Volvo EW160B Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EW160B Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions EW160B 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.
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
187 PPID1191.....705
187 PPID1309.....707
187 SID240.....709
187 SID250.....711
187 SID251.....713
187 SID253.....715
187 SID254.....717
E-ECU (MID128) Engine control unit; active measuring conditions.....719
E-ECU (MID128) Engine control unit; passive measuring conditions.....723
T-ECU (MID 130) Transmission control unit; active measuring; conditions.....726
T-ECU (MID 130) Transmission control unit; passive measuring; conditions.....729
V-ECU (MID187) Vehicle control unit; active measuring conditions.....732
V-ECU (MID187) Vehicle control unit; passive measuring conditions.....737
Pressure switch test with VCADS Pro.....741
Fan motor control test with VCADS Pro.....745
Brake system test with VCADS Pro.....747
31 - BATTERY.....750
Battery; storage.....751
Battery; description.....753
Battery; specifications.....755
Battery; charging.....756
Batteries; replacing.....758
32 - ALTERNATOR; CHARGE REGULATOR.....760
Charging; description.....761
Alternator; description.....762
Alternator; replacing incl function checking.....764
33 - STARTING SYSTEM.....768
Start circuit; description.....769
Starter motor; description.....771
Starter motor; specifications.....772
Preheating; description.....773
Preheating; specifications.....774
35 - LIGHTING.....775
Lighting; specifications.....776
36 - OTHER ELECTRICAL EQUIPMENT.....777
Electric horn; description.....780
Electric horn; specifications.....781
Windscreen wiper; description.....782
Windscreen wiper; components location.....783
Wiper controller; description.....785
Upper wiper motor; description.....787
Upper wiper motor; specifications.....788
Lower wiper motor; description.....789
Lower wiper motor; specifications.....791
Window limit switch; description.....792
Battery disconnect switch; description.....794
SW2704 Emergency engine speed control switch; description.....796
SW2704 Emergency engine speed control switch; specifications.....798
SW2706 Auto_manual select switch; description.....799
SW2706 Auto_manual select switch; specifications.....801
SW3101 Main switch; description.....802
SW3101 Main switch; specifications.....803
SW3301 Start switch; description.....804
SW3301 Start switch; specifications.....806
Multi-function lever switch; description.....808
Multi-function lever switch; specifications.....810
MA4201 Cruise control solenoid valve; description.....811
MA4201 Cruise control solenoid valve; specifications.....812
MA4202 Travel solenoid valve; description.....813
MA4202 Travel solenoid valve; specifications.....814
MA4203 Gear select solenoid valve; description.....815
MA4203 Gear select solenoid valve; specifications.....816
MA4204 Q-max solenoid valve; description.....817
MA4204 Q-max solenoid valve; specifications.....818
MA5501 Parking brake solenoid valve; description.....819
MA5501 Parking brake solenoid valve; specifications.....820
MA9104 Hammer solenoid valve; description.....821
MA9104 Hammer solenoid valve; specifications.....822
MA9107 Power boost solenoid valve; description.....823
MA9108 Control lockout solenoid valve; description.....824
MA9107 Power boost solenoid valve; specifications.....825
MA9108 control lockout solenoid valve; specifications.....826
MA9109 Quickfit solenoid valve; description.....827
MA9109 Quickfit solenoid valve; specifications.....829
MA9119 Boom float solenoid valve; description.....830
MA9110 9111 Rotator left_right solenoid valve; description.....832
MA9119 Boom float solenoid valve; specifications.....833
MA9110 9111 Rotator left_right solenoid valve; specifications.....834
MA9152 Axle locking solenoid valve; description.....835
MA9152 Axle locking solenoid valve; specifications.....836
MA9153 9154 9155 9156 Outrigger solenoid valve; description.....837
MA9153 9154 9155 9156 Outrigger solenoid valve; specifications.....839
PWM4201 Cruise flow control proportional solenoid valve; description.....840
PWM4201 Cruise flow control proportional solenoid valve; specifications.....841
PWM9101 Pump control proportional solenoid valve; description.....842
PWM9101 Pump control proportional solenoid valve; specifications.....844
PWM9102 Fan motor proportional solenoid valve; description.....845
PWM9102 Fan motor proportional solenoid valve; specifications.....847
PWM9103 Hammer flow control proportional solenoid valve; description.....848
PWM9103 Hammer flow control proportional solenoid valve; specifications.....849
PWM9104 Anti cavitation proportional solenoid valve; description.....850
PWM9104 Anti cavitation proportional solenoid valve; specifications.....851
Connectors-2558.....852
Connectors.....856
Engine control unit E-ECU; function description-2502.....860
Engine control unit E-ECU; function description.....861
Instrument control unit I-ECU; functional description.....862
Transmission control unit T-ECU; functional description.....864
Vehicle control unit V-ECU; functional description.....865
Engine control unit E-ECU; specifications.....866
Instrument control unit I-ECU; specifications.....868
Transmission control unit T-ECU; specifications.....870
Vehicle control unit V-ECU; specifications.....872
Control units changing; precaution.....875
I-ECU MID 140 non-programmed; replacing.....876
I-ECU MID 140 pre-programmed; replacing.....878
T-ECU; MID 130; changing non-programmed ECU.....880
T-ECU; MID 130; changing pre-programmed ECU.....882
V-ECU MID 187 non-programmed; replacing.....884
V-ECU MID 187 pre-programmed; replacing.....887
37 - CABLE; FUSE; RELAY.....890
Electrical symbols and designations.....892
Cable and component marking explanations.....895
Component designations.....897
Wiring diagrams; component list and index.....898
Wiring diagram 1.....907
Wiring diagram 2.....910
Wiring diagram 3.....913
Wiring diagram 4.....916
Wiring diagram 5.....919
Wiring diagram 6.....922
Wiring diagram 7.....925
Wiring diagram 8.....928
Wiring diagram 9.....931
Wiring diagram 10.....934
Wiring diagram 11.....937
Wiring diagram 12.....940
Wiring diagram 13.....943
Wiring diagram 14.....946
Wiring diagram 15.....949
Wiring diagram 16.....952
Wiring diagram 17.....955
Wiring diagram 18.....958
Wiring diagram 19.....961
Wiring diagram 20.....964
Wiring diagram 21.....967
Wiring diagram 22.....970
Wiring diagram 23.....973
Wiring diagram 24.....976
Wiring diagram 26.....981
Electrical distribution box; fuses and relays.....982
FU02 FU08 Battery fuse; specifications.....985
Grounding points; position.....987
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....990
IM3812 Hour counter; description.....992
SE2203 Engine oil pressure sensor; specifications.....994
SE2203 Engine oil pressure sensor; description.....996
SE2303 Fuel level sensor; description.....998
SE2303 Fuel level sensor; specifications.....1000
SE2306 Fuel_SE2601 Coolant temperature sensor; description.....1001
SE2306 Fuel_SE2601 Coolant temperature sensor; specifications.....1003
SE2501 2502 Air inlet vacuum and temperature switch; description.....1004
SE2501 2502 Air inlet vacuum and temperature switch; specifications.....1006
SE2507 Boost air temperature sensor; description.....1007
SE2507 Boost air temperature sensor; specifications.....1009
SE2507_2508 Boost air pressure_temperature sensor; description.....1010
SE2507_2508 Boost air pressure_temperature sensor; specifications.....1012
SE2508 Boost air pressure sensor; description.....1013
SE2508 Boost air pressure sensor; specifications.....1015
SE2603 Coolant level sensor; specifications.....1016
SE2701 Engine speed sensor (crankshaft); description.....1017
SE2701 Engine speed sensor (crankshaft); specifications.....1019
SE2702 Engine speed sensor (ring gear 129 teeth); description.....1020
SE2702 Engine speed sensor (ring gear 129 teeth); specifications.....1022
SE2703 Engine speed sensor (camshaft); description.....1023
SE2703 Engine speed sensor (camshaft); specifications.....1025
SE4201 Travel pedal pressure sensor; specifications.....1026
SE4203 Travel backward pressure switch; description.....1027
SE4203 Travel backward pressure switch; specifications.....1029
SE4901 Slew position sensor; specfications.....1030
SE5201 Brake pressure switch (5 bar); description.....1031
SE5201 Brake pressure switch (5 bar); specifications.....1033
SE5202 Brake pressure switch (50 bar); description.....1034
SE5202 Brake pressure switch (50 bar); specifications.....1036
SE5203 Brake pressure failure switch (80 bar); description.....1037
SE5203 Brake pressure failure switch (80 bar); specifications.....1039
SE6401 Steering pressure sensor; specifications.....1040
SE9101 Auto idle pressure switch; description.....1041
SE9101 Auto idle pressure switch; specifications.....1043
SE9102 Hammer pedal pressure sensor; specifications.....1044
SE9151 Safety lever limit switch; description.....1045
SE9151 Safety lever limit switch; specifications.....1047
SE9152 Hydraulic oil temperature sensor; description.....1048
SE9152 Hydraulic oil temperature sensor; specifications.....1050
SE9153 Hydraulic oil filter pressure switch; description.....1051
SE9153 Hydraulic oil filter pressure switch; specifications.....1053
SE9154 Boom_9155 Arm automatic idle pressure sensor; specifications.....1054
SE9160 Left control panel limit switch; description.....1055
SE9160 Left control panel limit switch; specifications.....1057
SE9401 Overload pressure switch; description.....1058
SE9401 Overload pressure switch; specifications.....1060
SE4201 Travel pedal pressure sensor; description.....1061
Service display unit; description.....1063
Service display unit; general information.....1066
Service display unit; engine.....1069
Service display unit; electrical system.....1071
Service display unit; hydraulics.....1078
Service display unit; self-diagnostics.....1082
39 - MISCELLANEOUS.....1092
Radio with tape player; description.....1093
Radio with tape player; specifications.....1094
DC–DC converter; description.....1095
DC–DC converter; specifications.....1097
4 - POWER TRANSMISSION.....1098
40 - GENERAL.....1099
Power transmission; description.....1100
Travel gearbox; description.....1101
43 - GEARBOX.....1107
Travel gearbox; description.....1108
Travel gearbox; designation.....1115
Travel gearbox; removing.....1116
Travel gearbox; installing.....1122
44 - HYDROSTATIC DRIVE.....1128
Travel motor; description.....1129
Travel motor; specifications.....1138
Shock valve removed; checking .....1139
Travel motor; installation.....1142
Travel motor; removal.....1146
Slew motor; specifications.....1150
Swing motor; replacing plate (brake).....1151
Centre passage; description.....1155
Centre passage; removing.....1158
Centre passage; installing.....1162
Center passage; disassembling and assembling.....1168
45 - PROPELLER SHAFT.....1176
Propeller shaft; replacement of spider.....1177
Propeller shaft; replacement of centre bearing.....1184
Propeller shaft; replacement.....1189
46 - FRONT AXLE; REAR AXLE.....1193
Front axle; removing.....1194
Front axle; installing.....1199
Front axle; replacement of bushing and king pin.....1203
Rear axle; removing.....1204
Rear axle; installing.....1208
49 - MISCELLANEOUS.....1213
Slew system for superstructure; specifications.....1214
Slew unit; description.....1215
Slew ring; measurement of axial clearance.....1225
Slew ring; axial clearance.....1228
Slew system for superstructure; measurement of rotational clearance.....1229
Slew ring; rotational clearance.....1232
5 - BRAKE.....1233
51 - WHEEL BRAKE.....1234
Wheel brake; description.....1235
Brake discs; specifications.....1239
Brake discs; measurement of wear.....1240
Brake discs; removal and installation.....1242
52 - HYDRAULIC BRAKE SYSTEM.....1243
Brake system bleeding.....1244
Foot brake valve; replacement.....1247
Discarded accumulators.....1254
55 - PARKING BRAKE.....1256
Parking brake; description.....1257
Parking brake; mechanical release.....1260
59 - MISCELLANEOUS.....1261
Retardation valve; description.....1262
Retardation valve; installation.....1263
Retardation valve; removing.....1265
6 - STEERING.....1267
62 - STEERING AXLE.....1268
Steering axle; specifications.....1269
Steering axle; description.....1270
King pin bearing; removal and installation of bearing.....1271
64 - STEERING.....1272
Steering system; description.....1273
Steering system; adjustment.....1278
Steering valve; removal.....1281
Steering valve; installation.....1284
Steering cylinder; repacking in machine.....1287
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....1295
71 - FRAME.....1296
Counterweight; removal.....1297
Counterweight; installation.....1299
Undercarriage; specifications.....1300
Undercarriage; description.....1301
76 - SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL_SIDE CONTROL.....1302
Pivot axle lock cylinder; description.....1303
Pivot axle lock cylinder; removal.....1305
Pivot axle lock cylinder; installation.....1307
Pivot axle lock cylinder; releasing for towing.....1309
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....1312
Wheel; removal.....1313
Wheel; installation.....1315
Stone protection rings; description.....1318
Stone protection ring; removing.....1319
Stone protection ring; installing.....1321
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....1323
80 - GENERAL.....1324
Superstructure covering; description.....1325
81 - CAB; NAKED; CANOPY.....1326
Cab; removal.....1327
Cab; installation.....1331
83 - DOORS; HATCH; COVER PLATE; (all).....1335
Cab door; removal of door catch.....1336
Cab door; installation of door catch.....1338
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.....1340
Window pane; replacement.....1341
Window pane with locking strip; replacing.....1347
Upper windshield; removing.....1348
Upper windshield; installing.....1350
85 - CAB INTERIOR; UPHOLSTERY.....1352
Operator's seat; removal.....1353
Operator's seat; installation.....1355
87 - AIR CONDITIONING UNIT.....1357
Air conditioning unit; specifications.....1359
Air conditioning unit; description.....1361
Air conditioning switch.....1367
Control system; description.....1370
Manual air conditioning; description.....1374
Function of manual air conditioning switch.....1375
Expansion valve; description.....1379
Evaporator; description.....1382
Compressor; description.....1383
Condenser; description.....1385
Drying filter; description.....1386
Receiver drier; changing.....1388
Refrigerant hoses.....1390
Blower motor.....1392
Ceramic resistor.....1393
Three point relay.....1395
Actuator; foot_face driver.....1397
Actuator; air mix door driver.....1399
Water temperature sensor.....1401
Duct temperature sensor.....1403
In-car temperature sensor.....1405
Ambient temperature sensor.....1407
Air conditioning unit; maintenance.....1409
Air conditioning unit; refrigerant check and recharging.....1412
Electrical circuit; air conditioner_heater .....1420
Heating system; description.....1422
Heater fan; changing.....1423
Heating coil; removal.....1429
Heating coil; installation.....1436
Diesel coolant heater (5kw); description.....1442
Electrical circuit; air conditioner_heater.....1445
Diesel heater; description.....1447
Diesel heater; principles.....1450
Diesel heater; specifications.....1455
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....1456
90 - GENERAL.....1457
Hydraulic system; cleanliness when handling hydraulic components.....1458
Hydraulic diagram; component list.....1460
Hydraulic system; position of main components.....1463
Hydraulic diagram.....1465
X2 (adjustable boom); hydraulic diagram.....1468
Description; general.....1469
Optional hydraulic equipment; index.....1470
Hydraulic oil; description.....1471
Hydraulic oil; specifications.....1475
Hydraulic system; repair of hydraulic components in workshop.....1476
Hydraulic oil; storage and handling.....1481
Hydraulic oil; filtering.....1482
Hydraulic components; storing and transporting.....1483
Vacuum pump; connection.....1484
Troubleshooting tips.....1487
Vacuum pump; disconnection.....1491
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....1493
Hydraulic system; work instructions.....1496
Hydraulic system; description.....1501
Hydraulic pressure; adjusting .....1503
Hydraulic pressure; specifications.....1550
Working hydraulic system; description.....1552
Main valve block (MCV); description .....1558
Hydraulic pressure; adjusting.....1562
Main valve block (MCV); description.....1609
Pressure-limiting valve; description.....1613
Pressure limiting valve (DA-valve); replacement.....1618
Blocking valve; description.....1622
Pressure limiting valve (PV-valve); replacement.....1624
Anti-cavitation valve; description.....1628
Anti-cavitation valve; changing.....1630
Shock valve; description.....1632
Shock valve; changing.....1633
Adjustable restricting valve on valve block MCV; description.....1635
Restriction in directional valve; description.....1640
Venting cover on directional valve; description.....1643
Draining LS-pressure to tank; description.....1646
Shutting off LS-pressure from bucket – in via dipper arm – out; description.....1648
Regeneration dipper arm – in; description.....1651
Regeneration boom – down; description.....1653
Hydraulic oil tank; description.....1655
Hydraulic oil tank; removal.....1657
Hydraulic oil tank; installation.....1662
Hydraulic oil cooler; description.....1666
Hydraulic oil cooler; removal.....1667
Hydraulic oil cooler; installation.....1672
Shock and anti-cavitation valve; description.....1676
Hose rupture valve for boom cylinder; description.....1678
Hose rupture valve for dipper arm cylinder; description.....1681
Hose rupture valve for dipper arm cylinder; changing.....1683
Line rupture valve for tilt cylinder X2; description.....1686
Hose rupture valve for tilt cylinder; description.....1688
Line rupture valve for tilt cylinder; replacement.....1689
Pivot axle lock cylinder; removal of hydraulic lock.....1694
Pivot axle lock cylinder; installation of hydraulic lock.....1696
Shock valve removed; checking.....1698
Working pump; specifications.....1701
Working pump; description.....1702
Working pump; removal.....1706
Working pump; installation.....1710
Servo _ fan and brake _ steering pump; specifications.....1715
Servo _ fan and brake _ steering pump; description.....1716
Servo pump; removal.....1718
Servo pump; installing.....1720
Control pressure valve; adjustment.....1723
Control pressure valve pedal; adjustment.....1725
Accumulator; description.....1728
Accumulator; removal.....1730
Accumulator; installing.....1731
Solenoid valve block.....1733
X1 equipment; component positions.....1735
X1 hammer; description.....1737
X1 shears _ grab bucket; description.....1747
Calibration of X1 hydraulic with flow control.....1757
X3 (rotator _ slope (grading) bucket); description.....1760
Outrigger leg _ support blade; description .....1764
Grab bucket _ shears; description.....1765
Floating position; description.....1769
Cruise control; component positions.....1771
Cruise control; description.....1774
92 - MECHANICAL EQUIPMENT_ATTACHMENT.....1783
Hydraulic attachment bracket (quickfit); description.....1784
Cylinder for hydraulic quickfit S6; removal.....1788
Cylinder for hydraulic quickfit (attachment bracket) S6; installation.....1795
Attachment bracket cylinder; reconditioning.....1798
97 - UNIT; DIGGING.....1804
Cylinder; troubleshooting.....1806
Cylinder data.....1808
Digging equipment bearings; measuring radial clearance.....1809
Digging equipment bearings; specifications.....1811
Digging equipment bearings; bushing; removal.....1812
Digging equipment bearings; bushing; installation.....1816
Digging equipment bearings; shimming.....1820
Digging equipment sinking; measurement.....1823
Outrigger leg _ support blade; description.....1825
Outrigger; removal.....1841
Outrigger; installation.....1845
Outrigger; removal of hydraulic lock.....1848
Outrigger; installation of hydraulic lock.....1850
Outrigger; removal of hydraulic cylinder.....1852
Outrigger; installation of hydraulic cylinder.....1857
Support blade; removal.....1861
Support blade; installation.....1864
Support blade; removal of hydraulic lock.....1867
Support blade; installation of hydraulic lock.....1869
Support blade; removal of hydraulic cylinder.....1871
Support blade; installation of hydraulic cylinder.....1874
Boom; removal.....1877
Boom; installation.....1883
Boom; adjustable; removal.....1892
Boom; adjustable; installation.....1900
Boom cylinder; removal.....1909
Boom cylinder; installation.....1914
Dipper arm; removal.....1919
Dipper arm; installation.....1922
Dipper arm; replacement of pin between dipper arm and boom.....1926
Dipper arm cylinder; removal.....1929
Dipper arm cylinder; installation.....1932
Tilt cylinder adjustable boom; removal.....1935
Tilt cylinder adjustable boom; installation.....1939
Bucket cylinder; removal.....1944
Bucket cylinder; installation.....1947
Volvo EW160B Excavators Repair Service Manual
