Volvo EW160C Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EW160C Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Construction Equipments EW160C 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 EW160C Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,979 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
0 - Foreword......2
0 - GENERAL......3
00 - DESCRIPTION; COMPLETE MACHINE......4
Description; complete machine......5
Component locations ......6
Product plates......8
03 - SPECIFICATIONS......9
Tightening torques......13
Conversion tables......19
Engine; specifications ......27
Engine; weights ......28
Valve system specifications ......29
Flywheel; weight ......31
Lubrication system; specifications ......33
Fuel pressure; specifications ......34
Fuel tank; specifications ......36
Injectors; specifications ......37
Cooling system; specifications ......38
Coolant pump; thermostat; specifications ......39
Engine speed control switch; specifications ......41
Electrical system; specifications ......42
Engine control unit E-ECU; specifications ......44
Electronic climate control unit ECC; specification ......46
Wireless control unit W-ECU; specification......48
Keypad; specification......50
Alternator; specifications ......53
Starter motor; specifications ......55
Electric horn; specifications ......56
Rotating beacon; specifications ......58
Travel alarm; specifications ......59
Wiper controller; specifications ......61
Windscreen flusher pump; specifications ......63
Start switch; specifications ......65
Control lockout lever switch; specifications......67
Emergency engine speed control switch; specifications_{06-43}......69
Emergency engine speed control switch; specifications_{06-25}......70
Auto_Manual pump control switch; specifications ......72
Relay; specifications......73
Circuit breaker; specification......75
Hour counter; specifications......77
Audio remote controller; specifications_{04-35}......79
Audio remote controller; specifications_{04-16}......82
Capacities......84
Specifications; weight......85
Engine; oil and filter; change. ......86
Radio with tape or CD player; specifications......89
DC–DC converter; specifications......92
Travel motor; specifications......93
Slew motor; specifications......95
Centre passage; specification......96
Propeller shaft; specifications......97
Front axle; specification......98
Rear axle; specification......99
Slew ring gear; specifications......100
Steering axle; specifications......101
Counterweight; specifications_{58-41}......102
Counterweight; specifications_{58-19}......103
Engine; volume ......104
Air cleaner; specification-5734......105
Air cleaner; specification ......106
Fuel filler pump; specifications ......107
Engine control; specifications ......108
Instrument control unit I-ECU; specifications ......109
Vehicle control unit V-ECU; specifications ......111
Battery; specifications ......116
Preheating; specifications ......117
Lighting; specifications ......118
Lower wiper motor; specifications ......119
Battery disconnect switch; specifications ......120
Multi-function lever switch; specifications ......121
Control levers; specifications ......122
Manual travel control switch; specifications ......129
Control lockout solenoid valve; specifications ......130
Stabiliser solenoid valve; specifications ......131
Electric center passage; specification ......132
Power outlet; specifications ......133
Flasher relay; specifications......134
Hydraulic oil filter pressure switch; specifications......135
Auto idle pressure switch; specifications......136
Slew position sensor; specfications......137
Rear view camera; specifications......138
Travel gearbox; specifications_{48-43}......139
Travel gearbox; specifications_{48-24}......140
Wheels; specifications......141
Cab; specifications......142
Cab; weight......145
Air conditioning unit; specifications......147
Diesel coolant heater (5kw); specifications......148
Automatic lubrication system; specifications......150
Brake pump; specifications......152
Steering pump; specifications......153
Control valve (steering unit); specification......154
Hydraulic pressure; specifications......155
X1; Specifications......157
Cruise control; specifications......161
Hydraulic tank; specifications......162
Working pump; specifications......163
Servo pump; specifications......164
Digging equipment bearings; specifications......165
Cylinder data......167
Hydraulic oil cooling system; specifications......168
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION......171
Lifting instructions......172
07 - STANDARD TIME......174
Operation numbers for additional work......175
08 - TOOL......177
E-tool; 1802 Extractor for pressure limiting valve......178
E-tool; 3500 Support plate for travel gearbox and motor......179
E-tool; 3501 Puller for gear wheel fan pump......181
E-tool; 3502 Plate for turning crankshaft......182
E-tool; 3506 Flange......184
E-tool; 3507 Plug......185
Infrared Thermometer......186
09 - MISCELLANEOUS......188
Service positions ......189
Welding on the machine......192
Hydraulic cylinders; dieseling......195
Control units; changing......197
1 - STANDARD PARTS; SERVICE......199
16 - LUBRICANT; FUEL; OTHER FLUID......200
Coolant with freezing and corrosion protection......201
Recommended lubricants......202
Coolant......205
Alternative fuels......210
17 - SERVICE......213
Bearings......216
Elimination of trapped hydraulic pressure......220
Replacement parts......222
Service......226
Service methods......227
Pressure testing......231
Hoses and tubes......235
Cleaning prior to repair......239
Arrival Inspection; according to Inspection Programme......240
Delivery Inspection; according to Inspection Programme......245
Maintenance of Stored Machines; according to Inspection Programme......247
Warranty inspection 100 hours......249
Warranty inspection 1000 hours......250
Periodic maintenance......251
Maintenance service; daily......253
Maintenance service; every 50 hours......254
Maintenance service; every 250 hours......255
Maintenance service; first 500 hours......256
Maintenance service; every 500 hours......257
Maintenance service; every 1000 hours......258
Maintenance service; every 2000 hours......259
Maintenance service; every 4000 hours......260
Maintenance service; every 6000 hours......261
Tyres; wear and air pressure; checking......262
Checking for cracks and leaks......264
Check engine oil level......265
Test-run and check......266
Grease points on dipper arm; lubrication......267
Grease points on booms; lubrication......270
Grease points on undercarriage; lubrication......272
Grease points on superstructure; lubrication_{16-18}......274
Grease points on superstructure; lubrication_{15-57}......275
Hydraulic system; checking oil level......276
Water separator; drain......278
Coolant level; check......280
Axles; checking oil level......281
Axle hubs; checking oil level......283
Travel gearbox oil level; checking......285
Fuel tank water and sediment; drain......287
Battery condition; check......289
Door hinges; lubricate with grease......292
Cab; prefilter; clean......294
Axles; changing oil......296
Hub reduction gear; changing oil......298
Engine; oil and filter; change.......300
Fuel filters; primary and secondary filter; replace_{03-47}......303
Fuel filters; primary and secondary filter; replace_{03-25}......305
Radiator and coolers; cleaning......307
Condenser; clean (with compressed air) (optional equipment)......310
Cab; main filter; clean......312
Belts and belt tension; check; replace when needed.......314
Service journal (included in Operator's manual); fill in......317
Wheel nuts; check torque......318
Brake system; checking function......319
Air cleaner primary filter; change......320
Air conditioning unit; maintenance......323
MATRIS; reading; export reading......324
VCADS Pro; logged errors; read off......326
Swing bath grease; check......328
Travel gearbox; changing oil......331
Brake discs; checking wear......333
Air cleaner secondary filter; change......336
Cab; prefilter; replace......338
Cab main filter; replacing......340
Fuel tank breather filter; replacing......342
Hydraulic oil return filter; changing......344
Hydraulic tank breather filter; changing......346
Hydraulic oil servo filter; change......348
Coolant's freezing point; check......350
Valve clearance and IEGR; check......352
Hydraulic system; changing oil......353
Hydraulic oil suction strainer; change......357
Turbocharger inclusive inlet and exhaust systems; leakage; check......360
Coolant; change......362
CareTrack backup battery; replacing......366
Creeping of hydraulic cylinder......369
Emergency operation; description......373
Towing......376
Secondary lowering of digging equipment......378
Starting engine with booster cables......380
19 - GENERAL......382
Safety concerns everybody!......383
Service positions......385
CE marking and declaration of conformity......388
Safety when handling the machine......390
Safety rules when servicing......394
Checklist after a fire or heat exposure ......396
Fire prevention measures......397
Health hazards with paint; plastics and rubber......400
Checklist after a fire or heat exposure......405
Some simple rules regarding tyre handling......409
Safety when using lifting equipment......411
Safety when handling oils and fuel......415
Safety when working with batteries......419
Starting with booster batteries......424
Safety when working with air conditioning refrigerant......428
Safety when working with hydraulic systems......433
Environmental handling for the future......435
Environmentally safe handling......439
Environmentally hazardous fluids......442
Working in environmentally contaminated areas......446
Decontamination......450
Waste handling......454
2 - ENGINE WITH MOUNTING AND EQUIPMENT......458
20 - GENERAL......459
Engine; description......460
E-ECU MID 128 pre-programmed; replacing......462
E-ECU MID 128 non-programmed; replacing......464
Engine; identification......466
Engine; volume......467
Engine; tightening torques......468
Component locations......471
Engine; weights ......473
21 - ENGINE......474
Engine; specifications......476
Cylinder compression; PC test......477
Engine characteristic curve......478
Basic check; Engine......480
Troubleshooting......482
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope......485
Engine and transmission; installing......491
Engine; weights......501
Cylinder head; description......502
Cylinder head gasket; description......504
Cylinder; description......506
Pistons; description......508
Piston rings; description......510
Piston cooling......512
Valve system specifications......514
Valves; description......517
Internal Exhaust Gas Recirculation (IEGR); description......519
Valves; adjusting......525
Engine timing gear; description......538
Camshaft; description......541
Timing gear case new gasket; installing......544
Flywheel; weight......561
Crankshaft; description......563
Vibration damper; description......566
Connecting rod; description......569
Crankshaft front oil seal; replacing......572
Crankshaft rear oil seal; replacing......581
Oil sump; description......592
Oil sump; replacing......594
Oil level sensor; replacing......599
Engine mounting......603
Engine mount front; replacing......606
Engine mounting rear; changing......610
22 - LUBRICATING SYSTEM......613
Lubricating system; description......614
Lubrication system; specifications......618
Lubrication system; principle of operation......619
Oil pump; replacing......623
Lubrication oil pressure; checking with pressure gauge......635
Oil cooler; replacing......637
Oil cooler; description......640
23 - FUEL SYSTEM......641
Fuel system; description......643
Fuel pressure; specifications......645
Instructions for working with electronic fuel injection......647
Fuel pressure; checking......648
Fuel feed pump; description......651
Fuel filter; description......652
Feed pump pressure; checking......653
Fuel filter; checking......657
Fuel system; bleeding_{029-10}......659
Fuel system; bleeding_{028-49}......661
Feed pump; replacing......663
Fuel filters; replacing......666
Fuel filter extra; replacing_{027-22}......668
Fuel filter extra; replacing_{027-01}......670
Fuel tank; specifications......672
Fuel filler pump; specifications......673
Fuel tank; description......674
Fuel tank; replacing......676
Air cleaner; Specification......684
Fuel filler pump; description......685
Fuel filling pump; removing......687
Fuel filling pump; installing......690
Fuel return pressure; checking......692
Injectors; description......694
Injectors; specifications......698
Injectors; replacing......699
High pressure fuel pump; checking......701
Fuel rail; description......705
Fuel rail; replacing......707
Fuel rail pressure; checking......712
Fuel rail pressure sensor; replacing......716
High pressure fuel pump; replacing......718
Fuel control valve (FCV); description......726
Fuel control valve (FCV); checking......728
Fuel control valve (FCV); replacing......732
Pressure relief valve (PRV); inspecting......735
Pressure relief valve (PRV); replacing......739
25 - INLET & EXHAUST SYSTEM......742
Inlet system; description......743
Exhaust system; description......744
Induction manifold gasket; replacing......745
Exhaust manifold gasket; replacing......748
Silencer; replacing......753
Exhaust pipe flexible tube; replacing......757
Turbocharger; description......759
Turbocharger; inspecting......762
Turbocharger; replacing......766
Air cleaner; description......770
Air cleaner; specification......771
Preheating coil; replacing......772
Charge air cooler; description......774
Charge air cooler; replacing......776
26 - COOLING SYSTEM......781
Cooling system; description......782
Cooling system; flushing......784
Cooling system; specifications......789
Coolant anti-freeze resistance; checking......790
Radiator; replacing......792
Radiator hose upper; replacing......798
Radiator hoses lower; replacing......802
Expansion tank; replacing......806
Coolant pump; thermostat; specifications......809
Coolant pump; replacing......811
Thermostat; inspecting......816
Thermostat; replacing......819
Fan belt and_or alternator belt; replacing......822
Fan belt and_or alternator-; compressor belt; replacing all belts......825
27 - ENGINE CONTROL......828
Engine control; specifications......829
Engine speed control switch; specifications......830
Engine speed control switch; description ......831
Engine speed control; function checking......832
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......833
30 - GENERAL......834
Electrical system; special instructions for servicing; general......840
Electrical system; special instructions for servicing; electronic components......843
Electrical system; special instructions for servicing; electrical components; batteries......845
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator......847
Electrical system; special instructions for servicing; action when working on machine......849
Electrical system; description......851
Electronic control system; description......853
Communication with data buses......856
Auxiliary start......859
Data buses; function......862
Service connection and programming connection......868
Data links; fault tracing with Oscilloscope......871
Electrical system; specifications......881
Power Boost control; description......883
Engine Protection......885
Start lock; description_{40-51}......887
Start lock; description_{40-33}......889
Power OFF......890
Quick fit control; description......891
Boom float position; description......892
Limp Home......894
Auto idle device; setting instructions......895
Parking brake; description......896
Control lockout system; description......897
Forward _ Reverse _ Neutral......898
Main pump pressure; checking and adjusting......899
Axle lock......900
Overload warning......902
VCADS Pro; parameter programming......904
Software parameters; description......906
Troubleshooting strategy......915
Troubleshooting; general......918
Collection of basic data......921
Error code information; general......923
Electrical cables and connectors; checking......926
Troubleshooting tools......932
Special tools for troubleshooting......933
VCADS Pro service tool......935
VCADS Pro; Operations......940
Connecting special tools......942
999 8699 Multi-pin breaker box......946
999 0014 Adapter cable......947
999 0025 Adapter cable......950
999 0062 Extension cable......952
8883 0028 Adapter cable......953
88890040 Oscilloscope for VCADS Pro......955
999 3893 Adapter cable......956
999 3894 Template......958
11 666 140 Multimeter......959
Measuring; general......960
Measuring symbols; description......962
Component descriptions......966
Component troubleshooting; structure; description......970
Component troubleshooting; checking wiring harness and input_output on ECU......972
Component troubleshooting; checking component......975
Component troubleshooting; checking subsystem (circuit)......978
AL3201; description and measuring......981
BA3101; description and measuring......983
CU9901; description and measuring......985
FU6; description and measuring......987
FU18; description and measuring......988
FU26; description and measuring......989
HE2501; description and measuring......990
MA2301–MA2306; description and measuring......992
MA2504; description and measuring ......994
MA2602; description and measuring......996
MA2504; description and measuring......998
MA4214; description and measuring......1000
MA4218; description and measuring......1002
MA4219; description and measuring......1004
MA4302; description and measuring......1006
MA4303; description and measuring......1008
MA5205; description and measuring......1010
MA9103; description and measuring......1012
MA9104; description and measuring......1014
MA9107; description and measuring......1016
MA9109; description and measuring......1018
MA9120; description and measuring......1020
MA9152; description and measuring......1022
MA9164; description and measuring......1024
MA9165; description and measuring......1026
MA9615; description and measuring......1028
MID 128 SID 230; description and measuring......1030
MID 140 PPID 1144; description and measuring......1031
MO3301; description and measuring ......1032
MO3301; description and measuring......1034
PPID1336; description and measuring......1036
PWM2303; description and measuring......1038
PWM9103; description and measuring ......1040
PWM4211; description and measuring......1042
PWM6603; description and measuring......1044
PWM9101; description and measuring......1045
PWM9103; description and measuring......1047
PWM9104; description and measuring......1049
PWM9105; description and measuring......1050
PWM9106; description and measuring......1052
PWM9109; description and measuring......1054
PWM9129; description and measuring......1056
RE2501; description and measuring ......1058
RE2501; description and measuring......1060
RExxxx; Relays general; description and measuring......1062
SAE J1708_1587 information link; description and measuring......1064
SAE J1939_CAN control link; description and measuring......1067
SE2202; description and measuring......1070
SE2203; description and measuring......1072
SE2205; description and measuring......1074
SE2301; description and measuring......1076
SE2302; description and measuring......1078
SE2303; description and measuring......1080
SE4217; description and measuring-0805......1082
SE2309; description and measuring......1084
SE2501; description and measuring......1086
SE2502; description and measuring......1088
SE2507; description and measuring......1090
SE2508; description and measuring......1092
SE2510; description and measuring......1094
SE2511; description and measuring......1096
SE2603; description and measuring......1098
SE2606; description and measuring_{56-49}......1100
SE2606; description and measuring_{56-18}......1102
SE2701; description and measuring......1104
SE2703; description and measuring......1106
SE2707; description and measuring......1108
SE4213; description and measuring......1110
SE4217; description and measuring......1112
SE4218; description and measuring......1114
SE5201; description and measuring......1116
SE5205; description and measuring......1118
SE8701; description and measuring......1120
SE8702; description and measuring......1122
SE8705; description and measuring......1124
SE8706; description and measuring......1126
SE9101; description and measuring......1128
SE9105; description and measuring......1130
SE9106; description and measuring......1132
SE9401; description and measuring......1134
SID211; description and measuring......1136
SID232; description and measuring......1137
SW2701; description and measuring......1138
SW3301; description and measuring......1140
SW3611; description and measuring......1142
SW4202; description and measuring......1144
SW4205; description and measuring......1146
SW9160; description and measuring......1148
SW9161; description and measuring......1150
SW9162; description and measuring......1152
Error codes; build-up......1154
Error code information; description......1159
E-ECU (MID128) Engine control unit; active measuring conditions......1161
E-ECU (MID128) Engine control unit; passive measuring conditions......1165
I-ECU (MID140) Instrument control unit; active measuring conditions......1169
I-ECU (MID140) Instrument control unit; passive measuring conditions......1171
W-ECU (MID142) Wireless control unit; active measuring conditions......1173
W-ECU (MID142) Wireless control unit; passive measuring conditions......1175
Care Track can not communicate with the machine......1177
ECC (MID146) Electronic climate control unit; active measuring conditions......1179
ECC (MID146) Electronic climate control unit; passive measuring conditions......1182
V-ECU (MID187) Vehicle control unit; active measuring conditions......1185
V-ECU (MID 187) Vehicle control unit; passive measuring; conditions......1190
31 - BATTERY......1195
Battery; storage......1196
Battery; description......1199
Battery; specifications......1201
Battery; charging......1202
Batteries; replacing......1204
32 - ALTERNATOR; CHARGE REGULATOR......1209
Charging; description......1210
Alternator; specifications......1212
Alternator; description......1214
Alternator; replacing incl function checking......1216
Alternator; testing......1220
33 - STARTING SYSTEM......1222
Starting operation......1223
Starter switch (engine start switch); replacing......1225
Starter motor; description......1227
Starter motor; specifications......1228
Starter motor; testing......1229
Starter relay; replacing......1231
Starter motor; replacing......1232
Preheating; description......1234
Preheating; specifications......1235
35 - LIGHTING......1236
Lighting; specifications......1237
Headlights; adjusting......1238
Rotating beacon; specifications......1240
Rotating beacon; replacing-1123......1241
36 - OTHER ELECTRICAL EQUIPMENT......1243
Electric horn; description......1245
Electric horn; specifications......1247
Horn; replacing......1249
Rotating beacon; description......1251
Rotating beacon; replacing......1253
Travel alarm; description......1255
Travel alarm; specifications......1257
Travel alarm; replacing......1259
Windscreen wiper; description......1261
Wiper controller; description......1263
Wiper controller; specifications......1265
Windscreen wiper controller; replacing......1267
Upper wiper motor; description......1269
Upper wiper motor; specifications......1271
Windscreen wiper front motor; replacing......1273
Windscreen wiper switch; replacing......1276
Windscreen flusher pump; replacing......1278
Lower wiper motor; description......1280
Lower wiper motor; specifications......1282
Windscreen flusher pump; specifications......1283
Windscreen wiper; components location......1285
Window limit switch; description......1287
Connectors; overview......1289
Switch; replacing......1303
Battery disconnect switch; description......1306
Battery disconnect switch; specifications......1308
Start switch; description......1309
Start switch; specifications......1312
Engine speed control switch; description......1314
Emergency engine speed control switch; description......1315
Emergency engine speed control switch; specifications_{55-02}......1317
Emergency engine speed control switch; specifications_{54-44}......1318
Multi-function lever switch; description......1320
Multi-function lever switch; specifications......1322
Control levers; specifications......1323
Manual travel control switch; description......1330
Manual travel control switch; specifications......1331
Auto_Manual pump control switch; description......1332
Auto_Manual pump control switch; specifications......1333
Control lockout solenoid valve; specifications......1334
Stabiliser solenoid valve; specifications......1335
Electric center passage; specification......1336
Electric center passage; description_{50-08}......1337
Electric center passage; description_{49-48}......1339
Power outlet; specifications......1341
Electric center passage; replacing......1342
Electronic climate control unit ECC; description......1345
Engine control unit E-ECU; function description......1347
Instrument control unit I-ECU; functional description......1349
Vehicle control unit V-ECU; functional description......1351
Electronic climate control unit ECC; specification......1353
Engine control unit E-ECU; specifications......1355
Instrument control unit I-ECU; specifications......1357
Vehicle control unit V-ECU; specifications......1359
Control units changing; precaution......1364
I-ECU MID 140 non-programmed; replacing......1365
I-ECU MID 140 pre-programmed; replacing......1367
V-ECU MID 187 non-programmed; replacing......1369
V-ECU MID 187 pre-programmed; replacing......1373
ECC (Electronic Climate Control); replacing......1377
37 - CABLE; FUSE; RELAY......1380
Electrical symbols and designations......1383
Explanation of wiring diagrams......1387
Component designations......1390
Component list Alternator; batteries; capacitors; electronic units; voltage outlet......1392
Component list Control lights_warning lights......1393
Component list; fuses......1395
Component list; Heating coils......1397
Component list; lights......1398
Component list; Miscellaneous......1400
Component list; motors......1401
Component list; relays......1402
Component list; sensors......1403
Component list; Solenoid valves......1405
Component list; Switches......1407
Wiring diagram; general......1409
Control system diagram......1411
Wiring diagram; electrical distribution box......1414
Wiring diagram SCH001......1417
Wiring diagram SCH002......1420
Wiring diagram SCH003......1423
Wiring diagram SCH004......1426
Wiring diagram SCH005......1431
Wiring diagram SCH006......1434
Wiring diagram SCH007......1437
Wiring diagram SCH008......1440
Wiring diagram SCH009......1443
Wiring diagram SCH010......1446
Wiring diagram SCH011......1449
Wiring diagram SCH012......1451
Wiring diagram SCH013......1454
Wiring diagram SCH014_{57-40}......1457
Wiring diagram SCH014_{57-16}......1460
Wiring diagram SCH015......1463
Wiring diagram SCH016......1466
Wiring diagram SCH017......1468
Wiring diagram SCH018......1471
Wiring diagram SCH019......1473
Wiring diagram SCH020......1476
Wiring diagram SCH021......1478
Wiring diagram SCH022_{53-08}......1481
Wiring diagram SCH022_{52-39}......1483
Wiring diagram SCH024......1485
Wiring diagram SCH025......1487
Wiring harnesses......1489
Electrical distribution box; description......1492
Fuse; description......1495
Relay; description......1497
Relay; specifications......1499
Flasher relay; specifications......1501
Circuit breaker; description......1502
Circuit breaker; specification......1504
Grounding points; frame connections......1506
Wiring diagram SCH01......1508
Wiring diagram SCH02......1511
Wiring diagram SCH03......1514
Wiring diagram SCH04......1517
Wiring diagram SCH05......1522
Wiring diagram SCH06......1525
Wiring diagram SCH07......1528
Wiring diagram SCH08......1531
Wiring diagram SCH09......1534
Wiring diagram SCH10......1537
Wiring diagram SCH11......1540
Wiring diagram SCH12......1542
Wiring diagram SCH13......1545
Wiring diagram SCH15......1548
Wiring diagram SCH16......1551
Wiring diagram SCH17......1553
Wiring diagram SCH18......1556
Wiring diagram SCH19......1558
Wiring diagram SCH20......1561
Wiring diagram SCH21......1563
Wiring diagram SCH24......1566
Wiring diagram SCH25......1568
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM......1570
Instruments and controls; overview......1572
Instruments and controls; front instrument panel......1573
Instruments and controls; left instrument panel......1575
Instruments and controls; right instrument panel......1577
Instruments and controls; rear instrument panel......1580
Control levers; description......1582
Hour counter; description......1584
Hour counter; specifications......1586
Slew position sensor; specfications......1588
Control lockout lever switch; description......1589
Control lockout lever switch; specifications......1592
Hydraulic oil filter pressure switch; specifications......1594
Auto idle pressure switch; specifications......1595
Engine oil pressure sensor; replacing......1596
Engine rotation speed sensor; replacing_{36-41}......1598
Engine rotation speed sensor; replacing_{36-19}......1600
Engine rotation speed sensor (camshaft); replacing_{35-49}......1603
Engine rotation speed sensor (camshaft); replacing_{35-28}......1606
Boost pressure _ charge-air temperature sensor; replacing......1608
Booting sequence......1610
MAIN MENU......1613
Menu tree......1616
Display unit; content......1618
SETUP......1625
Control types for X1 and X3 operation......1634
Pop-up screen......1637
Keypad; description_{28-19}......1640
Keypad; description_{27-01}......1643
Keypad; description_{26-09}......1647
Keypad; description_{24-46}......1651
Keypad; description_{21-00}......1654
Keypad; specification......1657
HVAC system-1745......1660
Theft protection......1663
Service mode......1666
Engine system......1668
Hydraulic system......1670
Electrical system......1672
Language......1676
Terminology......1678
39 - MISCELLANEOUS......1705
CareTrack system; description......1706
DC–DC converter; specifications......1709
DC–DC converter; description......1710
Radio with tape player; description......1712
Radio with tape or CD player; descriptions......1715
Radio with tape or CD player; specifications......1718
Audio remote controller; description_{06-48}......1721
Audio remote controller; description_{06-27}......1724
Audio remote controller; specifications_{05-55}......1727
Audio remote controller; specifications_{05-37}......1730
Antenna; replacing......1732
Speaker; replacing......1734
Wireless control unit W-ECU; specification-0349......1736
Wireless control unit W-ECU; specification......1738
W-ECU; MID 142; replacing......1740
4 - POWER TRANSMISSION......1743
40 - GENERAL......1744
Power transmission; description......1745
42 - TRANSMISSION; HYDRAULIC CONTROL......1746
Transmission mode; function check......1747
43 - GEARBOX......1749
Travel gearbox; bleeding......1750
Travel gearbox; removing......1753
Travel gearbox; installing......1757
Travel gearbox; description......1763
Travel gearbox; specifications......1773
Travel gearbox; troubleshooting......1774
44 - HYDROSTATIC DRIVE......1775
Travel motor; description_{50-42}......1776
Travel motor; description_{50-00}......1782
Travel motor speed; checking and adjusting......1788
Travel motor removed; seal replacing......1791
Travel motor; specifications......1794
Brake valve (counter balance valve)......1796
Travel motor pressure; checking and adjusting......1798
Travel motor; removing......1802
Travel motor; installing......1806
Slew motor; specifications......1811
Slew motor; description......1812
Swing motor brake discs; replacing (motor removed)......1816
Swing motor; brake kit; upgrade......1828
Swing motor pressure; checking and adjusting......1838
Pump coupling; removing......1843
Pump coupling; installing......1846
Centre passage; description......1850
Centre passage; removing......1853
Centre passage; installing......1858
Center passage; disassembling and assembling......1862
45 - PROPELLER SHAFT......1867
Propeller shaft; specifications......1868
Propeller shaft front; replacing......1869
Propeller shaft rear; replacing......1871
46 - FRONT AXLE; REAR AXLE......1873
Front axle; specification......1874
Front axle; description......1875
Front axle; removing......1877
Front axle; installing......1882
King pin and bushing; replacing......1886
Input shaft seal; replacing......1888
Rear axle; specification......1890
Axle; removing......1891
Axle; installing......1894
Shaft seals; replacing......1897
49 - MISCELLANEOUS......1898
Slew ring gear; specifications......1899
Tightening torque; specifications......1900
Swing ring gear; specifications......1901
Slew ring gear; description......1902
Swing ring; removing......1904
Swing ring; installing......1906
Swing ring gear inner seal; replacing......1908
Swing ring gear outer seal; replacing......1910
Slew ring; rotational clearance......1913
Slew ring; axial clearance......1914
Measuring rotational clearance......1915
Swing ring; measuring axial clearance......1918
5 - BRAKE......1921
52 - HYDRAULIC BRAKE SYSTEM......1922
Electrical digging brake; description......1923
Hydraulic brake system; description......1926
Brake system circuit pressure; checking and adjusting......1932
Brake system bleeding......1938
Service brakes function; checking......1941
Foot brake valve; replacing......1943
Brake accumulator; specifications......1948
Brake accumulator; description......1950
Discarded accumulators ......1951
Brake accumulator charging pressure; adjusting......1953
Brake pump; specifications......1956
55 - PARKING BRAKE......1957
Parking brake; description......1958
Parking brake; manually releasing......1963
Parking brake function; checking......1966
6 - STEERING......1968
62 - STEERING AXLE......1969
Steering axle; specifications......1970
Steering axle; description......1971
64 - STEERING......1973
Steering system; description......1974
Steering system working pressure; checking......1979
Steering valve; removing......1982
Steering valve; installing......1986
Steering pump; specifications......1991
Control valve (steering unit); specification......1992
Control valve (steering unit); description......1993
66 - LEVEL STEERING......1997
Steering system function; checking......1998
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT......2000
71 - FRAME......2001
Superstructure; removing......2002
Superstructure; installing......2007
Counterweight; specifications_{58-49}......2011
Counterweight; specifications_{58-27}......2012
Counterweight; removing_{57-59}......2013
Counterweight; removing_{57-38}......2015
Counterweight; installing_{57-03}......2018
Counterweight; installing_{56-40}......2020
Undercarriage; description......2023
Step; removing......2024
Step; installing......2026
76 - SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL _ SIDE CONTROL......2028
Pivot axle lock cylinder; description......2029
Pivot axle lock cylinder; removing......2036
Pivot axle lock cylinder; installing......2039
Pivot axle lock cylinder; releasing for towing......2042
Pivot axle lock cylinder seals; changing......2045
Pivot axle lock; function check......2050
77 - WHEELS; TRACKS; TYRE; HUB; DRUM......2052
Wheels; specifications......2053
Wheel; removing......2054
Wheel; installing......2057
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE......2060
81 - CAB; NAKED; CANOPY......2061
Cab; weight......2062
Cab; removing......2064
Cab; installing......2067
Cab suspension; description_{44-38}......2069
Cab suspension; description_{44-16}......2071
83 - DOORS; HATCH; COVER PLATE; (all)......2073
Cab door; removing door catch......2074
Cab door; installing door catch......2077
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING......2080
Windows; general......2081
Windscreen; replacing......2083
Side window; replacing......2090
Rear window; replacing......2097
Door window; replacing......2103
85 - CAB INTERIOR; UPHOLSTERY......2106
Seat; replacing_{37-46}......2107
Seat; replacing_{37-25}......2110
Seat cushion; replacing......2120
Seat support; replacing......2125
Longitudinal adjustment cable; replacing......2132
Longitudinal suspension cable; replacing......2138
Backrest; replacing......2142
Seat belt; replacing......2146
87 - AIR CONDITIONING UNIT......2149
Electronic climate control unit ECC; description......2150
Electronic climate control unit ECC; specification......2152
Wiring diagram......2154
HVAC system......2156
Air conditioning unit; specifications......2159
Air conditioning unit; description......2160
Air conditioning unit; maintenance......2166
ECC (Electronic Climate Control); replacing......2168
Air conditioning unit; refrigerant check and recharging......2171
Air distribution; description......2179
Cab filter; replacing......2182
Heating system; description......2184
Fan motor; replacing......2186
Heater core; replacing......2192
Cooler and Heater assembly; replacing......2194
Compressor; replacing incl draining and filling......2197
Receiver; replacing incl draining and filling......2202
Condenser; replacing incl draining and filling......2206
Evaporator; replacing incl draining and filling......2210
Expansion valve; replacing incl draining and filling......2216
Vent actuator; replacing......2222
Mode (foot) actuator; replacing......2225
Intake actuator; replacing......2228
Air mix door actuator; replacing......2231
Diesel coolant heater (5kw); specifications......2234
Diesel coolant heater (5kw); description......2236
Diesel coolant heater (5kw); principles......2239
Troubleshooting (5kw)......2244
88 - INTERIOR EQUIPMENT......2253
Instrument panel (left); replacing......2254
Instrument panel (right); replacing......2259
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS......2263
90 - GENERAL......2264
Tiltrotator control system; diagram - Image......2266
Hydraulic diagram; dozer blade and outrigger - Image......2272
Hydraulic diagram; grab piping - Image......2273
Hydraulic diagram; quick fit - Image......2274
Hydraulic diagram; X3 - Image......2276
Hydraulic diagram; X1 with pressure control - Image......2277
Hydraulic diagram; X1 with flow control - Image......2279
Hydraulic diagram; elevating cab - Image......2280
Hydraulic diagram; cruise control - Image......2281
Hydraulic diagram; control pattern selector valve - Image......2282
Hydraulic diagram; offset boom - Image......2283
Hydraulic diagram; boom float valve - Image......2285
Hydraulic diagram; with reversible cooling fan - Image......2286
Hydraulic diagram; complete - Image......2287
Hydraulic system; cleanliness when handling hydraulic components......2289
Hydraulic diagram; component list......2291
Hydraulic system; position of main components on superstructure......2294
Hydraulic diagram; complete_{13-10}......2296
Hydraulic diagram; complete_{12-49}......2299
Hydraulic diagram; with reversible cooling fan......2302
Hydraulic diagram; boom float valve......2305
Hydraulic diagram; offset boom......2308
Hydraulic diagram; control pattern selector valve......2313
Hydraulic diagram; cruise control......2316
Hydraulic diagram; elevating cab......2319
Hydraulic diagram; X1 with flow control......2321
Hydraulic diagram; X1 with pressure control_{08-38}......2324
Hydraulic diagram; X1 with pressure control_{08-17}......2327
Hydraulic diagram; X3......2330
Hydraulic diagram; quick fit......2333
Hydraulic diagram; grab piping......2338
Hydraulic diagram; dozer blade and outrigger......2341
Tiltrotator control system; diagram......2344
Description; general......2357
Optional hydraulic equipment; index......2358
Hydraulic oil; description......2360
Hydraulic system; repair of hydraulic components in workshop......2364
Hydraulic oil; storage and handling......2369
Hydraulic components; storing and transporting......2370
Vacuum pump; connection......2371
Vacuum pump; disconnection......2374
Hydraulic system; warming up......2376
Measuring tools and techniques......2380
91 - WORKING HYDRAULIC; SERVO HYDRAULICS......2385
Hydraulic system; work instructions......2388
Hydraulic system; description......2389
Hydraulic pressure; specifications......2390
Load holding valve; description......2392
Hydraulic oil; cleaning......2395
Hydraulic oil cooling system; description......2397
Hydraulic oil cooling system; specifications......2398
Cooling fan control valve; checking......2401
Oil cooler fan motor; checking......2405
Hydraulically driven cooling fan; description......2410
Hydraulic tank; specifications......2414
Hydraulic oil tank; description......2415
Hydraulic oil tank; releasing pressure......2418
Thermostatic function hydraulic oil; description......2419
Cooling fan speed; checking and adjusting_{53-18}......2424
Cooling fan speed; checking and adjusting with VCADS Pro_{52-50}......2429
Hydraulic oil cooler; removing......2433
Hydraulic oil cooler; installing......2441
Cooling fan pump; removing......2449
Cooling fan pump; installing......2454
Oil cooler fan motor; removing......2459
Oil cooler fan motor; installing......2462
Hydraulic oil tank; removing......2466
Hydraulic oil tank; installing......2470
Main control valve block; description......2475
Back-up valves_{45-33}......2478
Back-up valves_{45-13}......2481
Back-up valve; checking and adjusting......2484
Shock and anti-cavitation valve; description......2490
Line rupture valve (boom); description......2493
Line rupture valve (boom); troubleshooting......2496
Line rupture valve pressure; checking and adjusting......2498
Working pressure; checking and adjusting......2504
Secondary pressure limiting valve; checking......2515
Shock valve removed; checking......2518
Boom cylinder; rupture valve; replacing......2521
Dipper arm cylinder; rupture valve; replacing......2524
Rupture valve; replacing (2pcs boom tilt cylinder)......2527
Dipper arm in speed; checking and adjusting......2531
Pressure relief valves; description......2533
LS-pressure relief valve; replacing......2539
Safety relief valve; replacing......2544
Anti-cavitation valve; description......2549
Working pump; description......2551
Pump; removing......2554
Pump; installing......2560
Hydraulic pump (removed); changing shaft seal......2565
Working pump; specifications......2569
Hydraulic pump; standby pressure; checking and adjusting......2570
Servo system; description_{30-03}......2572
Servo system; description_{29-43}......2574
Servo valve; removing_{29-14}......2576
Servo valve; removing_{28-53}......2578
Servo valve; installing_{28-23}......2581
Servo valve; installing_{28-03}......2583
Servo pump; removing......2586
Servo pump; installing......2588
Pressure accumulator; description......2591
Servo accumulator; removing......2595
Servo accumulator; installing......2596
Discarded accumulators......2597
Servo pressure; checking and adjusting......2598
Control lockout lever; function check......2602
Servo Accumulator......2604
Servo pump; specifications......2605
Servo pump; troubleshooting......2606
Remote control valve (pedal); specifications......2608
Remote control valve (pedal); description......2610
Control lever; removing......2612
Control lever; installing......2622
Control pattern selector valve; description......2632
X1; description_{18-37}......2637
X1; description_{17-52}......2654
VCADS Pro; 91610-3 – X1 hydraulic pressure control system; test......2671
X1; function check......2676
Calibration of X1 hydraulic with flow control......2678
Calibration of X1 hydraulic with pressure control......2681
X1 pressure relief valve; adjusting......2683
X3; description......2687
X3; function check......2696
X3 pressure and flow; adjusting......2698
Boom float position; description......2703
Cruise control; description_{11-42}......2707
Cruise control; description_{11-18}......2713
Calibration of cruise control......2719
Reversible cooling fan; description......2721
Grab bucket; description......2725
Grab equipment; tool change......2731
Offset boom; description ......2733
Tiltrotator control system; description......2736
92 - MECHANICAL EQUIPMENT_ATTACHMENT......2751
Hydraulic quickfit; description......2752
Cylinder for hydraulic quickfit S1; removing......2756
Cylinder for hydraulic quickfit S1; installing......2758
Cylinder for hydraulic quickfit Universal; removing......2760
Cylinder for hydraulic quickfit Universal; installing......2764
Cylinder for hydraulic quickfit S6; removing......2768
Cylinder for hydraulic quickfit S6; installing......2775
Quickfit; removing......2778
Quickfit; installing......2780
Quickfit; function check......2783
97 - UNIT; DIGGING......2785
Cylinder; description......2787
Cylinder; troubleshooting_{00-56}......2790
Cylinder; troubleshooting_{00-38}......2792
Cylinder data......2794
Boom lifting cylinder; description......2795
Dipper arm cylinder; description......2797
Bucket cylinder; description......2799
Digging equipment bearings; measuring radial clearance......2801
Digging equipment bearings; specifications......2804
Bushing general; replacing......2806
Digging equipment bearings; shimming......2810
Creeping of hydraulic cylinder......2812
Stabilisers and stabiliser blade; description......2816
Stabilisers; installing......2828
Stabilisers; hydraulic cylinder; removing......2834
Boom; removing......2839
Boom; installing......2845
Boom foot bushing; replacing......2853
Offset boom; description......2854
2-piece boom; removing_{50-55}......2857
2-piece boom; removing_{50-35}......2861
2-piece boom; installing_{50-00}......2870
2-piece boom; installing_{49-41}......2874
Boom cylinder; removing......2884
Boom cylinder; installing......2889
Lower boom cylinder bushing; replacing......2894
Upper boom cylinder bushing; replacing......2895
Tilt cylinder 2-piece boom; removing......2896
Tilt cylinder 2-piece boom; installing......2901
Tilt cylinder 2-piece boom; rear bushing; replacing......2906
Tilt cylinder 2-piece boom; front bushing; replacing......2907
Dipper arm; removing......2908
Dipper arm; installing......2911
Dipper arm bushing-boom; replacing......2914
Dipper arm bushing-bucket; replacing......2915
Dipper arm bushing-lever; replacing......2916
Dipper arm cylinder; removing......2917
Dipper arm cylinder; installing......2921
Dipper arm cylinder bushing on boom; replacing......2924
Dipper arm cylinder bushing on dipper arm; replacing......2925
Bucket cylinder; removing......2926
Bucket cylinder; installing......2930
Bucket cylinder bushing on dipper arm; replacing......2934
Bucket cylinder bushing lever-link; replacing......2935
Lever link bushing-bucket cylinder; replacing......2936
Lever bushing-bucket; replacing......2937
99 - MISCELLANEOUS......2938
Automatic lubrication system; specifications......2939
Automatic lubrication system; description......2941
Control unit; description......2949
Control units; software functions......2951
Maintenance service; general......2957
Troubleshooting......2960
Bleeding air......2962
Hydraulic elevating cab; description......2963
Specifications......2968
Cab elevating cylinder; replacing......2969
E-tool Sleeve......2978
Volvo EW160C Excavators Repair Service Manual
