Volvo EW160D Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EW160D Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions EW160D 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 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
Cooling fan speed control; description................767
Fan belt and_or alternator-; compressor belt; replacing all belts................769
Cooling fan clutch; description................774
Cooling fan clutch; specifications................777
Cooling fan clutch; replacing................778
27 - ENGINE CONTROL................784
Engine control; specifications................785
Engine speed control switch; specifications................787
Engine speed control switch; description ................788
Engine speed control; function checking................789
29 - MISCELLANEOUS................790
Exhaust gas recirculation (EGR); component location................791
EGR system; tightening torques................793
EGR reed valve; replacing................796
EGR cooler; replacing................803
EGR temperature sensor; replacing ................816
EGR pressure sensor; replacing ................818
EGR valve; replacing................821
Exhaust Gas Recirculation (EGR); description................822
EGR actuator; replacing................827
EGR venturi tube; replacing................836
EGR system function; checking................839
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................842
30 - GENERAL................843
Electrical system; special instructions for servicing; general................849
Electrical system; special instructions for servicing; electronic components................851
Electrical system; special instructions for servicing; electrical components; batteries................852
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator................854
Electrical system; special instructions for servicing; action when working on machine................855
Electrical system; description................856
Electronic control system; description................857
Communication with data buses................859
Data buses; function................861
Service connection and programming connection................866
Data links; fault tracing with Oscilloscope................868
Electrical system; specifications................878
Tech Tool; operations ................879
Boom Suspension System; description................880
Power Boost control; description................883
Electrical digging brake; description ................885
Emergency operation; description................887
Start lock; description................890
Power OFF................891
Quick fit control; description................892
Boom float position; description ................894
Semi-auto DPF regeneration................896
Limp Home................899
Auto idle device; setting instructions................901
Travel speed control; description................903
Parking brake; description ................906
Control lockout system; description................908
Forward _ Reverse _ Neutral................909
Axle lock................910
Overload warning................913
ECO mode; description................915
VCADS Pro; parameter programming................917
Software parameters; description_{30-01}................919
Software parameters; description_{29-39}................932
Automatic engine shut-down................945
DPF regeneration control_{28-28}................948
DPF regeneration control_{27-37}................957
DPF regeneration control_{26-48}................965
Tiltrotator control system; software updating................973
Troubleshooting strategy................980
Troubleshooting; general................982
Collection of basic data................984
Error code information; general................986
Electrical cables and connectors; checking................988
Troubleshooting tools................993
Special tools for troubleshooting................994
VCADS Pro service tool................996
Tech Tool; operations ................1000
Power supply E-ECU; description and measuring................1002
PPID 437 explanation................1004
Connecting special tools................1005
999 8699 Multi-pin breaker box................1008
999 0014 Adapter cable................1009
999 0025 Adapter cable................1010
999 0062 Extension cable................1011
8883 0028 Adapter cable................1012
88890040 Oscilloscope for VCADS Pro................1013
999 3893 Adapter cable................1014
999 3894 Template................1015
11 666 140 Multimeter................1016
Measuring; general................1017
Measuring symbols; description................1018
Component descriptions................1021
Component troubleshooting; structure; description................1024
Component troubleshooting; checking wiring harness and input_output on ECU................1026
Component troubleshooting; checking component................1028
Component troubleshooting; checking subsystem (circuit)................1030
AL3201; description and measuring................1032
BA3101; description and measuring................1034
CU2501; description and measuring................1036
CU2503; description and measuring................1038
CU9901; description and measuring................1040
FU6; description and measuring................1042
FU18; description and measuring................1043
FU26; description and measuring................1044
FX1005; description and measuring................1045
FX1006; description and measuring................1048
FX1007; description and measuring................1051
FX1008; description and measuring................1054
FX1031; description and measuring................1057
HE2501; description and measuring................1060
MA2301–MA2306; description and measuring................1062
MA2508; description and measuring................1064
MA2509; description and measuring................1066
MA2510; description and measuring................1068
MA2512; description and measuring................1070
MA2602; description and measuring................1072
MA4214; description and measuring................1074
MA4226; description and measuring................1076
MA4227; description and measuring................1078
MA4302; description and measuring................1080
MA4303; description and measuring................1082
MA5205; description and measuring................1084
MA9109; description and measuring................1086
MA9120; description and measuring................1088
MA9121; description and measuring................1090
MA9122; description and measuring................1092
MA9125; description and measuring................1094
MA9152; description and measuring................1096
MA9164; description and measuring................1098
MA9165; description and measuring................1100
MA9615; description and measuring................1102
MA9618; description and measuring................1104
MA9619; description and measuring................1106
MA9620; description and measuring................1108
MID 140 PPID 1144; description and measuring................1110
MO3301; description and measuring................1111
Power supply; ACM (Aftertreatment Control Module); description and measuring................1113
PPID1336; description and measuring................1114
PWM2303; description and measuring................1116
PWM2602; description and measuring................1118
PWM4219; description and measuring................1120
PWM4220; description and measuring................1122
PWM9109; description and measuring................1124
PWM9129; description and measuring................1126
PWM9141; description and measuring................1128
PWM9143; description and measuring................1130
PWM9145; description and measuring................1132
PWM9146; description and measuring................1134
RE2501; description and measuring................1136
RExxxx; Relays general; description and measuring................1138
SAE J1708_1587 Information link; description and measuring................1140
SAE J1939_CAN control link; description and measuring................1143
SAEJ1939_CAN7 Control link; description and measuring................1146
SE2203; description and measuring................1149
SE2301; description and measuring................1151
SE2303; description and measuring................1153
SE2309; description and measuring................1155
SE2512; description and measuring................1157
SE2515; description and measuring................1159
SE2516; description and measuring................1161
SE2519; description and measuring................1163
SE2520; description and measuring................1165
SE2521; description and measuring................1167
SE2522; description and measuring................1169
SE2523; description and measuring................1171
SE2524; description and measuring................1173
SE2525; description and measuring................1175
SE2526; description and measuring................1177
SE2604; description and measuring ................1179
SE2603; description and measuring................1181
SE2604; description and measuring................1183
SE2606; description and measuring................1185
SE2701; description and measuring................1187
SE2703; description and measuring................1189
SE2704; description and measuring................1191
SE4216; description and measuring................1193
SE4217; description and measuring................1195
SE4234; description and measuring................1197
SE4307; description and measuring................1199
SE5201; description and measuring................1201
SE5221; description and measuring................1203
SE8701; description and measuring................1205
SE8702; description and measuring................1207
SE8705; description and measuring................1209
SE8706; description and measuring................1211
SE9105; description and measuring................1213
SE9109; description and measuring................1215
SE9188; description and measuring................1217
SE9401; description and measuring................1219
SID211; description and measuring................1221
SID232; description and measuring................1222
SW2701; description and measuring................1223
SW3301; description and measuring................1225
SW3619; description and measuring................1227
SW4202; description and measuring................1229
SW4205; description and measuring................1231
SW9160; description and measuring................1233
SW9161; description and measuring................1235
SW9162; description and measuring................1237
Error codes; build-up................1239
Error code information; description................1243
Care Track can not communicate with the machine................1245
31 - BATTERY................1247
Battery; storage................1248
Battery; description................1251
Battery; specifications................1253
Battery; charging................1254
Batteries; replacing................1256
32 - ALTERNATOR; CHARGE REGULATOR................1260
Charging; description................1261
Alternator; specifications................1262
Alternator; description................1263
Alternator; replacing incl function checking................1265
Alternator; testing................1269
33 - STARTING SYSTEM................1271
Starter switch (engine start switch); replacing................1272
Starter motor; description................1274
Starter motor; specifications................1275
Starter motor; testing................1276
Starter relay; replacing................1280
Starter motor; tightening torques................1282
Starter motor; replacing................1285
Preheating; description................1290
Preheating; specifications................1291
35 - LIGHTING................1292
Lights; specifications................1293
Headlights; adjusting................1294
Rotating beacon; specifications................1296
Rotating beacon; description................1297
Rotating beacon; replacing................1298
36 - OTHER ELECTRICAL EQUIPMENT................1300
Electric horn; description................1302
Electric horn; specifications................1304
Horn; replacing................1305
Travel alarm; description................1307
Travel alarm; specifications................1310
Travel alarm; replacing................1311
Windscreen wiper; description................1313
Wiper controller; description................1315
Wiper controller; specifications................1317
Windscreen wiper controller; replacing................1318
Upper wiper motor; description................1320
Upper wiper motor; specifications................1322
Windscreen wiper front motor; replacing................1323
Windscreen wiper switch; replacing................1326
Windscreen flusher pump; replacing................1328
Lower wiper motor; description................1330
Lower wiper motor; specifications................1332
Windscreen flusher pump; specifications................1333
Windscreen wiper; components location................1334
Window limit switch; description................1336
Connectors; overview................1338
Switch; replacing................1344
Battery disconnect switch; description................1347
Battery disconnect switch; specifications................1348
Start switch; description................1349
Start switch; specifications................1351
Engine speed control switch; description................1352
Emergency engine speed control switch; description................1353
Emergency engine speed control switch; specifications................1354
Multi-function lever switch; description................1355
Multi-function lever switch; specifications................1357
Control levers; specifications................1358
Manual travel control switch; description................1366
Manual travel control switch; specifications................1367
Auto_Manual pump control switch; description................1368
Auto_Manual pump control switch; specifications................1369
Stabiliser solenoid valve; specifications................1370
Servo valve block solenoids; specifications................1371
Dozer blade solenoid valve; specifications................1372
Electric center passage; specification................1373
Electric center passage; description................1374
Power outlet; specifications................1377
Electric center passage; replacing................1378
Engine control unit E-ECU; function description................1382
Instrument control unit I-ECU; functional description................1384
Vehicle control unit V-ECU; functional description................1386
Electronic climate control unit ECC; specification ................1387
Instrument control unit I-ECU; specifications................1388
Control units changing; precaution................1389
I-ECU MID 140 non-programmed; replacing................1390
I-ECU MID 140 pre-programmed; replacing................1392
V-ECU MID 187 non-programmed; replacing................1394
V-ECU MID 187 pre-programmed; replacing................1399
37 - CABLE; FUSE; RELAY................1404
Electrical symbols and designations................1408
Explanation of wiring diagrams................1412
Component designations................1415
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{007-00}................1416
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{006-41}................1418
Component list; fuses_{006-12}................1419
Component list; fuses_{005-53}................1421
Component list; Heating coils................1423
Component list; lights_{005-02}................1424
Component list; lights_{004-43}................1426
Component list; Miscellaneous_{004-14}................1428
Component list; Miscellaneous_{003-55}................1429
Component list; motors................1430
Component list; relays_{003-08}................1431
Component list; relays_{002-49}................1432
Component list; sensors_{002-11}................1433
Component list; sensors_{001-52}................1435
Component list; sensors_{001-33}................1437
Component list; Solenoid valves_{000-59}................1439
Component list; Solenoid valves_{000-40}................1441
Component list; Switches_{000-11}................1443
Component list; Switches_{059-52}................1445
ACM; I_O list................1447
ECC; I_O list................1450
E-ECU; I_O list................1452
I-ECU; I_O list................1456
V-ECU; I_O list................1458
W-ECU; I_O list................1464
Wiring diagram; general_{055-58}................1466
Wiring diagram; general_{055-39}................1468
Control system diagram_{055-11}................1470
Control system diagram_{054-40}................1473
Wiring diagram; electrical distribution box................1476
Wiring diagram SCH001_{53-08}................1479
Wiring diagram SCH001_{52-16}................1485
Wiring diagram SCH002_{51-15}................1491
Wiring diagram SCH002_{50-22}................1496
Wiring diagram SCH003_{49-24}................1501
Wiring diagram SCH003_{48-28}................1507
Wiring diagram SCH004_{47-28}................1513
Wiring diagram SCH004_{46-33}................1520
Wiring diagram SCH005_{45-25}................1526
Wiring diagram SCH005_{44-32}................1533
Wiring diagram SCH006_{43-36}................1538
Wiring diagram SCH006_{42-45}................1543
Wiring diagram SCH007_{41-49}................1548
Wiring diagram SCH007_{40-55}................1553
Wiring diagram SCH008_{40-02}................1558
Wiring diagram SCH008_{39-08}................1565
Wiring diagram SCH009_{38-08}................1572
Wiring diagram SCH009_{37-15}................1578
Wiring diagram SCH010_{36-13}................1584
Wiring diagram SCH010_{35-18}................1591
Wiring diagram SCH011_{34-16}................1598
Wiring diagram SCH011_{33-23}................1604
Wiring diagram SCH012_{32-21}................1610
Wiring diagram SCH012_{31-26}................1615
Wiring diagram SCH013_{30-20}................1620
Wiring diagram SCH013_{29-28}................1626
Wiring diagram SCH014_{28-40}................1632
Wiring diagram SCH014_{28-10}................1638
Wiring diagram SCH015_{27-26}................1642
Wiring diagram SCH015_{26-35}................1647
Wiring diagram SCH016_{25-39}................1652
Wiring diagram SCH016_{24-46}................1659
Wiring diagram SCH017_{23-51}................1666
Wiring diagram SCH017_{22-56}................1672
Wiring diagram SCH018_{21-52}................1678
Wiring diagram SCH018_{21-08}................1684
Wiring diagram SCH019_{20-10}................1690
Wiring diagram SCH019_{19-17}................1696
Wiring diagram SCH020_{18-13}................1702
Wiring diagram SCH020_{17-22}................1707
Wiring diagram SCH021_{16-25}................1712
Wiring diagram SCH021_{15-30}................1718
Wiring diagram SCH022_{14-25}................1724
Wiring diagram SCH022_{13-33}................1729
Wiring diagram SCH023................1734
Wiring diagram SCH024_{11-51}................1740
Wiring diagram SCH024_{11-20}................1743
Wiring diagram SCH025_{10-36}................1746
Wiring diagram SCH025_{09-46}................1751
Wiring diagram SCH027................1756
Wiring diagram SCH028_{08-10}................1762
Wiring diagram SCH028_{07-31}................1767
Wiring diagram SCH029_{06-38}................1772
Wiring diagram SCH029_{06-03}................1776
Wiring diagram SCH030_{05-22}................1780
Wiring diagram SCH030_{04-55}................1785
Electrical diagram; single acting trailer hydraulic................1790
Tiltrotator control system; diagram................1795
Wiring harnesses_{001-30}................1808
Wiring harnesses_{001-09}................1812
Power distribution box; description-041................1816
Power distribution box; description................1818
Electrical distribution box; description_{058-41}................1820
Electrical distribution box; description_{058-16}................1823
Electrical distribution box; circuit board replacing................1826
Fuse; description................1829
Relay; description................1831
Relay; specifications................1833
Flasher relay; specifications................1834
Grounding points; frame connections................1835
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM................1838
Instruments and controls; overview................1840
Display unit................1841
Instruments and controls; left instrument panel_{052-49}................1842
Instruments and controls; left instrument panel_{052-29}................1845
Instruments and controls; right instrument panel_{051-58}................1847
Instruments and controls; right instrument panel_{051-37}................1850
Instruments and controls; rear instrument panel................1853
Control levers; description................1854
Hour counter; description................1856
Hour counter; specifications................1857
Fuel level sensor; specifications................1858
Swing position sensor; specifications................1860
Control lockout lever switch; description................1861
Control lockout lever switch; specifications................1863
Auto idle pressure switch; specifications................1864
Engine oil pressure sensor; replacing................1865
CareTrack system; description................1868
Engine rotation speed sensor; replacing_{038-25}................1872
Engine rotation speed sensor (camshaft); replacing................1875
Hydraulic oil temperature sensor; replacing................1877
Boost pressure _ charge-air temperature sensor; replacing................1880
Temperature sensor cooling system; replacing................1885
NOx sensor; replacing................1887
Oil level sensor; replacing................1888
Fuel rail pressure sensor; replacing................1889
DPF (Diesel particulate filter) inlet temperature sensor; replacing................1890
DPF (Diesel particulate filter) outlet temperature sensor; replacing................1891
EGR temperature sensor; replacing................1892
EGR pressure sensor; replacing................1893
Booting sequence................1894
Main menu................1896
Display unit; content................1898
Setup................1905
Control types for X001 and X3 operation................1913
Pop-up screen................1915
Keypad; description................1917
Keypad; specification................1918
Theft protection................1920
Service mode................1922
Engine system................1924
Hydraulic system................1926
Electrical system................1928
Vehicle information................1932
Language................1934
39 - MISCELLANEOUS................1936
Audio remote controller; specifications................1937
Radio with MP3; specifications................1938
Audio remote controller; description................1939
Radio with MP3; description................1940
DC–DC converter; specifications................1942
DC–DC converter; description................1943
Radio with CD and MP3 player; specifications_{10-07}................1945
Radio with CD and MP3 player; specifications_{09-49}................1946
Radio with CD and MP3 player; description_{09-19}................1948
Radio with CD and MP3 player; description_{08-58}................1950
Antenna; replacing................1952
Speaker; replacing................1954
Wireless control unit W-ECU; specification................1956
W-ECU; MID142; changing non-programmed ECU................1957
W-ECU; MID142; changing pre-programmed ECU................1961
CareTrack antenna; replacing................1965
4 - POWER TRANSMISSION................1968
40 - GENERAL................1969
Power transmission; description................1970
Tech Tool; operations ................1971
42 - TRANSMISSION; HYDRAULIC CONTROL................1972
Transmission mode; function check................1973
43 - GEARBOX................1975
Travel gearbox; specifications................1976
Travel gearbox; description................1977
Travel gearbox; bleeding................1987
Travel gearbox; removing................1990
Travel gearbox; installing................1994
Travel gearbox multi-disc; replacing_{59-03}................2000
Travel gearbox multi-disc; replacing_{58-30}................2022
44 - HYDROSTATIC DRIVE................2025
Swing motor; specifications................2026
Swing motor; description................2027
Swing motor; removing................2031
Swing motor; installing................2034
Swing motor pressure; checking and adjusting................2036
Swing motor brake discs; replacing (motor removed)................2040
Travel motor; description................2049
Travel motor (electric proportional control); description................2054
Travel motor pressure; checking and adjusting................2062
Travel motor (electric proportional control) pressure; checking and adjusting................2066
Travel motor; calibrating................2070
Travel motor; specifications................2073
Travel motor regulation start; checking and adjusting................2074
Travel motor; removing................2079
Travel motor; installing................2083
Travel motor removed; seal replacing................2087
Retardation valve; replacing................2090
Pump coupling; removing................2095
Pump coupling; installing................2096
Center passage; specifications................2097
Center passage; description................2100
Centre passage; removing................2102
Centre passage; installing................2106
Center passage; disassembling and assembling................2111
45 - PROPELLER SHAFT................2116
Propeller shaft; specifications................2117
Propeller shaft front; replacing................2119
Propeller shaft rear; replacing................2122
46 - FRONT AXLE; REAR AXLE................2125
Front axle; specification................2126
Front axle; description................2128
Front axle; removing................2130
Front axle; installing................2134
King pin and bushing; replacing................2137
Input shaft seal; replacing................2138
Front axle knuckle_{35-48}................2140
Front axle knuckle_{35-27}................2143
Rear axle; specifications................2145
Rear Axle; removing................2146
Rear Axle; installing................2149
49 - MISCELLANEOUS................2152
Tightening torque; specifications................2153
Swing ring gear; specifications................2154
Swing ring gear; description................2155
Swing ring; removing................2159
Swing ring; installing................2160
Swing ring gear inner seal; replacing................2162
Swing ring gear outer seal; replacing_{30-12}................2164
Swing ring gear outer seal; replacing_{29-52}................2166
Measuring rotational clearance................2169
Swing ring; measuring axial clearance................2173
5 - BRAKE................2177
52 - HYDRAULIC BRAKE SYSTEM................2178
Electrical digging brake; description................2179
Hydraulic brake system; description................2182
Brake system circuit pressure; checking and adjusting................2187
Brake system; bleeding................2193
Service brakes function; checking................2195
Foot brake valve; replacing................2197
Brake accumulator; specifications................2202
Brake accumulator; description................2204
Accumulator; removing................2206
Accumulator; installing................2208
Brake accumulator charging pressure; adjusting................2210
Hydraulic oil filter; replacing ................2213
55 - PARKING BRAKE................2215
Parking brake; description................2216
Parking brake; manually releasing................2222
Parking brake function; checking................2225
6 - STEERING................2227
60 - GENERAL................2228
Steering system function; checking................2229
64 - STEERING................2231
Steering system; description_{15-18}................2232
Steering system; description_{14-50}................2237
Control valve (steering unit); description................2242
Steering system working pressure; checking................2246
Steering valve; removing................2249
Steering valve; installing................2253
Hydraulic oil filter; replacing................2258
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT................2260
71 - FRAME................2261
Superstructure; removing................2262
Superstructure; installing................2267
Counterweight; specifications................2271
Counterweight; removing................2272
Counterweight; installing................2275
Undercarriage; description................2278
Undercarriage; tightening torque................2280
Step; removing................2282
Step; installing................2284
76 - SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL _ SIDE CONTROL................2286
Pivot axle lock cylinder; description................2287
Pivot axle lock cylinder; removing................2294
Pivot axle lock cylinder; installing................2296
Pivot axle lock cylinder; releasing for towing................2298
Pivot axle lock cylinder seals; changing................2300
Pivot axle lock; function check................2305
77 - WHEELS; TRACKS; TYRE; HUB; DRUM................2307
Wheels; specifications................2308
Wheel; removing................2309
Wheel; installing................2311
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE................2313
80 - GENERAL................2314
Tech Tool; operations-................2315
81 - CAB; NAKED; CANOPY................2316
Cab; weight................2317
Cab; removing................2318
Cab; installing................2325
Cab suspension; description................2332
83 - DOORS; HATCH; COVER PLATE; (all)................2333
Cab door; removing door catch................2334
Cab door; installing door catch................2337
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING................2340
Windows; general................2341
Windscreen; replacing................2342
Side window; replacing................2355
Rear window; replacing................2361
Door window; replacing................2366
Cab roof window; replacing................2368
85 - CAB INTERIOR; UPHOLSTERY................2371
Seat; replacing................2372
Seat cushion; replacing................2381
Seat support; replacing................2386
Longitudinal adjustment cable; replacing................2392
Longitudinal suspension cable; replacing................2398
Backrest; replacing................2402
Seat belt; replacing................2406
Driver's seat; description................2409
Driver's seat; specifications................2412
Seat heater; checking................2413
87 - AIR CONDITIONING UNIT................2416
Electronic climate control unit ECC; description................2417
Electronic climate control unit ECC; specification................2418
Wiring diagram................2419
HVAC system................2420
Air conditioning unit; specifications................2422
Air conditioning unit; description................2423
Air-conditioning; component location................2429
Air conditioning unit; maintenance................2431
ECC MID 146 pre-programmed ECU; replacing................2433
ECC MID 146 non-programmed ECU; replacing................2436
Air conditioning unit; refrigerant check and recharging................2440
Air distribution; description................2448
Cab filter; replacing................2450
Heating system; description................2451
Fan motor; replacing................2453
Heater core; replacing................2459
Personal competence and accreditation................2465
Compressor; replacing incl draining and filling................2466
Receiver; replacing incl draining and filling................2470
Condenser; replacing incl draining and filling................2473
Evaporator; replacing incl draining and filling................2476
Expansion valve; replacing incl draining and filling................2481
Vent actuator; replacing................2486
Mode (foot) actuator; replacing................2489
Intake actuator; replacing................2492
Air mix door actuator; replacing................2495
Auxiliary heater; description................2498
Auxiliary heater; principles................2503
Diesel coolant heater (5kw); specifications................2507
Troubleshooting (5kw)................2508
88 - INTERIOR EQUIPMENT................2512
Instrument panel (left); replacing................2513
Instrument panel (right); replacing................2518
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS................2522
90 - GENERAL................2523
Hydraulic diagram; dozer blade and outrigger - Image................2525
Hydraulic diagram; grab piping - Image................2526
Hydraulic diagram; quick fit - Image................2527
Hydraulic diagram; X3 - Image................2529
Hydraulic diagram; X1 with pressure control - Image................2530
Hydraulic diagram; X1 with flow control - Image................2531
Hydraulic diagram; elevating cab - Image................2532
Hydraulic diagram; cruise control - Image................2534
Hydraulic diagram; offset boom - Image.pdf - Image................2535
Hydraulic diagram; offset boom - Image................2536
Hydraulic diagram; Boom Suspension System - Image................2537
Hydraulic diagram; boom float valve - Image................2538
Hydraulic diagram; travel (low speed) - Image................2539
Hydraulic diagram; with reversible cooling fan - Image................2540
Hydraulic diagram; single acting trailer hydraulic - Image................2541
Hydraulic diagram; complete - Image................2543
Explanations to hydraulic diagram................2544
Hydraulic system; cleanliness when handling hydraulic components................2555
Hydraulic diagram; component list................2557
Hydraulic system; position of main components................2560
Hydraulic diagram; complete................2563
Hydraulic diagram; single acting trailer hydraulic................2566
Hydraulic diagram; with reversible cooling fan................2571
Hydraulic diagram; travel (low speed)................2574
Hydraulic diagram; boom float valve................2577
Hydraulic diagram; Boom Suspension System................2580
Hydraulic diagram; offset boom................2583
Hydraulic diagram; cruise control................2588
Hydraulic diagram; elevating cab................2591
Hydraulic diagram; X1 with flow control................2594
Hydraulic diagram; X1 with pressure control................2597
Hydraulic diagram; X3................2600
Hydraulic diagram; quick fit................2603
Hydraulic diagram; grab piping................2608
Hydraulic diagram; dozer blade and outrigger................2611
Description; general................2614
Hydraulic oil; description................2615
Hydraulic system; repair of hydraulic components in workshop................2619
Hydraulic oil; storage and handling................2624
Hydraulic components; storing and transporting................2625
Vacuum pump; connection................2626
Vacuum pump; disconnection................2629
Hydraulic system; warming up................2631
Tech Tool; operations................2635
Measuring tools and techniques................2636
Hydraulic system; flushing................2641
91 - WORKING HYDRAULIC; SERVO HYDRAULICS................2642
Hydraulic system; work instructions................2645
Hydraulic system; description................2646
Hydraulic pressure; specifications................2647
Hydraulic oil; cleaning................2652
Changing the hydraulic oil................2654
Hydraulic oil cooling system; description................2657
Hydraulic oil cooling system; specifications................2658
Hydraulically driven cooling fan; description................2660
Hydraulic tank; specifications................2664
Hydraulic oil tank; description_{06-19}................2665
Hydraulic oil tank; description_{05-59}................2667
Hydraulic oil tank; releasing pressure................2669
Cooling fan speed; checking and adjusting with VCADS Pro................2670
Hydraulic oil cooler; removing................2675
Hydraulic oil cooler; installing................2676
Hydraulic oil tank; removing................2677
Hydraulic oil tank; installing................2680
Main control valve block; description................2683
Main control valve; removing................2688
Main control valve; installing................2692
Back-up valves................2695
Back-up valve; checking and adjusting................2698
Back-up pressure increase_{59-51}................2703
Back-up pressure increase_{59-30}................2705
Unload valve; checking and adjusting................2707
Unload valve; replacing................2711
Shock and anti-cavitation valve; description................2715
Line rupture valve (boom); description................2718
Line rupture valve for dipper arm cylinder; description................2721
Line rupture valve for 2-piece boom cylinder X2; description................2726
Line rupture valve (boom); troubleshooting................2731
Line rupture valve pressure; checking and adjusting................2733
Working pressure; checking and adjusting................2739
Secondary pressure limiting valve; checking................2748
Boom cylinder; rupture valve; replacing................2751
Dipper arm cylinder; rupture valve; replacing................2754
Rupture valve; replacing (2pcs boom tilt cylinder)................2757
Dipper arm in speed; checking and adjusting................2761
LS-pressure relief valve; replacing................2763
Pressure relief valves; description................2766
Hydraulic pump; specifications................2770
Working pump; description................2772
Pump; removing................2775
Pump; installing................2779
Servo system; description................2783
Servo valve; removing................2787
Servo valve; installing................2790
Servo pump; removing................2793
Servo pump; installing................2795
Accumulator; description................2797
Servo accumulator; removing................2799
Servo accumulator; installing................2801
Discarded accumulators................2803
Servo pressure; checking and adjusting................2804
Control lockout lever; function check................2807
Servo Accumulator................2809
Remote control valve (pedal); specifications................2810
Control pattern selector valve; description................2812
X1; description................2817
X1; Specifications................2828
Option X1 pressure control................2833
VCADS Pro; 91610-3 – X1 hydraulic pressure control system; test................2841
X1; function check................2844
Calibration of X1 hydraulic with flow control................2846
Calibration of X1 hydraulic with pressure control................2849
X1 Pre-set relief valve; description................2851
X1 pressure relief valve; adjusting................2855
X3; description................2859
X3; specifications................2868
X3; function check................2870
X3 pressure and flow; adjusting................2872
X3 shock and refilling valves; adjusting................2877
Boom float position; description................2881
Cruise control; specifications................2884
Cruise control; description................2885
Reversible cooling fan; description................2890
Grab bucket; description................2894
Tiltrotator control system; description................2900
Boom Suspension System; description_{30-00}................2915
Boom Suspension System; description_{29-35}................2924
Boom Suspension System; specifications_{29-02}................2933
Boom Suspension System; specifications_{28-42}................2936
Boom suspension system; component location................2938
Boom suspension accumulator; checking and adjusting................2940
Boom suspension system; changing accumulator................2944
Boom suspension system; solenoid valve test................2948
Trailer towing solution (TTS)................2950
Single acting trailer hydraulic................2958
92 - MECHANICAL EQUIPMENT_ATTACHMENT................2962
Standard quick coupler................2963
Universal quick coupler_{24-25}................2968
Universal quick coupler_{24-05}................2974
Steelwrist quick coupler_{23-29}................2978
Steelwrist quick coupler_{23-09}................2985
Hydraulic quickfit cylinder; removing................2986
Hydraulic quickfit cylinder; installing................2990
Cylinder for hydraulic quickfit S1; removing................2993
Cylinder for hydraulic quickfit S1; installing................2995
Cylinder for hydraulic quickfit Universal; removing................2997
Cylinder for hydraulic quickfit Universal; installing................3001
Cylinder for hydraulic quickfit S6; removing................3005
Cylinder for hydraulic quickfit S6; installing................3012
Quickfit; removing................3015
Quickfit; installing................3017
Quickfit; replacing................3020
Quickfit; function check_{16-54}................3024
Quickfit; function check_{16-34}................3026
Dozer blade; description................3028
97 - UNIT; DIGGING................3029
Cylinder; specifications................3030
Cylinder; description................3031
Boom lifting cylinder; description................3034
Dipper arm cylinder; description................3036
Bucket cylinder; description................3038
Digging equipment bearings; measuring radial clearance................3040
Digging equipment bearings; specifications................3043
Digging equipment bearings; shimming................3045
Stabilisers and stabiliser blade; description................3047
2-piece boom; removing................3049
2-piece boom; installing................3053
Dipper arm; removing................3057
Dipper arm; installing................3060
Bucket cylinder; removing................3063
Bucket cylinder; installing................3067
99 - MISCELLANEOUS................3071
Automatic lubrication system; specifications................3072
Automatic lubrication system; description................3073
Control unit; description................3080
Control units; software functions................3082
Maintenance service; general................3088
Automatic lubrication pump; removing................3091
Automatic lubrication pump; installing................3093
Troubleshooting................3099
Bleeding air................3101
Hydraulic elevating cab; description................3102
Cab elevating cylinder; replacing................3108
E-tool Sleeve................3113
Volvo EW160D Excavators Repair Service Manual
