EC160 Volvo, EC160B LC Volvo, EC160B NLC Volvo, EC160C L Volvo, EC160C NL, EC160D L Volvo, ED160C NL, EC160E L Volvo, EC160E NL Volvo Excavators Service Repair Manual
Complete repair service manual with Electrical Wiring Diagrams for EC160 Volvo, EC160B LC Volvo, EC160B NLC Volvo, EC160C L Volvo, EC160C NL, EC160D L Volvo, ED160C NL, EC160E L Volvo, EC160E NL Volvo Excavators, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Construction Equipment EC160 Series Excavators workshop service repair manual includes:
* 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.
...
000 - Foreword...2
000 - GENERAL...3
00 - DESCRIPTION; COMPLETE MACHINE...4
Machine View...5
Product plates...7
03 - SPECIFICATIONS...9
Tightening torques...10
Measurement conversion tables...21
Undercarriage; tightening torque_{02-46-38}...30
Undercarriage; tightening torque_{02-46-18}...31
Undercarriage; tightening torque_{02-45-59}...32
07 - STANDARD TIME...34
Operation numbers for additional work...35
08 - TOOL...37
Infrared Thermometer...38
09 - MISCELLANEOUS...42
Service positions...43
Welding on the machine...45
Hydraulic cylinders; dieseling...48
001 - STANDARD PARTS; SERVICE...52
17 - SERVICE...53
Bearings...56
Replacement parts...60
Safety when servicing...64
Service...68
Service methods...71
Pressure testing...75
Hoses and tubes...79
Cleaning prior to repair...83
Tech Tool; operations ...87
Arrival Inspection; according to Inspection Programme...89
Delivery Inspection; according to Inspection Programme...94
Maintenance of Stored Machines; according to Inspection Programme...98
Maintenance service; first 500 hours...102
Maintenance service; every 10 hours...103
Maintenance service; every 50 hours...104
Maintenance service; every 250 hours...105
Maintenance service; every 500 hours_{02-29-05}...106
Maintenance service; every 500 hours_{02-28-46}...108
Maintenance service; every 1000 hours_{02-28-15}...110
Maintenance service; every 1000 hours_{02-27-55}...112
Maintenance service; every 2000 hours_{02-27-24}...114
Maintenance service; every 2000 hours_{02-27-04}...116
Maintenance service; every 4000 hours_{02-26-34}...118
Maintenance service; every 4000 hours_{02-26-14}...120
Maintenance service; every 6000 hours_{02-25-43}...122
Maintenance service; every 6000 hours_{02-25-24}...123
Maintenance service; every 8000 hours_{02-24-46}...124
Maintenance service; every 8000 hours_{02-24-27}...125
Service position...126
Lubrication; every 50 hours...129
Test running and checking...131
Valves; adjusting ...133
Engine oil and filter; changing...138
Fuel filter; replacing...141
Water separator filter; replacing...143
Fuel tank breather filter; replacing...145
Diesel particulate filter; regenerating...148
Diesel particulate filter; checking and cleaning...150
AdBlue®_DEF pump unit filter; replacing...156
AdBlue®_DEF tank breather filter; replacing...160
Engine air cleaner primary filter; replacing...162
Engine air cleaner secondary filter; replacing...164
Coolant; changing-...166
Coolant freezing point; checking...169
Fan_alternator belt; checking...172
Radiator and hydraulic oil cooler; cleaning...174
MATRIS and Tech Tool; reading...176
Software update; checking...179
Battery; checking_{02-13-54}...183
Battery; checking_{02-13-32}...185
CareTrack backup battery; replacing_{02-12-57}...187
CareTrack backup battery; replacing_{02-12-35}...190
Track gearbox oil level; checking...195
Track gearbox oil; changing...197
Swing gearbox oil level; checking...199
Swing gearbox oil; changing...201
Swing ring gear bearing; lubricating...203
Swing bath grease; checking...205
Track shoe bolts; checking...206
Track tension and condition; checking...208
Cab door; covers; hinges; joints and locks; lubricating...210
Air conditioner main filter; cleaning...212
Air conditioner main filter; replacing...215
Cab prefilter; cleaning...218
Cab prefilter; replacing...220
Air conditioner compressor belt; checking...222
Hydraulic oil level; checking...224
Hydraulic oil; changing...226
Hydraulic oil suction strainer; cleaning...229
Hydraulic oil drain filter; replacing...231
Hydraulic oil servo filter; replacing...233
Hydraulic oil return filter; replacing...234
Hydraulic return filter on X1 option circuit; replacing...237
Hydraulic oil tank breather filter; replacing...239
Measuring condition...241
Cylinder speed...244
Creeping of hydraulic cylinder...247
Swing speed...249
Coasting left and right swing...250
Measuring of swing bearing clearance...252
Travel Speed...255
Track running speed...257
Straight traveling performance...259
19 - GENERAL...261
Safety concerns everybody!...262
CE-marking; EMC-directive...266
Cautions during operation...270
Safety when handling the machine...277
Safety rules when servicing...283
Move and operate machine safely...288
Fire prevention measures...291
Health hazards with paint; plastics and rubber...297
Checklist after a fire or heat exposure...302
Safety when using lifting equipment...306
Safety when handling oils and fuel...310
Safety when working with batteries...314
Starting with booster batteries...319
Safety when working with air conditioning refrigerant...323
Safety when working with hydraulic systems...328
Environmental handling for the future...332
Environmentally safe handling...336
Environmentally hazardous fluids...340
Working in environmentally contaminated areas...344
Decontamination...348
Waste handling...352
002 - ENGINE WITH MOUNTING AND EQUIPMENT...356
20 - GENERAL...357
Engine; description_{01-38-08}...358
Engine; description_{01-37-46}...365
Component locations...371
Tech Tool; operations_{01-36-33}...374
Tech Tool; operations_{01-36-14}...376
Engine control module (ECM); replacing pre-programmed...379
Engine control module (ECM); replacing non-programmed...381
Engine; reference values...384
Engine belts; replacing...387
21 - ENGINE...390
Engine; specifications...391
Engine rotation speed sensor (crank shaft); replacing...392
Engine rotation speed sensor (camshaft); replacing...394
Engine; removing...396
Engine; installing...406
Engine; replacing_{01-30-56}...415
Engine; replacing_{01-30-37}...419
Engine; tightening torques...422
Cylinder compression; testing...429
Crankcase ventilation; description...432
Valves; adjusting...436
Valve cover; removing...441
Valve cover; installing...444
Oil level sensor; replacing...447
22 - LUBRICATING SYSTEM...450
Lubrication system; description...451
Lubrication system; specifications...456
Lubrication system; component locations...458
Lubrication system; tightening torques...460
Lubrication oil pressure; checking with pressure gauge...463
Oil cooler; replacing...466
23 - FUEL SYSTEM...468
Fuel system; description...469
Fuel system; specifications...477
Fuel system; tightening torques...479
Carbon dioxide in fuel system; checking...487
Fuel system basics; checking...493
Fuel system; component location...496
Feed pump pressure; checking...498
Fuel system; bleeding...500
Water separator; specifications...502
Injectors; replacing...504
Injector sleeves; replacing...510
Fuel rail; replacing...518
Fuel rail pressure sensor; replacing...521
High pressure fuel pump; replacing...523
High pressure fuel pipes; replacing...526
Fuel control valve (FCV); replacing...528
Pressure relief valve (PRV); replacing...533
25 - INLET & EXHAUST SYSTEM...536
Inlet and exhaust system; description...538
Inlet and exhaust system; specification...544
Inlet and exhaust system; component location...546
Inlet and exhaust system; tightening torques...548
Exhaust pipe flexible tube; replacing...554
Exhaust Aftertreatment System; description...557
Exhaust Aftertreatment System; component location...570
Regeneration process; description...572
AdBlue®_DEF dosing injector; replacing...579
AdBlue®_DEF mixing tube; replacing...582
AdBlue®_DEF tank; replacing...586
AdBlue®_DEF; draining...588
Coolant valve; replacing...591
SCR (Selective catalytic reduction) muffler; replacing...594
AdBlue®_DEF quality; checking...599
SCR (Selective catalytic reduction) dosing system; checking...602
AdBlue®_DEF pump unit diagnostics; description...605
DPF (Diesel particulate filter); checking and cleaning...609
ACM (Aftertreatment control module) non-programmed; replacing...615
ACM (Aftertreatment control module) pre-programmed; replacing...618
Inlet throttle; replacing...620
DOC (Diesel oxidation catalyst); replacing...622
AdBlue®_DEF pump unit; replacing...625
AdBlue®_DEF tank armature; replacing...628
AdBlue®_DEF tank armature; cleaning...633
AdBlue®_DEF tank armature suction filter; replacing...636
AdBlue®_DEF hoses; replacing...638
AdBlue®_DEF...642
Crystallization of AdBlue®_DEF; checking...648
AdBlue®_DEF pump unit; filter; replacing...653
AdBlue®_DEF pump unit; flushing...656
AdBlue®_DEF pump unit; inlet nipple; replacing...659
Regeneration log; checking...662
AdBlue®_DEF tank; cleaning...674
Turbocharger; replacing...677
Charge air cooler; replacing...681
26 - COOLING SYSTEM...688
Cooling system; description...689
Cooling system; specifications...693
Carbon dioxide in coolant system; checking...695
Cooling system; component location...701
Cooling system; tightening torques...703
Coolant with anti-freeze and corrosion protection; recommendation...706
Cooling system pressure; checking...709
Coolant; changing...711
Radiator; replacing...714
Expansion tank; replacing...716
Coolant pump; replacing...719
Thermostat; replacing...722
Cooling fan control...725
Cooling fan rpm; specifications...729
Cooling fan clutch; description...730
27 - ENGINE CONTROL...733
Engine - Pump control; specification...734
29 - MISCELLANEOUS...736
EGR venturi tube; cleaning...737
Exhaust Gas Recirculation (EGR); description...739
Exhaust gas recirculation (EGR); component location...745
EGR system; tightening torques...747
EGR reed valve; replacing...749
EGR cooler; replacing...755
EGR actuator; replacing...760
EGR venturi tube; replacing...762
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...766
30 - GENERAL...767
Electrical system; special instructions for servicing; general...773
Electrical system; special instructions for servicing; electronic components...777
Electrical system; special instructions for servicing; electrical components; batteries...780
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator...784
Electrical system; special instructions for servicing; action when working on machine...787
Electrical system; description...790
Electronic control system; description...792
Auxiliary start...799
System voltage...803
Electrical system; specifications...806
Tech Tool; operations-...809
Power Boost control; description...811
Engine stops...814
CareTrack with anti-theft...816
Start lock; description...827
X1 control; description...829
X3 control; description...833
Electro hydraulic pump control; description...835
Power supply; description...840
Mode selection; description...845
Boom float position; description...849
Limp home...851
Travel speed; description...854
Overload warning...856
Seat belt...859
Auto Idle...861
Attachment quick coupler...863
Intermittent wiper and washer...865
Grading and lifting control; description...869
ECO mode; description...873
Software parameters; description...875
Automatic engine shut-down...887
General fault diagnosis information...890
Troubleshooting strategy...892
Collection of basic data...894
Information display; check...898
Error code information; general...901
Error codes; build-up...912
Conditions when checking...914
Lead and connector checks...919
Special tools for troubleshooting...925
Tech Tool; operations...928
AL3201; description and measuring_{12-13-16}...930
AL3201; description and measuring_{12-12-38}...934
BA3101; description and measuring_{12-11-51}...937
BA3101; description and measuring_{12-11-21}...940
BB1 Communication bus; description and measuring_{12-10-40}...943
BB1 Communication bus; description and measuring_{12-09-28}...947
BB2 Communication bus; description and measuring...950
CU9909; description and measuring...953
CU9911; description and measuring...956
FX1005; description and measuring...958
FX1006; description and measuring...961
FX1007; description and measuring...965
FX1008; description and measuring...969
FX1054; description and measuring...973
FX1074; description and measuring...976
FX1079; description and measuring...980
FX1116; description and measuring...983
FX1117; description and measuring...986
HE2501; description and measuring_{11-50-12}...989
HE2501; description and measuring_{11-49-44}...992
HE2511; description and measuring...995
HE2512; description and measuring...997
HE2513; description and measuring...999
Instrument Cluster (IC); description and measuring...1001
MA2301-MA2304; description and measuring...1004
MA2517; description and measuring...1006
MA2519; description and measuring...1008
MA9109; description and measuring...1011
MA9116; description and measuring...1014
MA9117; description and measuring...1017
MA9120; description and measuring...1020
MA9125; description and measuring...1023
MO2505; description and measuring...1026
MO3301; description and measuring_{11-37-12}...1029
MO3301; description and measuring_{11-36-39}...1032
Power supply; ACM (Aftertreatment Control Module); description and measuring...1035
Power supply CCM; description and measuring...1037
Power supply ECM; description and measuring...1039
Power supply GPMECU 1; description and measuring_{11-33-55}...1042
Power supply GPMECU 1; description and measuring_{11-33-26}...1045
Power supply HMICU; description and measuring_{11-32-47}...1047
Power supply HMICU; description and measuring_{11-32-16}...1050
Power supply W-ECU; description and measuring_{11-31-22}...1053
Power supply W-ECU; description and measuring_{11-30-51}...1056
Power supply W-ECU; description and measuring_{11-30-23}...1059
PWM2303; description and measuring...1062
PWM2602; description and measuring...1065
PWM9109; description and measuring...1068
PWM9123; description and measuring...1070
PWM9124; description and measuring...1073
PWM9129; description and measuring...1076
PWM9141; description and measuring_{11-25-28}...1078
PWM9141; description and measuring_{11-24-57}...1081
PWM9142; description and measuring_{11-24-14}...1084
PWM9142; description and measuring_{11-23-43}...1087
PWM9145; description and measuring...1090
PWM9146; description and measuring...1093
PWM9156; description and measuring...1096
PWM9157; description and measuring...1098
RE2501; description and measuring_{11-20-40}...1101
RE2501; description and measuring_{11-20-09}...1104
RE3101; description and measuring_{11-19-27}...1107
RE3101; description and measuring_{11-18-56}...1110
RE3102; description and measuring_{11-18-13}...1113
RE3102; description and measuring_{11-17-42}...1116
RE3502; description and measuring...1119
RE3507; description and measuring...1122
RE3508; description and measuring...1125
RE3511; description and measuring...1128
RE3608; description and measuring...1131
RE3611; description and measuring...1134
RE4206; description and measuring...1137
SAE J1939-1 SubNet 1; description and measuring...1140
SE2203; description and measuring...1143
SE2301; description and measuring...1146
SE2303; description and measuring_{11-09-15}...1149
SE2303; description and measuring_{11-08-45}...1152
SE2309; description and measuring...1155
SE2511; description and measuring...1158
SE2512; description and measuring...1161
SE2513; description and measuring...1164
SE2515; description and measuring...1167
SE2516; description and measuring...1170
SE2519; description and measuring...1173
SE2521; description and measuring...1176
SE2522; description and measuring...1179
SE2533; description and measuring...1182
SE2543; description and measuring...1185
SE2544; description and measuring...1188
SE2603; description and measuring...1191
SE2604; description and measuring...1194
SE2606; description and measuring...1197
SE2701; description and measuring...1200
SE2703; description and measuring...1202
SE8701; description and measuring...1204
SE8702; description and measuring...1207
SE8705; description and measuring...1210
SE8706; description and measuring...1213
SE9105; description and measuring_{10-54-48}...1216
SE9105; description and measuring_{10-54-26}...1220
SE9121; description and measuring...1224
SE9122; description and measuring...1227
SE9123; description and measuring...1230
SE9124; description and measuring...1233
SE9125; description and measuring...1236
SE9126; description and measuring...1239
SE9127; description and measuring...1242
SE9128; description and measuring...1245
SE9130; description and measuring...1248
SE9131; description and measuring...1251
SE9132; description and measuring...1254
SE9136; description and measuring...1257
SE9138; description and measuring...1260
SE9141; description and measuring_{01-14-19}...1263
SE9141; description and measuring_{01-13-32}...1266
SE9142; description and measuring_{01-12-24}...1269
SE9142; description and measuring_{01-11-40}...1272
SE9401; description and measuring_{01-10-44}...1275
SE9401; description and measuring_{01-10-02}...1278
SW2506; description and measuring...1281
SW3301; description and measuring_{01-08-16}...1284
SW3301; description and measuring_{01-07-30}...1287
SW3802; description and measuring...1290
SW3803; description and measuring...1293
SW9161; description and measuring_{01-03-01}...1296
SW9161; description and measuring_{01-02-23}...1299
SW9162; description and measuring...1302
Tiltrotator detection; description and measuring...1304
VSV controller; description and measuring...1307
31 - BATTERY...1310
Battery; storage...1311
Battery; description...1314
Battery; specifications...1317
Battery condition; checking...1318
Battery charging capacity; checking...1321
Battery; charging...1323
Batteries; replacing...1326
Earth lead to battery; replacing...1328
32 - ALTERNATOR; CHARGE REGULATOR...1330
Charging; description...1331
Alternator; specifications...1333
Alternator; description...1335
Alternator; replacing incl function checking...1338
Alternator; testing...1341
33 - STARTING SYSTEM...1345
Starting operation...1346
Starter motor; description...1347
Starter motor; specifications...1349
Starter motor; testing...1351
Starter motor; replacing...1355
Preheating; description...1357
Ignition switch; description and operation...1359
Ignition switch; specifications...1362
Starter switch; testing...1364
35 - LIGHTING...1367
Work lights and extra lights; description...1368
Work lights and extra lights; specifications...1371
Work lighting headlamp assembly; replacing...1374
36 - OTHER ELECTRICAL EQUIPMENT...1376
Electric pedal control on X1 (on_off); replacing...1378
Electric pedal control on X1 (proportional); replacing...1382
Travel alarm; description...1386
Electric horn; specifications...1389
Horn; replacing...1392
Rotating beacon; specifications_{12-42-37}...1394
Rotating beacon; specifications_{12-42-18}...1396
Rotating beacon; specifications_{12-41-59}...1398
Rotating beacon; specifications_{12-41-35}...1400
Rotating beacon; specifications_{12-41-15}...1402
Rotating beacon; specifications_{12-40-56}...1404
Rotating beacon; replacing...1406
Travel alarm; specifications...1409
Travel alarm; replacing...1412
Windscreen wiper front motor; replacing...1414
Windscreen wiper switch; replacing...1419
Windscreen flusher pump; replacing...1422
Windscreen wiper; description...1424
Upper wiper motor; description...1426
Upper wiper motor; specifications...1428
Lower wiper motor; description...1430
Lower wiper motor; specifications...1432
Windscreen flusher pump; specifications...1434
Window limit switch; description...1436
Connectors; overview...1439
Pre-heating relay; replacing...1449
Control lockout lever switch; replacing...1451
Ignition switch; replacing...1454
Engine limp home switch; description...1457
Engine limp home switch; specifications...1459
General purpose machine electronic control unit GPMECU; function description-[2840]...1461
General purpose machine electronic control unit GPMECU; function description...1463
Human machine interface control unit HMICU; function description...1466
GPMECU1 non-programmed; replacing...1468
GPMECU1 pre-programmed; replacing...1471
HMICU non-programmed; replacing...1474
HMICU pre-programmed; replacing...1478
37 - CABLE; FUSE; RELAY...1482
Electrical symbols and designations...1485
Explanation of wiring diagrams...1490
Component designations...1493
Component list Alternator; batteries; capacitors; electronic units; voltage outlet...1495
Component list; fuses_{12-19-32}...1497
Component list; fuses_{12-19-13}...1499
Component list; fuses_{12-18-54}...1501
Component list; Heating coils...1503
Component list; lights...1505
Component list; Miscellaneous...1507
Component list; motors...1508
Component list; relays...1509
Component list; sensors...1511
Component list; Solenoid valves...1513
Component list; Switches_{12-16-14}...1515
Component list; Switches_{12-15-55}...1517
ACM; I_O list...1519
CCM; I_O list...1522
ECM (Engine Control Module); I_O list...1526
GPMECU1; I_O list_{12-13-52}...1531
GPMECU1; I_O list_{12-13-30}...1534
HMICU; I_O list_{12-12-57}...1537
HMICU; I_O list_{12-12-35}...1540
HMICU; I_O list_{12-12-13}...1543
IC (Instrument Cluster); I_O list...1546
W-ECU; I_O list...1548
Wiring diagram_{12-10-39}...1550
Wiring diagram_{12-10-21}...1552
Wiring diagram; electrical distribution box...1554
Wiring diagram SCH01_{12-09-23}...1558
Wiring diagram SCH01_{12-09-00}...1563
Wiring diagram SCH02_{12-08-26}...1568
Wiring diagram SCH02_{12-08-00}...1573
Wiring diagram SCH02_{12-07-38}...1578
Wiring diagram SCH03_{12-07-04}...1583
Wiring diagram SCH03_{12-06-41}...1587
Wiring diagram SCH04_{12-06-06}...1591
Wiring diagram SCH04_{12-05-43}...1596
Wiring diagram SCH05_{12-05-08}...1601
Wiring diagram SCH05_{12-04-45}...1605
Wiring diagram SCH05_{12-04-22}...1609
Wiring diagram SCH07...1613
Wiring diagram SCH08_{12-03-19}...1617
Wiring diagram SCH08_{12-02-57}...1622
Wiring diagram SCH08_{12-02-34}...1627
Wiring diagram SCH10...1632
Wiring diagram SCH11...1635
Wiring diagram SCH12_{12-01-02}...1639
Wiring diagram SCH12_{12-00-40}...1644
Wiring diagram SCH13...1649
Wiring diagram SCH14_{11-59-25}...1652
Wiring diagram SCH14_{11-59-03}...1657
Wiring diagram SCH15...1662
Wiring diagram SCH16_{11-57-49}...1666
Wiring diagram SCH16_{11-57-26}...1670
Wiring diagram SCH17_{11-56-52}...1674
Wiring diagram SCH17_{11-56-29}...1678
Wiring diagram SCH18...1682
Wiring diagram SCH20_{11-55-27}...1685
Wiring diagram SCH20_{11-55-05}...1688
Wiring diagram SCH21_{11-54-32}...1691
Wiring diagram SCH21_{11-54-09}...1694
Wiring diagram SCH22...1697
Wiring diagram SCH24...1700
Wiring diagram SCH27...1704
Wiring diagram SCH28...1710
Wiring diagram SCH30_{11-51-25}...1719
Wiring diagram SCH30_{11-51-03}...1722
Wiring diagram SCH30_{11-50-40}...1725
Wiring diagram SCH30_{11-50-18}...1728
Wire harness layout...1731
Engine wire harness; replacing...1734
Electrical battery disconnect switch; replacing...1739
Electrical distribution box_{11-48-08}...1742
Electrical distribution box_{11-47-46}...1745
Electrical distribution box_{11-47-19}...1748
Electrical distribution box_{11-46-57}...1751
Electrical distribution box_{11-46-29}...1754
Electrical distribution box_{11-46-08}...1757
Electrical distribution box; circuit board replacing...1760
Relay; description_{11-44-24}...1764
Relay; description_{11-44-02}...1767
Relay; specifications...1770
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...1772
Instruments and controls; overview...1773
Instruments and controls; front instrument panel...1775
Instruments and controls; left instrument panel...1777
Instruments and controls; right instrument panel...1779
Instruments and controls; rear instrument panel...1781
Hour meter; replacing...1783
Fuel level sender; replacing...1786
Control lockout lever switch; description...1789
Control lockout lever switch; specifications...1792
Engine temperature sensor; replacing...1795
Engine oil pressure sensor; replacing...1797
Hydraulic oil temperature sensor; replacing...1799
Keypad; description...1802
Keypad; specification...1804
Service mode...1806
Engine system...1809
Hydraulic system...1812
Electrical system...1816
Volvo Smart View...1821
Volvo Smart View; specification...1825
Volvo Smart View camera; replacing...1828
Volvo Smart View; calibrating...1832
Volvo Smart View accuracy; checking...1837
39 - MISCELLANEOUS...1843
Radio with MP3; description...1844
Radio with MP3; specifications...1848
Radio; replacing...1850
DC–DC converter; description...1855
DC–DC converter; specifications...1858
Voltage converter; replacing...1861
Antenna; replacing...1865
Speaker; replacing...1868
CareTrack W-ECU; description...1870
W-ECU; replacing; non-programmed...1875
W-ECU; replacing; pre-programmed...1879
CareTrack battery; replacing...1883
CareTrack antenna; replacing-[2640]...1887
CareTrack antenna; replacing...1890
004 - POWER TRANSMISSION...1895
40 - GENERAL...1896
Tightening torque; specifications_{08-38-26}...1897
Tightening torque; specifications_{08-38-06}...1899
Power transmission; description...1901
43 - GEARBOX...1904
Function description-...1905
Track gearbox; specifications...1906
Track gearbox; description_{08-35-29}...1907
Track gearbox; description_{08-34-35}...1913
Track gearbox; maintenance standard...1917
Track unit; replacing...1923
Track gearbox cover; replacing...1930
Track gearbox (removed); replacing floating seal...1933
Track gearbox; disassembly...1945
Track gearbox; assembly...1953
Function description ...1962
Swing gearbox; specifications...1964
Swing gearbox; description...1965
Swing gearbox; maintenance standard...1969
Swing unit; replacing...1973
Swing gearbox; replacing...1978
Swing gearbox; disassembly...1983
Swing gearbox; assembly...1989
44 - HYDROSTATIC DRIVE...1996
Travel speed; description...1998
Track motor; specifications...2001
Track motor; description...2002
Track motor; maintenance standard...2009
Track motor; replacing...2016
Track motor relief valve; replacing...2024
Track motor; disassembly...2027
Track motor; assembly...2042
Swing motor; specifications...2057
Swing motor; description_{08-01-33}...2058
Swing motor; description_{08-01-06}...2062
Swing motor; maintenance standard_{07-59-54}...2069
Swing motor; maintenance standard_{07-59-23}...2076
Swing motor; replacing_{07-58-52}...2080
Swing motor; replacing_{07-58-29}...2084
Swing motor relief valve; replacing_{07-57-52}...2088
Swing motor relief valve; replacing_{07-57-29}...2090
Slew motor; adjustment_{07-56-54}...2092
Slew motor; adjustment_{07-56-28}...2095
Swing motor; replacing brake piston seal_{07-55-53}...2098
Swing motor; replacing brake piston seal_{07-55-30}...2102
Swing motor; replacing plate (brake)_{07-54-50}...2107
Swing motor; replacing plate (brake)_{07-54-27}...2112
Swing motor; disassembly_{07-53-40}...2117
Swing motor; disassembly_{07-53-11}...2123
Swing motor; assembly_{07-51-27}...2133
Swing motor; assembly_{07-50-55}...2142
Hydraulic pump coupling; description...2157
Pump gearbox coupling assembly; replacing...2159
Tightening torque; specifications-...2161
Center passage; specifications_{07-46-52}...2165
Center passage; specifications_{07-46-32}...2167
Center passage; specifications_{07-46-12}...2169
Center passage; specifications_{07-45-53}...2170
Center passage; description_{07-45-22}...2172
Center passage; description_{07-44-58}...2175
Center passage; description_{07-44-35}...2178
Center passage; description_{07-44-12}...2181
Center passage; maintenance standard...2184
Center passage; replacing_{07-42-51}...2189
Center passage; replacing_{07-42-22}...2195
Center passage; replacing seal kit...2202
Center passage; disassembly_{07-39-23}...2208
Center passage; disassembly_{07-38-41}...2213
Center passage; disassembly_{07-37-55}...2217
Center passage; assembly_{07-36-40}...2223
Center passage; assembly_{07-35-46}...2230
Center passage; assembly_{07-34-50}...2237
49 - MISCELLANEOUS...2244
Swing ring gear; specifications...2245
Swing ring gear; description...2246
Swing ring gear; replacing...2249
Swing ring gear grease pipe; replacing...2252
Swing ring gear inner seal; replacing...2257
Swing ring gear outer seal; replacing...2260
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...2267
70 - GENERAL...2268
Undercarriage; tightening torque_{07-20-48}...2269
Undercarriage; tightening torque_{07-20-29}...2270
Undercarriage; tightening torque_{07-20-10}...2271
Frame and track unit; specifications...2273
Frame and track unit; description...2274
71 - FRAME...2276
Machine weight; specifications...2277
Superstructure; removing...2279
Superstructure; installing...2284
Tightening torque; specifications-...2289
Counterweight; tightening torques...2290
Counterweight; specifications...2292
Counterweight; description...2293
Counterweight; removing...2295
Counterweight; installing...2298
Undercarriage; description_{07-09-08}...2301
Undercarriage; description_{07-08-45}...2304
Undercarriage; description_{07-08-23}...2307
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...2309
Selection of track shoes...2311
Idler; description_{07-07-08}...2313
Idler; description_{07-06-41}...2315
Idler; description_{07-06-09}...2318
Idler; description_{07-05-42}...2320
Idler; measurement of wear_{07-05-03}...2323
Idler; measurement of wear_{07-04-19}...2327
Front idler; replacing one...2331
Idler; disassembly...2335
Idler; assembly...2340
Tools & equipment...2345
Sprocket; measurement of wear...2350
Sprocket; replacing one...2354
Track chain; description...2357
Track link; dimension...2359
Track; adjusting track sag_{06-57-13}...2361
Track; adjusting track sag_{06-56-49}...2365
Track chain; measurement of wear_{06-56-06}...2367
Track chain; measurement of wear_{06-55-34}...2373
Track shoe; replacing one...2379
Track links; replacing...2383
Track chain assembly; removing...2388
Track chain assembly; installing...2393
Top roller; description...2398
Top roller; measurement of wear_{06-50-45}...2400
Top roller; measurement of wear_{06-50-04}...2403
Top roller; replacing one...2406
Bottom roller; description_{06-46-08}...2411
Bottom roller; description_{06-45-46}...2413
Bottom roller; measurement of wear_{06-45-11}...2415
Bottom roller; measurement of wear_{06-44-48}...2418
Bottom roller; replacing one...2422
Bottom roller; replacing seal...2427
Track guards_{06-41-35}...2432
Track guards_{06-41-12}...2433
Track guard; replacing one...2435
Spring package; assembly dimension_{06-38-59}...2439
Spring package; assembly dimension_{06-38-37}...2441
Recoil spring cylinder seal kit; replacing...2443
Track recoil spring (tensioner) assembly; replacing_{06-37-35}...2447
Track recoil spring (tensioner) assembly; replacing_{06-37-13}...2450
Spring package; disassembling_{06-36-38}...2454
Spring package; disassembly_{06-36-15}...2457
Spring package; disassembly_{06-35-42}...2462
Spring package; assembly_{06-35-02}...2465
Spring package; assembly_{06-34-30}...2469
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...2472
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...2473
Windows; general...2474
Windscreen; replacing...2477
Side window; replacing...2491
Rear window; replacing...2498
Door window; replacing...2506
85 - CAB INTERIOR; UPHOLSTERY...2509
Seat; replacing_{06-16-49}...2510
Seat; replacing_{06-16-02}...2517
Seat cushion; replacing...2520
Seat support; replacing...2526
Longitudinal adjustment cable; replacing...2533
Longitudinal suspension cable; replacing...2539
Backrest; replacing...2543
Driver's seat; description...2547
Driver's seat; specifications...2552
Seat heater; checking...2556
87 - AIR CONDITIONING UNIT...2560
HVAC system...2561
Air conditioning unit; specifications_{06-08-50}...2565
Air conditioning unit; specifications_{06-08-31}...2567
Air conditioning unit; description...2569
Performance test; AC unit...2576
Air conditioning unit; maintenance...2582
CCM pre-programmed ECU; replacing...2585
CCM non-programmed ECU; replacing...2590
Air conditioning unit; refrigerant check and recharging...2595
Air distribution; description...2603
Heating system; description...2606
Fan motor; replacing...2608
Heater core; replacing...2612
Cooler and Heater assembly; replacing...2619
Compressor; replacing incl draining and filling...2626
Receiver; replacing incl draining and filling...2630
Evaporator; replacing incl draining and filling...2634
Expansion valve; replacing incl draining and filling...2642
Vent actuator; replacing...2650
Mode (foot) actuator; replacing...2653
Intake actuator; replacing...2656
Air mix door actuator; replacing...2659
Compressor; replacing magnetic clutch (compressor removed)...2662
Auxiliary heater; specifications...2668
Auxiliary heater; description...2670
Auxiliary heater; principles...2673
Troubleshooting...2676
88 - INTERIOR EQUIPMENT...2686
Instrument panel (left); replacing...2687
Instrument panel (right); replacing...2691
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...2695
90 - GENERAL...2696
Hydraulic diagram; with option components - Image...2697
Hydraulic diagram; standard - Image...2701
Explanations to hydraulic diagram...2702
Hydraulic diagram; standard...2713
Hydraulic diagram; with option components_{005-45-40}...2716
Hydraulic diagram; with option components_{005-45-18}...2722
Hydraulic system; position of main components...2728
Hydraulic system; cleanliness when handling hydraulic components...2731
Description; general...2735
Hydraulic system; description...2736
Recommended hydraulic oil; specifications...2737
Hydraulic pressure; specifications...2741
Hydraulic system; repair of hydraulic components in workshop...2743
Hydraulic oil; storage and handling...2748
Hydraulic components; storing and transporting...2752
Tech Tool; operations...2756
92 - MECHANICAL EQUIPMENT_ATTACHMENT...2758
Attachment quick coupler; description_{04-10-55}...2759
Attachment quick coupler; description_{04-10-28}...2772
Attachment quick coupler; operation...2783
Attachment quick coupler; replacing_{04-09-22}...2786
Attachment quick coupler; replacing_{04-09-00}...2795
Attachment quick coupler; adjustment...2805
Attachment quick coupler solenoid valve; description_{04-08-03}...2809
Attachment quick coupler solenoid valve; description_{04-07-41}...2814
Tightening torques ...2817
Remote control valve (dozer blade); specifications...2819
Remote control valve (dozer blade); description...2820
Control lever (dozer blade); replacing...2823
Dozer blade; specifications...2830
Dozer blade; description...2831
Dozer blade cylinder; specifications...2834
Dozer blade cylinder; description...2836
Dozer blade cylinder; replacing...2838
Check valve; replacing...2845
97 - UNIT; DIGGING...2850
Tightening torques...2852
Function description...2861
Digging unit; maintenance...2864
Bushing general; replacing...2868
Cylinder; description...2873
Cylinder; disassembly and assembly_{03-59-24}...2878
Cylinder; disassembly and assembly_{03-59-02}...2897
Cylinder; troubleshooting...2914
Boom; specifications...2918
Boom; description...2919
Boom; replacing...2922
Boom cylinder; specifications...2940
Boom cylinder; description...2942
Boom cylinder; replacing...2944
Lower boom cylinder bushing; replacing...2953
Upper boom cylinder bushing; replacing...2958
Dipper arm; specifications...2962
Dipper arm; description...2963
Dipper arm; replacing...2966
Link; description...2979
Dipper arm connecting rod; replacing...2982
Connecting rod yoke; replacing...2990
Dipper arm cylinder; specifications...2997
Dipper arm cylinder; description...2999
Dipper arm cylinder; replacing...3001
Dipper arm cylinder bushing on boom; replacing...3011
Dipper arm cylinder bushing on dipper arm; replacing...3017
Tiltable ditching bucket; description...3021
Tiltable ditching bucket cylinder; specifications...3026
Tiltable ditching bucket cylinder; description...3028
Hydraulic Cylinder; disassembling and assembling...3031
Bucket cylinder; specifications...3039
Bucket cylinder; description...3041
Bucket cylinder; replacing...3043
Bucket cylinder bushing on dipper arm; replacing...3054
Bucket cylinder bushing lever-link; replacing...3059
EC160 Volvo, EC160B LC Volvo, EC160B NLC Volvo, EC160C L Volvo, EC160C NL, EC160D L Volvo, ED160C NL, EC160E L Volvo, EC160E NL Volvo Excavators Service Repair Manual
