environmentally contaminated areas.......329

002 - ENGINE WITH MOUNTING AND EQUIPMENT.......330

20 - GENERAL.......331

Component locations.......332

Engine control module (ECM), replacing non-programmed.......334

Engine control module (ECM), replacing pre-programmed.......337

Engine, description.......340

Engine, reference values.......347

Tech Tool, operations.......350

21 - ENGINE.......352

Crankcase ventilation, description.......353

Cylinder compression, testing.......357

Engine mount front, replacing.......360

Engine mounting rear, changing.......365

Engine mounting, tightening torque.......368

Engine, installing.......371

Engine, removing.......381

Engine, replacing_{09-01-42}.......391

Engine, replacing_{09-01-54}.......393

Engine, specifications.......396

Engine, tightening torques.......397

Oil level sensor, replacing.......404

Valve cover, installing.......406

Valve cover, removing.......410

Valve system, specifications.......414

Valves, adjusting.......415

22 - LUBRICATING SYSTEM.......423

Lubrication oil consumption, checking.......424

Lubrication oil pressure, checking with pressure gauge.......428

Lubrication system, component locations-[5624].......430

Lubrication system, component locations.......432

Lubrication system, description.......434

Lubrication system, specifications.......439

Lubrication system, tightening torques.......441

23 - FUEL SYSTEM.......444

Carbon dioxide in fuel system, checking.......445

Feed pump pressure, checking.......451

Fuel control valve (FCV), replacing.......453

Fuel filler pump, specifications.......458

Fuel filling pump, installing.......459

Fuel filling pump, removing.......461

Fuel rail pressure sensor, replacing.......464

Fuel rail, replacing.......466

Fuel system, bleeding.......469

Fuel system, component location.......471

Fuel system, description.......473

Fuel system, specifications.......480

Fuel system, tightening torques.......482

Fuel tank, description.......488

Fuel tank, replacing.......489

Fuel tank, specification.......494

High pressure fuel pipes, replacing.......495

High pressure fuel pump, replacing.......497

Injector sleeves, replacing.......500

Injectors, replacing.......510

Pressure relief valve (PRV), replacing.......515

25 - INLET & EXHAUST SYSTEM.......519

ACM (Aftertreatment control module) non-programmed, replacing.......521

ACM (Aftertreatment control module) pre-programmed, replacing.......523

AdBlue_DEF dosing injector, replacing.......525

AdBlue_DEF hoses, replacing.......528

AdBlue_DEF mixing tube, replacing.......533

AdBlue_DEF pump unit diagnostics, description.......536

AdBlue_DEF pump unit, flushing.......540

AdBlue_DEF pump unit, inlet nipple, replacing.......544

AdBlue_DEF pump unit, replacing.......548

AdBlue_DEF quality, checking.......553

AdBlue_DEF tank armature suction filter, replacing.......556

AdBlue_DEF tank armature, cleaning.......558

AdBlue_DEF tank armature, replacing_{08-40-37}.......561

AdBlue_DEF tank armature, replacing_{08-40-49}.......567

AdBlue_DEF tank, cleaning.......572

AdBlue_DEF tank, replacing_{08-45-06}.......576

AdBlue_DEF tank, replacing_{08-45-19}.......586

AdBlue_DEF, draining.......595

AdBlue_DEF.......598

Coolant valve, replacing_{08-44-15}.......603

Coolant valve, replacing_{08-44-27}.......606

Crystallization of AdBlue_DEF, checking.......609

DOC (Diesel oxidation catalyst), replacing.......614

DPF (Diesel particulate filter), checking and cleaning.......618

Exhaust Aftertreatment System, component location_{08-46-30}.......619

Exhaust Aftertreatment System, component location_{08-46-42}.......621

Exhaust Aftertreatment System, description.......623

Exhaust aftertreatment system muffler unit, installing.......637

Exhaust aftertreatment system muffler unit, removing.......640

Exhaust pipe flexible tube, replacing.......644

Inlet and exhaust system, component location.......646

Inlet and exhaust system, description.......648

Inlet and exhaust system, specification.......654

Inlet and exhaust system, tightening torques.......656

Inlet throttle, replacing.......662

Preheating coil, replacing.......664

Regeneration log, checking.......668

Regeneration process, description.......679

SCR (Selective catalytic reduction) dosing system, checking.......686

SCR (Selective catalytic reduction) muffler, replacing.......688

Turbocharger, replacing.......691

Wastegate, checking.......695

26 - COOLING SYSTEM.......697

AC compressor belt, replacing.......698

Carbon dioxide in coolant system, checking.......700

Coolant pump, replacing.......706

Cooling fan clutch, description.......713

Cooling fan clutch, replacing.......715

Cooling fan control.......721

Cooling fan rpm, specifications.......724

Cooling fan, description.......725

Cooling system pressure, checking.......726

Cooling system, component location.......728

Cooling system, description.......731

Cooling system, specifications.......735

Cooling system, tightening torques.......737

Expansion tank, replacing.......740

Fan belt and_or alternator belt, replacing.......743

Radiator, assembling.......746

Radiator, description.......751

Radiator, disassembling.......753

Radiator, installing.......757

Radiator, removing.......764

Thermostat, replacing.......770

27 - ENGINE CONTROL.......773

Engine control, specifications_{08-29-55}.......774

Engine control, specifications_{08-30-06}.......775

Engine control, specifications_{08-30-16}.......777

Engine speed control, description_{08-30-35}.......779

Engine speed control, description_{08-30-46}.......782

Engine speed control, description_{08-30-59}.......785

29 - MISCELLANEOUS.......789

EGR cooler, replacing.......790

EGR reed valve, replacing.......795

EGR system, tightening torques.......797

EGR valve, replacing.......799

EGR venturi tube, cleaning.......801

EGR venturi tube, replacing.......803

Exhaust Gas Recirculation (EGR), description.......806