Volvo EC160D Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EC160D Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions EC160D 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 EC160D Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,432 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL....2
00 - DESCRIPTION; COMPLETE MACHINE....3
Machine view....4
Product plates....6
03 - SPECIFICATIONS....8
Tightening torques....9
Measurement conversion tables....20
Engine; software specifications....29
Alternator; specifications....32
Starter motor; specifications....33
Preheating; specifications....34
Engine limp home switch; specifications....35
Relay; specifications....37
Undercarriage; tightening torque_{14-25}....39
Undercarriage; tightening torque_{14-04}....40
Undercarriage; tightening torque_{13-42}....41
Counterweight; tightening torques....43
Lubrication system; specifications....45
Engine; tightening torques_{12-03}....47
Engine; tightening torques_{11-38}....50
07 - STANDARD TIME....52
Operation numbers for additional work....53
08 - TOOL....55
E-tools; NET 8940-00290 Swing motor guide pin....56
E-tools; NET 8940-00420 Replace tool for the swing ring gear....57
E-tools; NET 8940-00320 Swing motor guide pin and swing ring gear....59
09 - MISCELLANEOUS....61
Service positions....62
Welding on the machine....65
Hydraulic cylinders; dieseling....68
Control units; changing....72
1 - STANDARD PARTS; SERVICE....74
16 - LUBRICANT; FUEL; OTHER FLUID....75
Engine oil....76
Fuel....78
Hydraulic oil....81
Recommended lubricants....86
Coolant_{02-34}....89
Coolant_{02-12}....94
Coolant with freezing and corrosion protection....98
Grease....102
Alternative fuels....106
Specification; filling capacities....109
17 - SERVICE....110
Bearings....113
Replacement parts....117
Safety when servicing....121
Service....125
Service methods....128
Pressure testing....132
Hoses and tubes....136
Cleaning prior to repair....140
VCADS Pro; Operations....144
Arrival Inspection; according to Inspection Programme....146
Delivery Inspection; according to Inspection Programme....151
Maintenance of Stored Machines; according to Inspection Programme....155
Maintenance service; first 500 hours....159
Maintenance service; daily....160
Maintenance service; every 50 hours....161
Maintenance service; every 250 hours....162
Maintenance service; every 500 hours....163
Maintenance service; every 1000 hours....165
Maintenance service; every 2000 hours....167
Maintenance service; every 3000 hours....169
Maintenance service; every 4000 hours....171
Maintenance service; every 4500 hours....173
Maintenance service; every 6000 hours_{51-00}....174
Maintenance service; every 6000 hours_{50-39}....175
Test-run and check....176
MATRIS; reading; export reading....179
VCADS Pro; logged errors; read off....182
The machine; check for external damages; cracks and wear damages....185
Washer fluid level; check....188
Engine; oil level; check....189
Coolant level; check....190
Hydraulic oil level; check....191
Fuel filter; change....193
Water separator; check_drain....195
Water separator filter element; change....196
Fuel tank sediment; drain....198
Fuel tank air ventilation filter; change....200
Hydraulic oil servo filter; change....203
Air cleaner; cleaning filter element....204
Air cleaner; primary filter replacing....206
Air cleaner; secondary filter replacing....208
Battery condition; check....211
Air conditioner compressor belt; check....213
Fan belt and belt tension; check....215
Radiator outside_hydraulic oil cooler outside; cleaning....216
Hydraulic oil drain filter; change....218
Hydraulic oil suction strainer; clean....220
Valves; adjusting....222
Coolant anti-freeze resistance; checking....230
Coolant; changing....234
DPF (Diesel particulate filter); checking and cleaning....236
Spark plug; replacing....241
Air conditioner main filter; clean....243
Air conditioner main filter; change....247
Cab; prefilter; clean....251
Cab prefilter; replacing....253
Lubrication; see lubrication chart....255
Swing gearbox oil level; check....257
Swing motor gearbox; changing oil....259
Swing ring gear bearing; lubricate....261
Swing bath grease; check....264
Cab; door; covers; hinges; joints and locks; lubricate....266
Track shoe bolts; check....268
Track tension_condition; check....270
Track gearbox oil level; check....272
Track motor gearbox; changing oil....274
Loose and loss of bolts; check....276
X1 return filter (optional equipment); change....279
Service history (included in the respective Operator's manual); fill in.....281
Engine oil and filter; changing....284
CareTrack backup battery; replacing_{28-02}....287
CareTrack backup battery; replacing_{27-37}....290
Hydraulic oil; changing....295
Hydraulic oil return filter; replacing....298
Hydraulic oil tank breather filter; replacing....301
Measuring condition....304
Cylinder speed....307
Creeping of hydraulic cylinder....310
Swing speed....313
Coasting left and right swing....314
Measuring of swing bearing clearance....316
Travel Speed....319
Track running speed....321
Straight traveling performance....323
Starting engine with booster cables....325
19 - GENERAL....329
Safety concerns everybody!....330
CE-marking; EMC-directive....334
Cautions during operation....338
Safety when handling the machine....345
Safety rules when servicing....352
Move and operate machine safely....357
Fire prevention measures....360
Health hazards with paint; plastics and rubber....366
Checklist after a fire or heat exposure....371
Safety when using lifting equipment....375
Safety when handling oils and fuel....379
Safety when working with batteries....383
Starting with booster batteries....388
Safety when working with air conditioning refrigerant....392
Safety when working with hydraulic systems....397
Environmental handling for the future....401
Environmentally safe handling....405
Environmentally hazardous fluids....409
Working in environmentally contaminated areas....413
Decontamination....417
Waste handling....421
2 - ENGINE WITH MOUNTING AND EQUIPMENT....425
20 - GENERAL....426
Engine; description....427
Engine; software specifications....431
Component locations....434
VCADS Pro; Operations....437
E-ECU MID 128 pre-programmed; replacing....439
E-ECU MID 128 non-programmed; replacing....441
21 - ENGINE....443
Engine; specifications....444
Engine characteristic curve....445
Engine; removing....447
Engine; tightening torques_{03-55}....458
Engine; tightening torques_{03-33}....461
Crankcase ventilation; description....463
Valve system specifications....467
Valves; adjusting....468
Oil level sensor; replacing....476
22 - LUBRICATING SYSTEM....479
Lubricating system; description....480
Lubrication system; specifications....485
Lubrication system; tightening torques....487
Lubrication system; component locations....489
Lubrication oil pressure; checking with pressure gauge....491
23 - FUEL SYSTEM....494
Fuel system; description....495
Fuel system; specifications....501
Fuel system; tightening torques....503
Carbon dioxide in fuel system; checking....505
Fuel system; component location....511
Feed pump pressure; checking....513
Fuel system; bleeding....516
Fuel tank; volume....518
Fuel filler pump; specifications....519
Fuel tank; description....520
Fuel filling pump; removing....522
Fuel filling pump; installing....525
Injectors; replacing....527
High pressure fuel pump; checking....537
Injector sleeves; replacing_{48-50}....543
Injector sleeves; replacing_{48-26}....553
Fuel rail; replacing....561
Fuel rail pressure; checking....568
Fuel rail pressure sensor; replacing....573
High pressure fuel pump; replacing....576
Fuel control valve (FCV); checking....579
Fuel control valve (FCV); replacing....584
Pressure relief valve (PRV); replacing....588
High pressure fuel system pressure; relieving....591
25 - INLET & EXHAUST SYSTEM....595
Inlet and exhaust system; description....596
Inlet and exhaust system; component location....601
Inlet and exhaust system; tightening torques_{42-50}....603
Inlet and exhaust system; tightening torques_{42-29}....605
Exhaust pipe flexible tube; replacing....607
Exhaust Aftertreatment System; description....610
Exhaust Aftertreatment System; component location....622
Regeneration process; description....624
Exhaust aftertreatment system; specifications....629
DPF (Diesel particulate filter); checking and cleaning....632
Spark plug control unit; replacing....637
Air pump safety valve; replacing....639
ACM (Aftertreatment control module) non-programmed; replacing....642
ACM (Aftertreatment control module) pre-programmed; replacing....645
Spark plug; inspecting....648
Spark plug; replacing....650
Spark plug cable; replacing....652
Air pump; replacing....654
Burner function; checking....658
Burner; replacing....664
DOC (Diesel oxidation catalyst); replacing....670
Turbocharger; description....673
Turbocharger; replacing....676
Preheating coil; replacing....679
Air cleaner; cleaning filter element....684
Air cleaner; primary filter replacing....686
Air cleaner; secondary filter replacing....688
Charge air cooler; replacing....691
26 - COOLING SYSTEM....701
Cooling system; description....702
Carbon dioxide in coolant system; checking....705
Cooling system; component location....711
Cooling system; tightening torques....713
Cooling system pressure; checking....715
Radiator; description....717
Coolant anti-freeze resistance; checking....719
Coolant; changing....724
Radiator; replacing....726
Radiator hoses all; replacing....728
Expansion tank; replacing....730
Thermostat; replacing....733
Thermostat; checking....737
Thermostat; specifications....741
Cooling fan control....743
Fan belt and_or alternator belt; replacing....746
Fan belt and_or alternator-; compressor belt; replacing all belts....749
Cooling fan clutch; description....752
27 - ENGINE CONTROL....755
Engine - Pump control; specification....756
29 - MISCELLANEOUS....758
EGR actuator; replacing....759
Exhaust Gas Recirculation (EGR); description....762
Exhaust gas recirculation (EGR); component location....767
EGR system; tightening torques....769
EGR reed valve; replacing....772
EGR cooler; replacing....776
EGR valve; replacing....783
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....786
30 - GENERAL....787
Electrical system; special instructions for servicing; general....793
Electrical system; special instructions for servicing; electronic components....797
Electrical system; special instructions for servicing; electrical components; batteries....800
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator....804
Electrical system; special instructions for servicing; action when working on machine....807
Electrical system; description....810
Electronic control system; description....812
Communication with data buses....815
Auxiliary start....818
Data buses; function....822
Service connection and programming connection....827
VCADS Pro; Operations_{12-08}....830
VCADS Pro; Operations_{11-45}....833
Electrical system; specifications....835
Power Boost control; description....838
Emergency operation; description....841
Anti-theft system....843
CareTrack with anti-theft....846
Start lock; description....855
Safe start and stop; description....857
X1 control; description....860
X1 pressure control; description....865
X3 control; description....867
Response mode....870
Electro hydraulic pump control; description....873
Quick fit control; description....877
Mode selection; description....879
Boom float position; description....883
Overload warning....885
Auto Idle....888
Grading and lifting control; description....890
ECO mode; description....893
VCADS Pro; 17030-3 - Parameter; programming....896
Software parameters; description....899
Automatic engine shut-down....911
DPF regeneration control....914
General fault diagnosis information....922
Troubleshooting strategy....924
Collection of basic data....927
Information display; check....931
Error codes; build-up....934
Conditions when checking....939
Lead and connector checks....944
Troubleshooting tools....950
Special tools for troubleshooting....952
VCADS Pro service tool....954
AL3201; description and measuring....958
BA3101; description and measuring....961
CU2501; description and measuring....963
CU2503; description and measuring....966
CU9901; description and measuring....969
FU18; description and measuring....972
FU26; description and measuring....974
FX1005; description and measuring....976
FX1006; description and measuring....979
FX1007; description and measuring....983
FX1008; description and measuring....987
FX1031; description and measuring....991
HE2501; description and measuring....994
IG2501; description and measuring....997
MA2301-MA2304; description and measuring....1000
MA2508; description and measuring....1002
MA2509; description and measuring....1005
MA2510; description and measuring....1008
MA2512; description and measuring....1011
MA4212; description and measuring....1014
MA9109; description and measuring....1016
MA9116; description and measuring....1019
MA9117; description and measuring....1021
MA9118; description and measuring....1024
MA9120; description and measuring....1027
MA9121; description and measuring....1029
MA9122; description and measuring....1031
MA9125; description and measuring....1034
MID140 PID251; description and measuring....1036
MID140 PPID1144; description and measuring....1041
MO2502; description and measuring....1043
MO2505; description and measuring....1046
MO3301; description and measuring....1048
Power supply; ACM (Aftertreatment Control Module); description and measuring....1050
Power supply ECC; description and measuring....1052
Power supply E-ECU; description and measuring....1055
Power supply I-ECU; description and measuring....1057
Power supply V-ECU; description and measuring....1060
Power supply W-ECU; description and measuring....1062
PPID1336; description and measuring....1064
PWM2303; description and measuring....1067
PWM2601; description and measuring....1069
PWM2602; description and measuring....1072
PWM9109; description and measuring....1075
PWM9123; description and measuring....1077
PWM9124; description and measuring....1079
PWM9129; description and measuring....1081
PWM9141; description and measuring....1083
PWM9142; description and measuring....1086
PWM9145; description and measuring....1089
PWM9146; description and measuring....1091
PWM9156; description and measuring....1093
PWM9157; description and measuring....1096
RE2501; description and measuring....1099
RE3101; description and measuring....1102
RE3301; description and measuring....1105
RE4206; description and measuring_{05-34}....1108
RE4206; description and measuring_{02-08}....1110
SAE J1708_1587 Information link; description and measuring....1115
SAE J1939_CAN control link; description and measuring....1118
SAEJ1939_CAN7 Control link; description and measuring....1121
SE2203; description and measuring....1124
SE2301; description and measuring....1127
SE2303; description and measuring....1130
SE2309; description and measuring....1133
SE2512; description and measuring....1136
SE2519; description and measuring....1139
SE2520; description and measuring....1142
SE2521; description and measuring....1145
SE2522; description and measuring....1148
SE2523; description and measuring....1151
SE2524; description and measuring....1154
SE2525; description and measuring....1157
SE2526; description and measuring....1160
SE2529; description and measuring....1163
SE2603; description and measuring....1166
SE2604; description and measuring....1170
SE2606; description and measuring....1173
SE2701; description and measuring....1176
SE2703; description and measuring....1178
SE8701; description and measuring....1180
SE8702; description and measuring....1183
SE8705; description and measuring....1186
SE8706; description and measuring....1189
SE9105; description and measuring....1192
SE9121; description and measuring....1195
SE9122; description and measuring....1198
SE9123; description and measuring....1201
SE9124; description and measuring....1204
SE9125; description and measuring....1207
SE9126; description and measuring....1210
SE9127; description and measuring....1213
SE9128; description and measuring....1216
SE9129; description and measuring....1219
SE9130; description and measuring....1222
SE9131; description and measuring....1225
SE9132; description and measuring....1228
SE9138; description and measuring....1231
SE9401; description and measuring....1234
SID211; description and measuring....1237
SID232; description and measuring....1240
SW2506; description and measuring....1242
SW2701; description and measuring....1245
SW3301; description and measuring....1248
SW9160; description and measuring....1251
SW9161; description and measuring....1254
SW9162; description and measuring....1256
VCADS Pro socket; measuring....1258
VCADS Pro; connecting problems....1261
31 - BATTERY....1264
Starting engine with booster cables....1265
Battery; storage....1269
Battery; description....1272
Battery; specifications....1275
Battery charging capacity; checking....1276
Battery; charging....1279
Batteries; replacing....1282
Earth lead to battery; replacing....1285
32 - ALTERNATOR; CHARGE REGULATOR....1288
Charging; description....1289
Alternator; specifications....1291
Alternator; description....1292
Alternator; replacing incl function checking....1295
Alternator; testing....1299
33 - STARTING SYSTEM....1303
Starting operation....1304
Starter motor; description....1306
Starter motor; specifications....1308
Starter motor; testing....1310
Starter relay; replacing....1314
Starter motor; replacing....1316
Starter switch; testing....1318
35 - LIGHTING....1321
Work lights and extra lights; description....1322
Work lights and extra lights; specifications_{36-38}....1325
Work lights and extra lights; specifications_{36-05}....1328
Work lighting headlamp assembly; replacing....1331
36 - OTHER ELECTRICAL EQUIPMENT....1334
Travel alarm; description....1336
Electric horn; specifications....1338
Horn; replacing....1341
Rotating beacon; specifications....1343
Rotating beacon; replacing....1345
Travel alarm; specifications....1347
Travel alarm; replacing....1350
Windscreen wiper front motor; replacing....1352
Windscreen wiper switch; replacing....1357
Windscreen flusher pump; replacing....1360
Windscreen wiper controller; replacing....1362
Windscreen wiper; description....1366
Wiper controller; description....1368
Wiper controller; specifications....1370
Upper wiper motor; description....1372
Upper wiper motor; specifications....1374
Lower wiper motor; description....1376
Lower wiper motor; specifications....1378
Windscreen flusher pump; specifications....1380
Window limit switch; description....1382
Connectors; overview....1385
Pre-heating relay; replacing....1394
Control lockout lever switch; replacing....1398
Ignition switch; replacing....1401
Start switch; description....1403
Start switch; specifications....1406
Engine limp home switch; description....1408
Engine limp home switch; specifications....1410
Auto_Manual pump control switch; description....1412
Auto_Manual pump control switch; specifications....1414
Electronic climate control unit ECC; description ....1416
Engine control unit E-ECU; function description....1418
Instrument control unit I-ECU; functional description....1420
Vehicle control unit V-ECU; functional description....1423
Electronic climate control unit ECC; specification ....1425
Instrument control unit I-ECU; specifications....1427
I-ECU MID 140 non-programmed; replacing....1429
I-ECU MID 140 pre-programmed; replacing....1432
V-ECU MID 187 non-programmed; replacing....1435
V-ECU MID 187 pre-programmed; replacing....1439
Engine speed control switch; replacing....1443
37 - CABLE; FUSE; RELAY....1447
Electrical symbols and designations....1449
Explanation of wiring diagrams....1454
Component designations....1458
Component list Alternator; batteries; capacitors; electronic units; voltage outlet....1461
Component list; fuses....1462
Component list; Heating coils....1464
Component list; lights....1465
Component list; Miscellaneous....1466
Component list; motors....1467
Component list; relays....1468
Component list; sensors....1469
Component list; Solenoid valves....1471
Component list; Switches....1473
ACM; I_O list....1475
ECC; I_O list....1478
E-ECU; I_O list....1481
I-ECU; I_O list....1484
V-ECU; I_O list....1487
W-ECU; I_O list....1492
Wiring diagram ....1494
Control system diagram....1496
Wiring diagram; electrical distribution box....1499
Wiring diagram SCH01....1504
Wiring diagram SCH02_{36-34}....1509
Wiring diagram SCH02_{35-49}....1513
Wiring diagram SCH03_{34-48}....1517
Wiring diagram SCH03_{34-01}....1522
Wiring diagram SCH04_{32-50}....1527
Wiring diagram SCH04_{32-03}....1532
Wiring diagram SCH05_{31-05}....1537
Wiring diagram SCH05_{30-15}....1542
Wiring diagram SCH07....1547
Wiring diagram SCH08_{28-14}....1550
Wiring diagram SCH08_{27-28}....1554
Wiring diagram SCH10....1558
Wiring diagram SCH11....1561
Wiring diagram SCH12....1564
Wiring diagram SCH13....1568
Wiring diagram SCH14....1572
Wiring diagram SCH15....1575
Wiring diagram SCH16....1579
Wiring diagram SCH17_{18-34}....1582
Wiring diagram SCH17_{17-54}....1585
Wiring diagram SCH18....1588
Wiring diagram SCH21....1591
Wiring diagram SCH22....1594
Wiring diagram SCH24_{54-13}....1596
Wiring diagram SCH24_{53-35}....1598
Wiring diagram SCH30....1600
Wiring harnesses....1603
Engine wire harness; replacing....1606
Battery disconnector; replacing....1615
Electrical distribution box....1618
Electrical distribution box; circuit board replacing....1620
Fuse; description....1625
Relay; description....1628
Relay; specifications....1631
Circuit breaker; specification....1633
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1635
Instruments and controls; overview....1636
Instruments and controls; front instrument panel....1638
Instruments and controls; left instrument panel....1640
Instruments and controls; right instrument panel....1641
Instruments and controls; rear instrument panel....1644
Hour counter; specifications....1646
Hour meter; replacing....1648
Fuel level sender; replacing....1651
Control lockout lever switch; description....1654
Control lockout lever switch; specifications....1657
Engine temperature sensor; replacing....1660
Engine oil pressure sensor; replacing....1662
Engine rotation speed sensor; replacing....1664
Engine rotation speed sensor (camshaft); replacing....1666
Hydraulic oil temperature sensor; replacing....1668
Display unit-19....1670
Display unit....1692
Control types for X1 and X3 operation....1714
Keypad; description....1717
Keypad; specification....1720
Service mode....1723
Engine system....1726
Hydraulic system....1729
Electrical system....1732
Vehicle information....1736
39 - MISCELLANEOUS....1738
Audio remote controller; description....1739
Audio remote controller; specifications....1741
Radio with CD and MP3 player; description....1743
Radio with CD and MP3 player; specifications....1746
Radio; replacing....1748
DC–DC converter; description....1753
DC–DC converter; specifications....1756
Voltage converter; replacing....1762
Antenna; replacing....1767
Speaker; replacing....1770
CareTrack W-ECU; description....1772
Wireless control unit W-ECU; specification....1777
W-ECU; MID142; changing non-programmed ECU_{43-02}....1779
W-ECU; MID142; changing non-programmed ECU_{42-36}....1782
CareTrack battery; replacing....1786
CareTrack antenna; replacing....1790
4 - POWER TRANSMISSION....1795
40 - GENERAL....1796
Tightening torque; specifications....1797
Power transmission; description....1798
43 - GEARBOX....1801
Function description ....1802
Track gearbox; specifications....1804
Track gearbox; description_{35-15}....1805
Track gearbox; description_{34-27}....1811
Track gearbox; maintenance standard....1815
Track unit; replacing....1821
Track gearbox cover; replacing....1828
Track gearbox; disassembly....1831
Track gearbox; assembly....1839
Function description....1848
Swing gearbox; specifications....1850
Swing gearbox; description_{24-18}....1851
Swing gearbox; description_{23-49}....1854
Swing gearbox; maintenance standard....1858
Swing unit; replacing....1862
Swing gearbox; replacing....1867
Swing gearbox; disassembly....1872
Swing gearbox; assembly....1878
44 - HYDROSTATIC DRIVE....1885
Track motor; specifications....1886
Track motor; description....1887
Track motor; maintenance standard....1901
Track motor relief valve; replacing....1908
Track motor; disassembly....1912
Track motor; assembly....1927
Swing motor; specifications....1943
Swing motor; description....1944
Swing motor; maintenance standard....1951
Swing motor; replacing....1955
Swing motor relief valve; replacing....1958
Swing motor; replacing brake piston seal....1960
Swing motor; replacing plate (brake)....1964
Swing motor; disassembly....1969
Swing motor; assembly....1979
Hydraulic pump coupling; description....1994
Pump gearbox coupling assembly; replacing....1996
Tightening torque; specifications_{48-55}....1998
Tightening torque; specifications_{48-30}....2000
Center passage; specifications_{47-52}....2003
Center passage; specifications_{47-30}....2004
Center passage; description_{46-56}....2006
Center passage; description_{46-30}....2009
Center passage; maintenance standard....2013
Center passage; replacing....2018
Center passage; replacing seal kit....2025
Center passage hose (valve – center passage); replacing....2031
Center passage hose (center passage – motor); replacing....2033
Center passage; disassembly....2036
Center passage; assembly....2042
49 - MISCELLANEOUS....2049
Swing ring gear; specifications....2050
Swing ring gear; description....2051
Swing ring gear; replacing....2054
Swing ring gear grease pipe; replacing....2057
Swing ring gear inner seal; replacing....2062
Swing ring gear outer seal; replacing....2065
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....2069
70 - GENERAL....2070
Undercarriage; tightening torque_{29-02}....2071
Undercarriage; tightening torque_{28-39}....2072
Undercarriage; tightening torque_{28-17}....2073
Undercarriage; tightening torque_{27-47}....2075
Frame and track unit; specifications....2077
Frame and track unit; description....2078
71 - FRAME....2079
Machine weight; specifications....2080
Superstructure; removing....2082
Superstructure; installing....2087
Tightening torque; specifications....2093
Counterweight; tightening torques....2095
Counterweight; specifications....2097
Counterweight; description....2098
Counterweight; removing....2099
Counterweight; installing....2102
Undercarriage; description....2105
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....2108
Selection of track shoes....2110
Idler; description_{11-03}....2112
Idler; description_{10-38}....2115
Idler; measurement of wear_{10-01}....2117
Idler; measurement of wear_{09-30}....2121
Front idler; replacing one....2125
Idler; disassembly....2129
Idler; assembly....2134
Tools & equipment....2139
Sprocket; measurement of wear_{05-37}....2144
Sprocket; measurement of wear_{05-07}....2148
Sprocket; replacing one....2152
Track chain; description_{02-41}....2155
Track chain; description_{02-16}....2157
Track link; dimension_{01-39}....2159
Track link; dimension_{01-13}....2161
Track link; dimension_{00-48}....2163
Track; adjusting track sag_{00-10}....2165
Track; adjusting track sag_{59-44}....2169
Track; adjusting track sag_{59-15}....2171
Track chain; measurement of wear_{58-35}....2173
Track chain; measurement of wear_{57-58}....2179
Track shoe; replacing one....2185
Track links; replacing....2189
Track shoes....2194
Track chain assembly; removing....2196
Track chain assembly; installing....2201
Top roller; description_{53-26}....2206
Top roller; description_{53-01}....2208
Top roller; measurement of wear_{51-27}....2210
Top roller; measurement of wear_{50-55}....2213
Top roller; replacing one....2216
Bottom roller; description_{49-22}....2221
Bottom roller; description_{48-57}....2223
Bottom roller; measurement of wear....2225
Bottom roller; replacing one....2228
Bottom roller; replacing seal....2233
Track guards_{42-27}....2238
Track guards_{42-02}....2239
Track guard; replacing one....2241
Spring package; assembly dimension_{39-33}....2245
Spring package; assembly dimension_{39-08}....2247
Recoil spring cylinder seal kit; replacing....2249
Track recoil spring (tensioner) assembly; replacing....2253
Spring package; disassembling_{36-24}....2257
Spring package; disassembly_{35-58}....2260
Spring package; disassembly_{35-21}....2264
Spring package; assembly....2267
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....2270
80 - GENERAL....2271
VCADS Pro; Operations....2272
81 - CAB; NAKED; CANOPY....2274
Cab; weight....2275
Cab; removing_{31-49}....2277
Cab; removing_{31-23}....2287
Cab; installing....2297
Cab suspension; description....2306
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....2309
Engine hood; replacing....2310
Tool box assembly; replacing....2313
83 - DOORS; HATCH; COVER PLATE; (all)....2316
Door; replacing....2317
Cab door; changing door catch....2321
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....2327
Rear-view mirror; replacing....2328
Windows; general....2330
Windscreen; replacing....2333
Side window; replacing....2347
Rear window; replacing....2354
Door window; replacing....2360
85 - CAB INTERIOR; UPHOLSTERY....2363
Seat; replacing_{18-11}....2364
Seat; replacing_{17-45}....2371
Seat cushion; replacing....2374
Seat support; replacing....2380
Longitudinal adjustment cable; replacing....2387
Longitudinal suspension cable; replacing....2394
Backrest; replacing....2399
Driver's seat; description....2404
Driver's seat; specifications....2409
Seat heater; checking....2413
87 - AIR CONDITIONING UNIT....2417
Electronic climate control unit ECC; description....2418
Electronic climate control unit ECC; specification....2420
Wiring diagram....2422
HVAC system....2424
Air conditioning unit; specifications....2427
Air conditioning unit; description....2429
Performance test; AC unit....2435
Air conditioning unit; maintenance....2441
ECC MID 146 pre-programmed ECU; replacing....2444
ECC MID 146 non-programmed ECU; replacing....2448
Fan motor; replacing-35....2452
Fan motor; replacing....2455
Heater core; replacing....2459
Cooler and Heater assembly; replacing....2466
Compressor; replacing incl draining and filling....2474
Receiver; replacing incl draining and filling....2478
Condenser; replacing incl draining and filling....2483
Evaporator; replacing incl draining and filling....2487
Expansion valve; replacing incl draining and filling....2496
Vent actuator; replacing....2506
Mode (foot) actuator; replacing....2509
Intake actuator; replacing....2512
Air mix door actuator; replacing....2515
Compressor; replacing magnetic clutch (compressor removed)....2518
Auxiliary heater; specifications....2524
Auxiliary heater; description....2526
Auxiliary heater; principles....2529
Troubleshooting_{54-20}....2533
Troubleshooting_{53-22}....2543
88 - INTERIOR EQUIPMENT....2553
Instrument panel (left); replacing....2554
Instrument panel (right); replacing....2559
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....2563
90 - GENERAL....2564
Hydraulic diagram; standard - Image....2565
Hydraulic diagram; with option components - Image....2566
Explanations to hydraulic diagram....2568
Hydraulic diagram; standard....2579
Hydraulic diagram; with option components....2582
Hydraulic system; position of main components....2588
Hydraulic system; cleanliness when handling hydraulic components....2591
Hydraulic diagram; schematic....2595
Description; general....2598
Hydraulic system; description....2600
Hydraulic oil; description....2604
Recommended hydraulic oil; specifications....2608
Hydraulic pressure; specifications....2612
Hydraulic system; repair of hydraulic components in workshop....2614
Hydraulic oil; storage and handling....2619
Hydraulic components; storing and transporting....2623
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....2627
Hydraulic system; work instructions....2633
Hydraulic components; description....2638
Hydraulic tank; specifications....2641
Hydraulic tank; description....2642
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....2646
Oil level gauge; replacing....2650
Breather; replacing....2652
Hydraulic oil tank; replacing....2654
Servo hydraulic block....2663
Shuttle valve block; description....2666
Check valve; description....2669
Oil cooler line bypass valve (check valve); replacing....2671
Pump suction hose and pipe; replacing....2676
Pipe and hose (pump - valve); replacing....2679
Hydraulic oil cooling system; specifications....2681
Hydraulic oil cooling system; description....2682
Hydraulic oil cooler; description....2684
Hydraulic oil cooler; replacing....2686
Main control valve; specifications....2687
Main control valve; description....2689
Pressure relief valve; troubleshooting....2711
Main control valve troubleshooting....2715
General; precautions....2720
General; tools....2723
Main spool; disassembly and assembly....2727
Main relief valve; description....2730
Main relief valve; adjustment....2733
Main relief valve; disassembly....2736
Main relief valve; assembly....2739
Main pressure relief valve; replacing....2742
Port relief valve; description....2744
Port relief valve pressure; measuring and adjusting....2747
Port relief valve; disassembly and assembly....2750
Flow control valve; description....2753
Flow control valve; disassembly and assembly....2755
2 stage port relief valve; description....2758
2 stage port relief valve; adjustment....2762
2 stage port relief valve; disassembly and assembly....2765
Boom holding valve; description....2768
Boom holding valve; disassembly and assembly....2772
Boom regenerating valve; description....2775
Boom regenerating check valve; disassembly....2777
Boom back pressure check valve; disassembly....2779
Arm holding valve; description....2781
Arm holding valve; disassembly and assembly....2782
Arm regenerating valve; description....2783
Arm regenerating valve; disassembly....2787
Arm parallel conflux check valve; disassembly and assembly....2789
Arm parallel conflux changeover valve; disassembly....2791
Conflux check valve; disassembly....2793
Bucket regenerating valve; description....2795
Bucket regenerating valve; disassembly....2799
Bucket flow control valve; description....2801
Bucket flow control valve; disassembly....2803
Slew priority valve; disassembly....2806
Center bypass valve; disassembly and assembly....2809
Load check valve – single; disassembly and assembly....2811
Control valve; replacing....2813
Tightening torques ....2822
Line rupture valve (boom); specifications....2826
Line rupture valve (boom); description....2828
Line rupture valve pressure; checking and adjusting....2834
Line rupture valve (boom); air breathing....2837
Boom cylinder; rupture valve; replacing....2840
Disassembly and assembly; general....2847
Line rupture valve (boom); disassembly....2850
Line rupture valve (boom); assembly....2853
Line rupture valve (boom); troubleshooting....2856
Line rupture valve (arm); specifications....2859
Line rupture valve (arm); description....2861
Line rupture valve relief pressure; measurement....2867
Line rupture valve (arm); air breathing....2869
Dipper arm cylinder; rupture valve; replacing....2872
Line rupture valve (arm); disassembly....2879
Line rupture valve (arm); assembly....2882
Line rupture valve (arm); troubleshooting....2885
Hydraulic pump; specifications....2887
Hydraulic pump; description....2888
Hydraulic pump; maintenance standard; Specifications....2894
Pump; troubleshooting....2898
Pump; disassembly....2903
Pump; assembly....2909
Pump; installation....2914
Regulator; description....2916
Regulator; disassembly and assembly....2922
Proportional solenoid valve; Specifications....2932
Current_pressure; specifications....2935
Proportional solenoid valve; Description....2936
Proportional solenoid valve; measuring and adjustment....2939
Proportional solenoid valve; troubleshooting....2944
Hydraulic pump (removed); changing shaft seal....2947
Hydraulic pump; replacing....2950
Hydraulic pump regulator; replacing....2968
Proportional solenoid valve (power shift); replacing....2973
Servo pump; specifications....2977
Servo pump; description....2978
Servo pump; parts inspection....2982
Servo hydraulic pressure; adjustment....2985
Servo pump; replacing....2988
Pressure accumulator; specifications....2992
Pressure accumulator; description....2994
Accumulator; replacing....2996
Tightening torques-....2998
Remote control valve (Lever); specifications....3002
Remote control valve (Lever); description....3004
Remote control valve (Lever); maintenance standard; Specifications....3014
Remote control valve (lever); replacing....3017
Remote control valve (Lever); disassembly....3020
Remote control valve (Lever); assembly....3033
Remote control valve (Lever); troubleshooting....3046
Remote control valve (pedal); Specifications....3049
Remote control valve (pedal); description....3050
Remote control valve (pedal); maintenance standard; Specifications....3058
Remote control valve (pedal); replacing....3061
Remote control valve (pedal); disassembly....3066
Remote control valve (pedal); assembly....3076
Remote control valve (pedal); troubleshooting....3088
Solenoid valve; Specifications....3091
Solenoid valve; Description....3092
Solenoid valve; inspection....3095
Solenoid valve; troubleshooting....3098
Solenoid valve; disassembly and assembly....3102
Solenoid valve; replacing....3106
Tightening Torques....3110
X1 Line; description_{03-27}....3113
X1 Line; description_{03-02}....3116
Hammer and shear pedal valve (RCV); replacing....3128
Hammer return filter; specifications....3133
Hammer return filter; description....3135
Solenoid valve; specifications....3136
Solenoid valve; description....3138
Solenoid valve (1) for hammer and shear selection....3141
3 way selector valve; specifications....3143
3 way selector valve; description....3145
Proportional solenoid valve; specifications....3148
Proportional solenoid valve; description....3150
Stop valve....3152
Tightening torques....3154
Adjustable boom; specifications....3157
Adjustable boom (1st boom); description....3159
Adjustable boom (2nd boom); description....3162
Adjustable boom cylinder; specifications....3165
Adjustable boom cylinder; description....3167
Adjustable boom valve; description....3169
Adjustable boom valve; disassembly....3175
Remote control valve (pedal); specifications....3184
Straight travel pedal; description....3186
Single pedal stopper position....3190
Control pattern selector valve; specifications....3192
Control pattern selector valve; description....3194
Solenoid valve for rotator....3198
Rotator pump; specifications....3200
Rotator pump; description....3202
Rotator pump; parts inspection....3206
Rotator (X3 Line option); description....3208
Rotator valve; adjustment....3213
Boom float position; description....3216
92 - MECHANICAL EQUIPMENT_ATTACHMENT....3219
Attachment quick coupler; description....3220
Attachment quick coupler; operation....3222
Attachment quick coupler solenoid valve; description....3225
Quickfit; removing....3228
Quickfit; installing....3230
Tightening torques....3233
Dozer blade; description....3235
Dozer blade cylinder; specifications....3238
Dozer blade cylinder; description....3240
97 - UNIT; DIGGING....3242
Tightening torques ....3244
Function description....3252
Digging unit; maintenance....3255
Cylinder; description....3259
Cylinder; disassembly and assembly....3264
Cylinder; troubleshooting....3281
Tightening torques....3285
Boom; specifications....3286
Boom; description....3287
Boom; removing....3290
Boom; installing....3295
Boom; replacing....3300
Boom cylinder; specifications....3302
Boom cylinder; description....3304
Boom cylinder; removing....3306
Boom cylinder; installing....3309
Boom cylinder; replacing....3311
Lower boom cylinder bushing; replacing....3316
Upper boom cylinder bushing; replacing....3320
Dipper arm; specifications....3324
Dipper arm; description....3325
Dipper arm; removing....3328
Dipper arm; installing....3332
Dipper arm; replacing....3336
Link; description....3350
Dipper arm connecting rod; removing....3352
Dipper arm connecting rod; installing....3355
Dipper arm connecting rod; replacing....3358
Connecting rod yoke; removing....3366
Connecting rod yoke; installing....3369
Connecting rod yoke; replacing....3372
Dipper arm cylinder; specifications....3379
Dipper arm cylinder; description....3381
Dipper arm cylinder; removing....3383
Dipper arm cylinder; installing....3386
Dipper arm cylinder; replacing....3389
Dipper arm cylinder bushing on boom; replacing....3394
Dipper arm cylinder bushing on dipper arm; replacing....3398
Bucket assembly; replacing....3402
Bucket cylinder; specifications....3405
Bucket cylinder; description....3407
Bucket cylinder; replacing_{15-42}....3409
Bucket cylinder; replacing_{15-17}....3421
Bucket cylinder bushing on dipper arm; replacing....3426
Bucket cylinder bushing lever-link; replacing....3430
Volvo EC160D Excavators Repair Service Manual
