Volvo EW160D Excavator Workshop Service Repair Manual PDF Download - MVLVCONEW160D.zip
A full factory-style service and repair guide, complete with electrical wiring diagrams, covering the Volvo EW160D Excavator — packed with everything needed to service, troubleshoot, fix, and rebuild these machines to professional standards.
This Volvo Constructions EW160D 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 EW160D Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,114 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
Description; complete machine................5
Component locations ................6
Product plates................10
03 - SPECIFICATIONS................11
Tightening torques................12
Conversion tables................18
Machine weights................26
Capacities................28
Specifications; weight................29
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION................30
Lifting instructions................31
07 - STANDARD TIME................34
Operation numbers for additional work................35
08 - TOOL................37
E-tool; 3500 Support plate for travel gearbox and motor................38
E-tool; 3502 Plate for turning crankshaft................40
Infrared Thermometer................42
E-3509................44
E-3508................46
09 - MISCELLANEOUS................48
Service positions ................49
Welding on the machine................52
Hydraulic cylinders; dieseling................53
Control units; changing................55
1 - STANDARD PARTS; SERVICE................56
16 - LUBRICANT; FUEL; OTHER FLUID................57
Coolant with freezing and corrosion protection................58
Recommended lubricants_{040-03}................60
Recommended lubricants_{039-31}................64
Coolant................67
Alternative fuels................72
17 - SERVICE................75
Bearings................79
Elimination of trapped hydraulic pressure................80
Replacement parts................82
Service................83
Service methods................84
Pressure testing................85
Hoses and tubes................86
Cleaning prior to repair................87
Tech Tool; operations-................88
Arrival Inspection; according to Inspection Programme................89
Delivery Inspection; according to Inspection Programme................94
Maintenance of Stored Machines; according to Inspection Programme................96
Periodic maintenance................98
Service positions ................99
Maintenance service; daily................102
Maintenance service; every 050 hours................103
Maintenance service; every 250 hours................104
Maintenance service; first 500 hours................105
Maintenance service; every 500 hours................106
Maintenance service; every 1000 hours................108
Maintenance service; every 2000 hours................110
Maintenance service; every 3000 hours_{28-35}................112
Maintenance service; every 3000 hours_{28-13}................114
Maintenance service; every 4000 hours................116
Maintenance service; every 4500 hours................118
Maintenance service; every 6000 hours_{26-57}................119
Maintenance service; every 6000 hours_{26-35}................120
Boom suspension accumulator; checking and adjusting ................121
Tyres; wear and air pressure; checking................125
Checking for cracks and leaks................127
Check engine oil level................128
Test-run and check................129
Lubrication................130
Grease points on dipper arm; lubrication................131
Grease points on booms; lubrication................134
Grease points on undercarriage; lubrication................136
Grease points on superstructure; lubrication................140
Hydraulic system; checking oil level................142
Water separator; drain................144
Coolant level; check................145
Axles; checking oil level................147
Travel gearbox oil level; checking................150
Fuel tank water and sediment; drain................152
Battery condition; check................154
Door hinges; lubricate with grease................157
Cab; prefilter; clean................159
Axles; changing oil................161
Engine; oil and filter; change.................165
Fuel filters; primary and secondary filter; replace................169
Radiator; cleaning................171
Cab; main filter; clean................174
Belts and belt tension; check; replace when needed.................177
Trailer hitch; checking................180
Swing ring gear; grease check................184
Service journal (included in Operator's manual); fill in................186
Wheel nuts; check torque................187
Brake system; checking function................188
Engine; air cleaner; main filter; replacing.................189
Air conditioning unit; maintenance ................192
MATRIS; reading; export reading................193
VCADS Pro; logged errors; read off................195
Travel gearbox; changing oil................197
Brake discs; checking wear................199
Engine; air cleaner; secondary filter; replacing.................202
Cab; prefilter; replace................204
Cab main filter; replacing................206
Fuel tank breather filter; replacing................210
Hydraulic oil return filter; changing_{001-58}................212
Hydraulic oil return filter; changing_{001-32}................214
Hydraulic tank breather filter; changing................216
Hydraulic oil servo filter; change_{000-05}................218
Hydraulic oil servo filter; change_{058-36}................222
Coolant's freezing point; check................225
Valves; adjusting ................227
Hydraulic system; changing oil................235
Turbocharger inclusive inlet and exhaust systems; leakage; check................239
Coolant; change................243
DPF (Diesel particulate filter); checking and cleaning ................247
Spark plug; replacing ................253
Hydraulic oil suction strainer; cleaning................255
CareTrack backup battery; replacing................258
Measuring condition................261
Cylinder speed................262
Creeping of hydraulic cylinder................265
Swing speed................269
Measuring of swing bearing clearance................270
Coasting left and right swing................271
Travel Speed................273
Towing................274
Secondary lowering of digging equipment................277
Starting engine with booster cables................279
19 - GENERAL................281
Safety concerns everybody!................282
Service positions................284
CE marking and declaration of conformity................287
Safety when handling the machine................289
Safety rules when servicing................293
Checklist after a fire or heat exposure................295
Fire prevention measures................296
Health hazards with paint; plastics and rubber................299
Some simple rules regarding tyre handling................301
Safety when using lifting equipment................303
Safety when handling oils and fuel................304
Safety when working with batteries................305
Starting with booster batteries................307
Safety when working with air conditioning refrigerant................308
Safety when working with hydraulic systems................310
Environmental handling for the future................312
Environmentally safe handling................313
Environmentally hazardous fluids................315
Working in environmentally contaminated areas................316
Decontamination................317
Waste handling................318
2 - ENGINE WITH MOUNTING AND EQUIPMENT................319
20 - GENERAL................320
Engine; description................321
Engine; identification................325
Engine; volume................326
Component locations................327
Engine; weights ................330
Electric components location_{18-17}................331
Electric components location_{17-45}................338
E-ECU MID 128 pre-programmed; replacing................345
E-ECU MID 128 non-programmed; replacing................348
21 - ENGINE................351
Engine; specifications................352
Cylinder compression; PC test................353
Engine characteristic curve................354
Basic check; Engine................356
Troubleshooting ................357
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope................359
Engine; removing................365
Engine; installing................375
Engine; weights................386
Engine; tightening torques................387
Crankcase ventilation; description................389
Valve system specifications................390
Valves; adjusting................391
Valve cover; removing................399
Valve cover; installing................404
Crankshaft; description................409
Vibration damper; description................410
Connecting rod; description................412
Oil sump; replacing................414
Oil level sensor; replacing ................421
Engine mount front; replacing................425
Engine mounting rear; changing................430
Engine mounting; tightening torque................433
22 - LUBRICATING SYSTEM................436
Lubricating system; description................437
Lubrication system; specifications................441
Lubrication system; tightening torques................443
Lubrication system; component locations................445
Lubrication oil pressure; checking with pressure gauge................447
Oil cooler; replacing................451
Oil cooler; description................455
23 - FUEL SYSTEM................456
Fuel system; description................458
Fuel system; specifications................464
Fuel system; tightening torques................466
Fuel pressure; specifications................472
Instructions for working with electronic fuel injection................474
Fuel pressure; checking................475
Fuel system; component location................478
Fuel feed pump; description-5118................480
Fuel feed pump; description................481
Fuel filter; description................482
Feed pump pressure; checking................483
Fuel filter; checking................488
Fuel system; bleeding................489
Feed pump; replacing................491
Fuel filters; replacing................497
Fuel filter extra; replacing................499
Fuel tank; specification................501
Fuel filler pump; specifications................502
Fuel tank; description................503
Fuel tank; replacing................505
Fuel filler pump; description................513
Fuel filling pump; removing................515
Fuel filling pump; installing................518
Fuel return pressure; checking................520
Injectors; specifications................522
Injectors; replacing................523
High pressure fuel pump; checking................532
Injector sleeves; replacing................537
Fuel rail; replacing................546
Fuel rail pressure; checking................554
Fuel rail pressure sensor; replacing ................559
High pressure fuel pump; replacing................561
Fuel control valve (FCV); checking................566
Fuel control valve (FCV); replacing................571
Pressure relief valve (PRV); inspecting................574
Pressure relief valve (PRV); replacing................579
25 - INLET & EXHAUST SYSTEM................582
Inlet and exhaust system; description................584
Inlet and exhaust system; component location................588
Inlet and exhaust system; tightening torques................590
Exhaust pipe flexible tube; replacing................592
Exhaust Aftertreatment System; description_{29-31}................595
Exhaust Aftertreatment System; description_{28-49}................606
Exhaust Aftertreatment System; component location................617
Regeneration process; description................619
Exhaust aftertreatment system; specifications................624
DPF regeneration control................627
Semi-auto DPF regeneration ................628
Perform a service regeneration................629
DPF (Diesel particulate filter); checking and cleaning................631
Exhaust aftertreatment system; tightening torques................637
DPF (Diesel particulate filter) inlet temperature sensor; replacing ................639
Spark plug control unit; replacing................642
Glow plug; replacing................644
Fuel metering unit A; replacing................646
Fuel metering unit B; replacing................650
Air pump safety valve; replacing................656
DPF (Diesel particulate filter) outlet temperature sensor; replacing ................658
ACM (Aftertreatment control module) non-programmed; replacing................661
ACM (Aftertreatment control module) pre-programmed; replacing................663
Spark plug; inspecting................665
Spark plug cable; replacing................667
Air pump; replacing................669
Burner function; checking................672
Burner; replacing................677
Spark plug; replacing................684
NOx sensor; replacing ................686
DOC (Diesel oxidation catalyst); replacing................690
Turbocharger; description................693
Turbocharger; replacing................695
Air cleaner; description................700
Air cleaner; specification................701
Preheating coil; replacing................702
Charge air cooler; replacing................704
26 - COOLING SYSTEM................707
Cooling system; description................708
Cooling system; specifications................711
Carbon dioxide in coolant system; checking................712
Cooling system; tightening torques................718
Cooling system; component location................719
Cooling system pressure; checking................722
Coolant anti-freeze resistance; checking................724
Radiator; description................726
Radiator; replacing................728
Radiator hoses all; replacing................732
Expansion tank; replacing................735
Radiator; removing................738
Radiator; installing................745
Coolant pump; thermostat; specifications................752
Coolant pump; replacing................753
Thermostat; inspecting................760
Thermostat; replacing................763