Volvo EC160C Excavators Service Repair Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EC160C Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions EC160C 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 EC160C Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,095 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...11
Measurement conversion tables...22
Engine; specifications...31
Engine; weights...32
Valve system specifications...33
Flywheel; weight...35
Lubrication system; specifications...37
Fuel system; tightening torques...40
Fuel tank; specifications...44
Fuel filler pump; specifications...45
Cooling system; specifications...47
Coolant pump; thermostat; specifications...48
Engine - Pump control; specification...50
Engine speed control switch; specifications...52
Electrical system; specifications...54
Engine control unit E-ECU; specifications...56
Electronic climate control unit ECC; specification...58
Wireless control unit W-ECU; specification...60
Keypad; specification...62
Battery; specifications...65
Alternator; specifications...66
Starter motor; specifications...68
Preheating; specifications...69
Work lights and extra lights; specifications...71
Electric horn; specifications...73
Rotating beacon; specifications...75
Travel alarm; specifications...77
Wiper controller; specifications...79
Upper wiper motor; specifications...81
Lower wiper motor; specifications...83
Windscreen flusher pump; specifications...85
Start switch; specifications...87
Control lockout lever switch; specifications...89
Auto_Manual pump control switch; specifications...91
Relay; specifications...93
Fuse; specifications_{29-22}...95
Fuse; specifications_{29-00}...97
Circuit breaker; specification...99
Hour counter; specifications...101
Audio remote controller; specifications_{27-46}...103
Audio remote controller; specifications_{27-25}...106
Vehicle control unit V-ECU; specifications...108
Radio with tape or CD player; specifications...114
Radio with CD and MP3 player; specifications...117
Track gearbox; specifications...120
Swing gearbox; specifications...121
Track motor; specifications...122
Swing motor; specifications...123
Tightening torque; specifications_{24-01}...124
Tightening torque; specifications_{23-40}...126
Swing ring gear; specifications...128
Frame and track unit; specifications...129
Counterweight; tightening torques...130
Counterweight; specifications...132
Cab; weight...133
Diesel coolant heater (5kw); specifications...135
Recommended hydraulic oil; specifications...136
Hydraulic pressure; specifications...139
Hydraulic tank; specifications...140
Hydraulic oil cooling system; specifications...141
Main control valve; specifications...142
Line rupture valve (boom); specifications...144
Line rupture valve (arm); specifications...146
Hydraulic pump; specifications...148
Proportional solenoid valve; specifications ...149
Current_pressure; specifications...152
Servo pump; specifications...153
Pressure accumulator; specifications...154
Remote control valve (Lever); specifications...156
Remote control valve (pedal); specifications...158
Solenoid valve; specifications ...160
Hammer return filter; specifications...162
Proportional solenoid valve; specifications...163
Solenoid valve; specifications...165
Logic valve; specifications...167
Adjustable boom and cylinder; specifications...168
Control pattern selector valve; specifications...170
Rotator valve; specifications_{12-54}...172
Rotator pump; specifications_{12-33}...173
Attachment quick coupler solenoid valve; specification...174
Dozer blade cylinder; specifications...175
Boom; specifications...177
Boom lifting cylinder; specifications...178
Dipper arm; specifications...180
Dipper arm cylinder; specifications...181
Bucket cylinder; specifications...183
Automatic lubrication system; specifications...185
07 - STANDARD TIME...187
Operation numbers for additional work...188
08 - TOOL...190
NET 8940-00200 Replace tool for the remote control valve joint...191
E-tools; NET 8940-00270 Replace tool for the swing ring gear...193
E-tools; NET 8940-00300 Swing ring gear guide pin...195
NET 8940-00290 Track motor guide pin...197
09 - MISCELLANEOUS...199
Service positions...200
Welding on the machine...203
Hydraulic cylinders; dieseling...206
Control units; changing...210
1 - STANDARD PARTS; SERVICE...212
16 - LUBRICANT; FUEL; OTHER FLUID...213
Recommended lubricants...214
Coolant with freezing and corrosion protection...217
Alternative fuels...221
17 - SERVICE...224
Bearings...226
Replacement parts...230
Safety when servicing...234
Service...238
Service methods...240
Pressure testing...244
Hoses and tubes...248
Cleaning prior to repair...252
Arrival Inspection; according to Inspection Programme...256
Delivery Inspection; according to Inspection Programme...261
Maintenance of Stored Machines; according to Inspection Programme...265
Maintenance service; according to display message...269
Maintenance service; daily...272
Maintenance service; every 50 hours...275
Maintenance service; every 100 hours...280
Maintenance service; every 250 hours...286
Maintenance service; every 500 hours...295
Maintenance service; every 1000 hours...310
Maintenance service; every 2000 hours...327
Maintenance service; every 4000 hours...346
Maintenance service; every 6000 hours...366
Track motor gearbox; changing oil...388
Swing motor gearbox; changing oil...390
Coolant anti-freeze resistance; checking...392
Engine oil and filter; changing...396
CareTrack backup battery; replacing...399
Hydraulic oil; changing...402
Hydraulic oil return filter; replacing...404
Hydraulic oil tank breather filter; replacing...407
Measuring condition...409
Cylinder speed...411
Creeping of hydraulic cylinder...414
Swing speed...416
Coasting left and right swing...417
Measuring of swing bearing clearance...419
Travel Speed...422
Track running speed...424
Straight traveling performance...426
Starting engine with booster cables...428
19 - GENERAL...432
Safety concerns everybody!...433
CE-marking; EMC-directive...437
Safety when handling the machine...440
Safety rules when servicing...447
Fire prevention measures...451
Health hazards with paint; plastics and rubber...457
Checklist after a fire or heat exposure...462
Safety when using lifting equipment...466
Safety when handling oils and fuel...470
Safety when working with batteries...474
Starting with booster batteries...479
Safety when working with air conditioning refrigerant...483
Safety when working with hydraulic systems...488
Environmental handling for the future...492
Environmentally safe handling...496
Environmentally hazardous fluids...499
Working in environmentally contaminated areas...503
Decontamination...507
Waste handling...511
2 - ENGINE WITH MOUNTING AND EQUIPMENT...515
20 - GENERAL...516
Engine; description...517
E-ECU MID 128 pre-programmed; replacing...518
E-ECU MID 128 non-programmed; replacing...521
Engine; identification...524
Engine; tightening torques...525
Component locations...529
Engine; weights ...531
Fuel system; tightening torques ...532
21 - ENGINE...536
Engine; specifications...537
Engine characteristic curve...538
Basic check; Engine...540
Troubleshooting ...542
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...545
Engine; weights...551
Cylinder head; description...552
Cylinder head gasket; description...554
Cylinder block; description...556
Cylinder; description ...558
Pistons; description...559
Piston rings; description...561
Piston cooling...563
Valve system specifications...565
Valves; description...568
Internal Exhaust Gas Recirculation (IEGR); description...570
Engine timing gear; description...576
Camshaft; description...579
Flywheel; weight...582
Crankshaft; description...584
Vibration damper; description...587
Connecting rod; description...590
Oil sump; description...593
Engine mounting...595
22 - LUBRICATING SYSTEM...597
Lubricating system; description...598
Lubrication system; specifications...602
Lubrication system; principle of operation...605
23 - FUEL SYSTEM...609
Fuel system; description...610
Fuel system; tightening torques...615
Instructions for working with electronic fuel injection...619
Carbon dioxide in fuel system; checking...622
Fuel system; bleeding...625
Feed pump; replacing...627
Fuel filters; replacing...630
Fuel filter extra; replacing...632
Fuel tank; specifications...634
Fuel filler pump; specifications...635
Fuel tank; description...637
Fuel filler pump; description...638
Fuel filling pump; removing...640
Fuel filling pump; installing...642
Injectors; description...644
Injector; replacing one...648
Fuel rail pressure; checking...652
Fuel control valve (FCV); description...656
Fuel control valve (FCV); replacing...658
25 - INLET & EXHAUST SYSTEM...664
Inlet system; description...665
Exhaust system; description...666
Silencer; replacing...667
Exhaust pipe flexible tube; replacing...670
Turbocharger; description...673
Turbocharger; inspecting...676
Turbocharger; replacing...678
Preheating coil; replacing...682
Charge air cooler; description...684
Charge air cooler; replacing...686
Charge air cooler connection (hose; tube); replacing...698
26 - COOLING SYSTEM...700
Cooling system; description...701
Cooling system; specifications...703
Coolant anti-freeze resistance; checking...704
Coolant; changing...709
Radiator; replacing...712
Radiator hose upper; replacing...715
Radiator hoses lower; replacing...717
Expansion tank; replacing...720
Coolant pump; thermostat; specifications...722
Thermostat; checking...724
Reversible cooling fan; description...728
Fan belt and_or alternator belt; replacing...731
Fan...734
Engine block heater; description...737
27 - ENGINE CONTROL...738
Engine - Pump control; specification ...739
Engine speed control switch; specifications...741
Engine speed control switch; description...743
Engine speed control switch; inspection...746
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...748
30 - GENERAL...749
Electrical system; special instructions for servicing; general...754
Electrical system; special instructions for servicing; electronic components...757
Electrical system; special instructions for servicing; electrical components; batteries...759
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator...762
Electrical system; special instructions for servicing; action when working on machine...764
Electrical system; description...766
Electronic control system; description...768
Communication with data buses...771
Auxiliary start...774
Data buses; function...777
Service connection and programming connection...783
Electrical system; specifications...786
Power Boost control; description...788
Engine Protection...790
Emergency operation; description...793
Start lock; description...796
X1 control; description...798
X1 pressure control; description...803
X3 control; description...805
Electro hydraulic pump control; description...808
Quick fit control; description...810
Engine - Pump control; specification...812
Mode selection; description...814
Boom float position; description ...817
Auto Idle...819
VCADS Pro; 17030-3 - Parameter; programming...821
Software parameters; description...824
Troubleshooting strategy...832
Troubleshooting; general...835
Collection of basic data...838
Error code information; general...841
Electrical cables and connectors; checking...844
Troubleshooting tools...850
Special tools for troubleshooting...852
VCADS Pro service tool...854
Connecting special tools...859
999 8699 Multi-pin breaker box...863
999 0062 Extension cable...865
999 0014 Adapter cable...867
999 0025 Adapter cable...870
999 3894 Template...872
8883 0028 Adapter cable...874
999 3893 Adapter cable...876
11 666 140 Multimeter...878
Measuring; general...880
Measuring symbols; description...882
Component descriptions...886
Component troubleshooting; structure; description...890
Component troubleshooting; checking wiring harness and input_output on ECU...892
Component troubleshooting; checking component...895
Component troubleshooting; checking subsystem (circuit)...898
AL3201; description and measuring...901
BA3101; description and measuring...905
CU9901; description and measuring...908
FU6; description and measuring...910
FU18; description and measuring...912
FU26; description and measuring...914
HE2501; description and measuring...916
MA2301–MA2306; description and measuring...918
MA2504; description and measuring...921
MA2602; description and measuring...923
MA4216; description and measuring...925
MA9105; description and measuring...927
MA9106; description and measuring...929
MA9109; description and measuring...931
MA9116; description and measuring...934
MA9117; description and measuring...936
MA9118; description and measuring...938
MA9120; description and measuring...940
MA9103; description and measuring...942
MA9104; description and measuring...944
MA9107; description and measuring...946
MA9166; description and measuring...948
MID 128 SID 230; description and measuring...950
MID 140 PID 251; description and measuring...953
MID 140 PPID 1144; description and measuring...956
MO3301; description and measuring...958
PPID1336; description and measuring...960
PWM2303; description and measuring...963
PWM9102; description and measuring...965
PWM9109; description and measuring...967
PWM9123; description and measuring...969
PWM9124; description and measuring...971
PWM9129; description and measuring...973
PWM9130; description and measuring...975
PWM9101; description and measuring...977
PWM9103; description and measuring...979
PWM9105; description and measuring...981
PWM9106; description and measuring...983
RE2501; description and measuring...985
RE3101; description and measuring...988
RE3301; description and measuring...990
RE4206; description and measuring...992
SAE J1708_1587 information link; description and measuring...994
SAE J1939_CAN control link; description and measuring...996
SE2202; description and measuring...999
SE2203; description and measuring...1002
SE2205; description and measuring...1005
SE2301; description and measuring...1007
SE2302; description and measuring...1010
SE2303; description and measuring...1013
SE2309; description and measuring...1016
SE2501; description and measuring...1018
SE2502; description and measuring...1021
SE2507; description and measuring...1024
SE2508; description and measuring...1027
SE2603; description and measuring...1030
SE2606; description and measuring...1033
SE2701; description and measuring...1036
SE2703; description and measuring...1039
SE8701; description and measuring...1042
SE8702; description and measuring...1045
SE8705; description and measuring...1048
SE8706; description and measuring...1051
SE9105; description and measuring...1054
SE9121; description and measuring...1057
SE9122; description and measuring...1059
SE9123; description and measuring...1061
SE9124; description and measuring...1063
SE9125; description and measuring...1065
SE9126; description and measuring...1067
SE9127; description and measuring...1069
SE9128; description and measuring...1071
SE9129; description and measuring...1073
SE9130; description and measuring...1075
SE9131; description and measuring...1077
SE9132; description and measuring...1079
SE9138; description and measuring...1081
SE9401; description and measuring...1083
SID211; description and measuring...1085
SID232; description and measuring...1088
SID240; description and measuring...1091
SID253; description and measuring...1093
SW2701; description and measuring...1095
SW3301; description and measuring...1097
SW9160; description and measuring...1099
SW9161; description and measuring...1102
SW9162; description and measuring...1105
Error codes; build-up...1108
SAE code; conversion for component designation; E-ECU...1113
SAE code; conversion to component designation; I–ECU...1115
SAE code; conversion to component designation; ECC...1117
SAE code; conversion to component designation; V-ECU...1118
ECC (MID146) Electronic climate control unit; active measuring conditions...1120
ECC (MID146) Electronic climate control unit; passive measuring conditions...1123
31 - BATTERY...1126
Starting engine with booster cables...1127
Battery; storage...1131
Battery; description...1133
Battery; specifications...1135
Battery charging capacity; checking...1136
Battery; charging...1140
Batteries; replacing...1142
Earth lead to battery; replacing...1146
Starter motor lead to battery; replacing...1149
32 - ALTERNATOR; CHARGE REGULATOR...1152
Charging; description...1153
Alternator; specifications...1155
Alternator; description...1157
Alternator; replacing incl function checking...1159
Alternator; testing...1161
33 - STARTING SYSTEM...1164
Starting operation...1165
Starter switch (engine start switch); replacing...1168
Starter motor; description...1170
Starter motor; specifications...1172
Starter motor; testing...1173
Starter relay; replacing...1176
Starter motor; replacing...1178
Preheating; description...1180
Preheating; specifications...1182
Starter switch; testing_{51-43}...1184
Starter switch; testing_{50-52}...1187
35 - LIGHTING...1190
Work lights and extra lights; description...1191
Work lights and extra lights; specifications...1193
Work lighting headlamp assembly; replacing_{46-48}...1195
Work lighting headlamp assembly; replacing_{46-18}...1197
36 - OTHER ELECTRICAL EQUIPMENT...1199
Electric horn; description...1201
Electric horn; specifications...1203
Horn; replacing...1205
Rotating beacon; description_41-36...1207
Rotating beacon; description...1208
Rotating beacon; specifications...1210
Rotating beacon; replacing...1212
Travel alarm; description...1214
Travel alarm; specifications...1216
Travel alarm; replacing...1218
Windscreen wiper switch; replacing...1220
Windscreen flusher pump; replacing...1222
Windscreen wiper controller; replacing...1224
Windscreen wiper; description...1226
Wiper controller; description...1228
Wiper controller; specifications...1230
Upper wiper motor; description...1232
Upper wiper motor; specifications...1234
Lower wiper motor; description...1236
Lower wiper motor; specifications...1238
Windscreen flusher pump; specifications...1240
Window limit switch; description...1242
Connectors; overview...1245
Pre-heating relay; replacing...1259
Control lockout lever switch; replacing...1261
Start switch; description...1264
Start switch; specifications...1267
Emergency engine speed control switch; description...1269
Emergency engine speed control switch; specifications...1271
Auto_Manual pump control switch; description...1273
Auto_Manual pump control switch; specifications...1275
Electronic climate control unit ECC; description ...1277
Engine control unit E-ECU; function description...1278
Instrument control unit I-ECU; functional description...1280
Vehicle control unit V-ECU; functional description...1283
Electronic climate control unit ECC; specification_{13-02}...1285
Electronic climate control unit ECC; specification_{12-31}...1288
Engine control unit E-ECU; specifications...1290
Instrument control unit I-ECU; specifications...1292
hicle control unit V-ECU; specifications...1295
Control units changing; precaution...1300
I-ECU MID 140 non-programmed; replacing...1302
I-ECU MID 140 pre-programmed; replacing...1304
V-ECU MID 187 non-programmed; replacing...1306
V-ECU MID 187 pre-programmed; replacing...1310
Engine speed control switch; replacing...1314
37 - CABLE; FUSE; RELAY...1318
Electrical symbols and designations...1320
Explanation of wiring diagrams...1324
Component designations...1327
Component list Alternator; batteries; capacitors; electronic units; voltage outlet...1329
Component list Control lights_warning lights...1331
Component list; fuses...1332
Component list; Heating coils...1334
Component list; lights...1335
Component list; Miscellaneous...1336
Component list; motors...1337
Component list; relays...1338
Component list; sensors...1339
Component list; Solenoid valves...1341
Component list; Switches...1343
Wiring diagram ...1345
Control system diagram...1347
Wiring diagram; electrical distribution box...1350
Wiring diagram SCH01_{14-43}...1354
Wiring diagram SCH01_{13-57}...1357
Wiring diagram SCH02...1360
Wiring diagram SCH03...1363
Wiring diagram SCH04...1366
Wiring diagram SCH07...1370
Wiring diagram SCH08...1373
Wiring diagram SCH10...1377
Wiring diagram SCH11...1380
Wiring diagram SCH12_{05-44}...1383
Wiring diagram SCH12_{05-07}...1386
Wiring diagram SCH12_{04-34}...1389
Wiring diagram SCH12_{03-57}...1392
Wiring diagram SCH13...1395
Wiring diagram SCH14...1398
Wiring diagram SCH15_{01-06}...1401
Wiring diagram SCH15_{00-31}...1405
Wiring diagram SCH15_{59-55}...1409
Wiring diagram SCH16...1413
Wiring diagram SCH17...1416
Wiring diagram SCH18_{57-05}...1419
Wiring diagram SCH18_{56-31}...1422
Wiring diagram SCH20...1425
Wiring diagram SCH21...1428
Wiring diagram SCH22...1431
Wiring diagram SCH23...1433
Wiring diagram SCH24_{51-48}...1436
Wiring diagram SCH24_{51-10}...1439
Wiring harnesses...1442
Main switch; replacing...1447
Electrical distribution box_{42-39}...1451
Electrical distribution box_{41-36}...1454
Fuse; description...1457
Fuse; specifications...1459
Relay; description...1461
Relay; specifications...1463
Circuit breaker; description...1465
Circuit breaker; specification...1467
Grounding points; frame connections...1469
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...1471
Instruments and controls; overview...1473
Instruments and controls; front instrument panel...1475
Instruments and controls; left instrument panel...1477
Instruments and controls; right instrument panel...1479
Instruments and controls; rear instrument panel...1482
Control levers; description...1484
Hour counter; description...1486
Hour counter; specifications...1488
Control lockout lever switch; description...1490
Control lockout lever switch; specifications...1493
Engine rotation speed sensor (camshaft); replacing...1495
Booting sequence...1497
MAIN MENU...1500
Menu tree...1503
Display unit; content...1505
SETUP...1512
Control types for X1 and X3 operation...1521
Pop-up screen...1524
Keypad; description_{15-29}...1527
Keypad; description_{13-59}...1531
Keypad; description...1535
Keypad; specification...1538
HVAC system ...1541
Theft protection...1544
Service mode...1547
Engine system...1550
Hydraulic system...1552
Electrical system...1555
Language_{01-02}...1558
Language_{00-36}...1561
Terminology...1565
39 - MISCELLANEOUS...1592
CareTrack system; description...1593
Radio with tape player; description...1596
Radio with tape or CD player; descriptions...1599
Radio with tape or CD player; specifications...1602
Audio remote controller; description_{55-37}...1605
Audio remote controller; description_{55-11}...1608
Audio remote controller; specifications_{54-26}...1611
Audio remote controller; specifications_{54-04}...1614
Radio; description...1616
Radio with CD and MP3 player; description...1619
Radio with CD and MP3 player; specifications...1623
Radio; replacing_{51-38}...1626
Radio; replacing_{51-13}...1630
DC–DC converter; description...1633
DC–DC converter; specifications...1635
Voltage converter; replacing...1641
Antenna; replacing...1643
Speaker; replacing...1646
Wireless control unit W-ECU; specification_{46-55}...1648
Wireless control unit W-ECU; specification_{46-27}...1650
4 - POWER TRANSMISSION...1652
40 - GENERAL...1653
Power transmission; description...1654
43 - GEARBOX...1656
Function description ...1657
Track gearbox; specifications...1658
Track gearbox; description...1659
Track gearbox; maintenance standard...1664
Track unit; replacing...1669
Track gearbox cover; replacing...1673
Track gearbox; disassembly...1676
Track gearbox; assembly...1683
Track gearbox; troubleshooting...1691
Function description...1693
Swing gearbox; specifications...1695
Swing gearbox; description_{33-21}...1696
Slew gearbox; description_{32-54}...1699
Slew gearbox; lubrication...1702
Swing gearbox; maintenance standard...1705
Swing gearbox; disassembly...1708
Swing gearbox; assembly...1714
44 - HYDROSTATIC DRIVE...1721
Track motor; specifications...1723
Track motor; description...1724
Track motor; precautions for operation...1738
Track motor; maintenance standard...1741
Track motor relief valve; replacing...1744
Track motor; disassembly...1748
Track motor; assembly...1763
Track motor; troubleshooting...1778
Swing motor; specifications...1783
Swing motor; description...1784
Slew motor; precautions for operation...1791
Swing motor; maintenance standard...1792
Swing motor; replacing...1794
Swing motor relief valve; replacing...1797
Swing motor; replacing brake piston seal...1799
Swing motor; replacing plate (brake)...1803
Swing motor; disassembly...1808
Swing motor; assembly...1818
Slew motor; troubleshooting...1833
Hydraulic pump coupling; description...1835
Pump gearbox coupling assembly; replacing...1837
Tightening torque; specifications_{03-38}...1839
Tightening torque; specifications_{03-12}...1841
Center passage; description_{00-36}...1843
Center passage; description_{00-10}...1846
Center passage; replacing...1850
Center passage; replacing seal kit...1857
Center passage hose (valve – center passage); replacing...1863
Center passage hose (center passage – motor); replacing...1865
Center passage; disassembling...1868
Center passage; assembly...1873
Center passage; inspection and troubleshooting...1879
49 - MISCELLANEOUS...1884
Swing ring gear; specifications...1885
Slew ring gear; description...1886
Swing ring gear grease pipe; replacing...1888
Swing ring gear outer seal; replacing...1891
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...1894
70 - GENERAL...1895
Frame and track unit; specifications...1896
71 - FRAME...1897
Machine weight; specifications...1898
Superstructure; removing...1900
Superstructure; installing...1905
Counterweight; tightening torques...1911
Counterweight; specifications...1913
Counterweight; removing_{45-46}...1914
Counterweight; removing_{45-21}...1916
Counterweight; installing...1918
Undercarriage; description...1920
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...1922
Selection of track shoes...1924
Idler; description_{40-53}...1925
Idler; description_{40-27}...1928
Idler; measurement of wear...1931
Front idler; replacing one...1935
Idler; disassembly...1938
Idler; assembly...1942
Tools & equipment...1946
Sprocket; measurement of wear...1951
Sprocket; replacing one...1955
Track chain; description...1957
Track; adjusting track sag_{33-59}...1959
Track; adjusting track sag_{33-32}...1963
Track chain; measurement of wear...1965
Track chain; wear limit...1970
Track links; replacing...1972
Track chain assembly; removing...1977
Track chain assembly; installing...1982
Top roller; description...1985
Top roller; measurement of wear...1988
Top roller; replacing one...1991
Top roller; disassembly...1994
Top roller; assembly...1997
Bottom roller; description...2001
Bottom roller; measurement of wear...2004
Bottom roller; replacing one...2007
Track guard; replacing one...2011
Track recoil spring (tensioner) assembly; replacing...2014
Spring package; disassembling_{20-10}...2017
Spring package; disassembly_{19-44}...2020
Spring package; assembly...2023
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...2026
81 - CAB; NAKED; CANOPY...2027
Cab; weight...2028
Cab; removing...2030
Cab; installing...2037
Cab suspension; description...2041
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...2043
Engine hood; replacing...2044
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...2047
Rear-view mirror; replacing...2048
Windows; general...2050
Windscreen; replacing...2052
Side window; replacing...2066
Rear window; replacing...2073
Door window; replacing...2079
85 - CAB INTERIOR; UPHOLSTERY...2082
Seat; replacing...2083
Seat support; replacing...2086
87 - AIR CONDITIONING UNIT...2093
Electronic climate control unit ECC; description...2094
Electronic climate control unit ECC; specification...2096
Wiring diagram...2098
HVAC system...2100
Air conditioning unit; specifications...2103
Air conditioning unit; description...2105
Performance test; AC unit...2112
Air conditioning unit; maintenance...2118
Air distribution; description...2121
Cab filter; replacing...2124
Heating system; description...2127
Fan motor; replacing...2129
Heater core; replacing...2132
Cooler and Heater assembly; replacing...2135
Compressor; replacing incl draining and filling...2138
Receiver; replacing incl draining and filling...2143
Condenser; replacing incl draining and filling...2147
Evaporator; replacing incl draining and filling...2151
Expansion valve; replacing incl draining and filling...2157
Vent actuator; replacing...2163
Mode (foot) actuator; replacing...2166
Intake actuator; replacing...2169
Air mix door actuator; replacing...2172
Diesel coolant heater (5kw); specifications...2175
Diesel coolant heater (5kw); description...2176
Diesel coolant heater (5kw); principles...2179
Troubleshooting (5kw)...2183
88 - INTERIOR EQUIPMENT...2192
Instrument panel (left); replacing...2193
Instrument panel (right); replacing...2197
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...2201
90 - GENERAL...2202
Hydraulic diagram; standard - Image...2204
Hydraulic diagram; with option components - Image...2205
Hydraulic system; position of main components - Image...2206
Hydraulic diagram; schematic - Image...2207
Hydraulic diagram; slew (left) - Image...2208
Hydraulic diagram; travel - Image...2209
Hydraulic diagram; straight travel - Image...2210
Hydraulic diagram; boom raise - Image...2211
Hydraulic diagram; boom lower - Image...2212
Boom float position; hydraulic circuits - Image...2213
Hydraulic diagram; control pattern selector valve - Image...2214
Hydraulic diagram; X001 line - Image...2216
Adjustable boom (X002); hydraulic diagram - Image...2217
Rotator (X003 Line option); hydraulic circuits - Image...2218
Hydraulic quickfit - Image...2219
Hydraulic diagram; bucket curl - Image...2220
Hydraulic diagram; bucket dump - Image...2221
Hydraulic diagram; dozer blade - Image...2222
Hydraulic diagram; arm in - Image...2223
Hydraulic diagram; arm out - Image...2224
Explanations to hydraulic diagram...2225
Hydraulic diagram; standard...2236
Hydraulic diagram; with option components...2239
Hydraulic circuits; ports...2243
Hydraulic system; position of main components...2245
Hydraulic system; cleanliness when handling hydraulic components...2248
Hydraulic diagram ports; standard...2252
Hydraulic diagram ports; with option components...2260
Hydraulic diagram; schematic...2272
Hydraulic diagram; slew (left)...2274
Hydraulic diagram; travel...2277
Hydraulic diagram; straight travel...2280
Hydraulic diagram; boom raise...2283
Hydraulic diagram; boom lower...2286
Boom float position; hydraulic circuits_{030-22}...2289
Boom float position; hydraulic circuits_{030-01}...2290
Hydraulic diagram; control pattern selector valve...2293
Hydraulic diagram; X001 line...2298
Adjustable boom (X002); hydraulic diagram...2305
Rotator (X003 Line option); hydraulic circuits...2308
Hydraulic quickfit...2311
Hydraulic diagram; bucket curl...2313
Hydraulic diagram; bucket dump...2316
Hydraulic diagram; dozer blade...2319
Hydraulic diagram; arm in...2322
Hydraulic diagram; arm out...2325
Description; general...2328
Hydraulic system; description...2330
Hydraulic oil; description...2334
Recommended hydraulic oil; specifications...2338
Hydraulic pressure; specifications...2342
Hydraulic system; repair of hydraulic components in workshop...2343
Hydraulic oil; storage and handling...2348
Hydraulic components; storing and transporting...2352
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...2356
Hydraulic system; work instructions...2362
Hydraulic components; description...2367
Hydraulic tank; specifications...2370
Hydraulic tank; description...2371
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...2375
Oil level gauge; replacing...2379
Breather; replacing...2381
Hydraulic oil tank; replacing...2383
Servo hydraulic block...2390
Shuttle valve block; description...2392
Check valve; description...2396
Pump suction hose and pipe; replacing...2399
Pipe and hose (pump - valve); replacing...2401
Hydraulic oil cooling system; specifications...2403
Hydraulic oil cooling system; description...2404
Hydraulic oil cooler; replacing...2406
Fan pump; description...2409
Fan pump; disassembly_{009-19}...2414
Fan pump; disassembly_{008-55}...2417
Fan pump; assembly_{008-21}...2419
Fan pump; assembly_{007-56}...2422
Oil cooler fan pump; replacing...2424
Fan motor; description...2429
Fan motor; tools...2435
Fan motor; disassembly...2438
Fan motor; assembly...2446
Fan motor; troubleshooting...2453
Oil cooler fan motor; replacing...2456
Proportional relief valve; description...2468
Main control valve; specifications...2472
Main control valve; description...2474
Main control valve troubleshooting...2491
General; precautions...2496
General; tools...2499
Main spool; disassembly and assembly...2503
Main relief valve; description...2506
Main relief valve; adjustment...2508
Main relief valve; disassembly...2511
Main relief valve; assembly...2514
Main pressure relief valve; replacing...2517
Port relief valve; description...2519
Port relief valve pressure; measuring and adjusting...2522
Port relief valve; disassembly and assembly...2525
Flow control valve; description...2528
Flow control valve; disassembly and assembly...2530
002 stage port relief valve; description...2533
002 stage port relief valve; adjustment...2537
002 stage port relief valve; disassembly and assembly...2539
Boom holding valve; description...2542
Boom holding valve; disassembly and assembly...2546
Boom regenerating valve; description...2549
Boom regenerating check valve; disassembly...2551
Boom 002 conflux shut-off valve; disassembly...2553
Boom back pressure check valve; disassembly...2555
Arm holding valve; description...2557
Arm holding valve; disassembly and assembly...2558
Arm regenerating valve; description...2559
Arm regenerating valve; disassembly...2563
Arm parallel conflux check valve; disassembly and assembly...2565
Arm parallel conflux changeover valve; disassembly...2567
Conflux check valve; disassembly...2569
Bucket regenerating valve; description...2571
Bucket regenerating valve; disassembly...2575
Bucket flow control valve; description...2577
Bucket flow control valve; disassembly...2579
Slew priority valve; disassembly...2582
Center bypass valve; disassembly and assembly...2585
Load check valve – single; disassembly and assembly...2587
Line rupture valve (boom); specifications...2589
Line rupture valve (boom); description...2591
Line rupture valve relief pressure; adjustment_{038-09}...2597
Line rupture valve relief pressure; adjustment_{037-47}...2598
Boom cylinder; rupture valve; replacing...2600
Line rupture valve (boom); disassembly...2603
Line rupture valve (boom); troubleshooting...2605
Line rupture valve (arm); specifications...2607
Line rupture valve (arm); description...2609
Line rupture valve relief pressure; measurement...2614
Dipper arm cylinder; rupture valve; replacing...2615
Line rupture valve (arm); disassembly...2620
Line rupture valve (arm); troubleshooting...2622
Troubleshooting; diagnosing procedure...2624
Examples; hydraulic system...2629
Examples; power transmission...2638
Hydraulic pump; specifications...2648
Hydraulic pump; description...2649
Hydraulic pump; maintenance standard; Specifications...2655
Pump; troubleshooting...2659
Pump; tools...2664
Pump; disassembly...2666
Pump; assembly...2672
Pump; installation...2678
Regulator; description...2680
Regulator; disassembly and assembly...2686
Proportional solenoid valve; specifications ...2696
Current_pressure; specifications...2699
Proportional solenoid valve; description ...2700
Proportional solenoid valve; measuring and adjustment...2703
Proportional solenoid valve; troubleshooting...2706
Hydraulic pump (removed); changing shaft seal...2709
Hydraulic pump; replacing...2712
Hydraulic pump regulator; replacing...2724
Proportional solenoid valve (power shift); replacing...2727
Servo pump; specifications...2729
Servo pump; description...2730
Servo pump; parts inspection...2734
Servo hydraulic pressure; adjustment...2737
Servo pump; replacing...2739
Pressure accumulator; specifications...2742
Pressure accumulator; description...2744
Accumulator; replacing...2748
Remote control valve (Lever); specifications...2751
Remote control valve (Lever); description...2753
Remote control valve (Lever); maintenance standard; Specifications...2763
Remote control valve (lever); replacing...2765
Remote control valve (Lever); disassembly...2769
Remote control valve (Lever); assembly...2782
Remote control valve (Lever); troubleshooting...2795
Remote control valve (pedal); specifications...2797
Remote control valve (pedal); description...2799
Remote control valve (pedal); maintenance standard; Specifications...2806
Remote control valve (pedal); replacing...2808
Remote control valve (pedal); disassembly...2812
Remote control valve (pedal); assembly...2823
Remote control valve (pedal); troubleshooting...2836
Solenoid valve; specifications ...2838
Solenoid valve; description ...2840
Solenoid valve; inspection...2844
Solenoid valve; troubleshooting...2847
Solenoid valve; disassembly and assembly...2851
Solenoid valve; replacing...2855
Hammer and Shears (X001 Line option); description...2857
Hammer and shear pedal valve (RCV); replacing...2858
Hammer return filter; specifications...2862
Hammer return filter; description...2863
Solenoid valve; specifications...2865
Solenoid valve; description...2867
Hammer and shear selector and shuttle valve; description...2870
Proportional solenoid valve; specifications...2872
Proportional solenoid valve; description...2874
Logic valve; specifications...2877
Logic valve; description...2878
Adjustable boom and cylinder; specifications...2880
Adjustable boom (001st boom); description...2882
Adjustable boom (002nd boom); description...2885
Adjustable boom cylinder; description...2888
Adjustable boom; hydraulic line...2891
Control pattern selector valve; specifications...2894
Control pattern selector valve; description...2896
Control pattern selector valve; hydraulic circuits...2899
Rotator pump; specifications...2900
Rotator valve; specifications...2901
Rotator pump; description...2902
Rotator (X003 Line option); description...2904
Rotator valve; adjustment...2906
Overload warning device; description...2909
Overload warning device; operation...2911
Standard of the setting pressure...2913
Checking and Adjusting procedure...2915
Boom float position; description...2918
92 - MECHANICAL EQUIPMENT_ATTACHMENT...2920
Attachment quick coupler; description_{048-30}...2921
Attachment quick coupler; description_{048-06}...2923
Attachment quick coupler solenoid valve; specification...2929
Attachment quick coupler solenoid valve; description...2930
Quickfit; removing...2932
Quickfit; installing...2935
Dozer blade; description...2939
Dozer blade cylinder; specifications...2942
Dozer blade cylinder; description...2944
97 - UNIT; DIGGING...2945
Digging unit; maintenance...2947
Cylinder; description...2949
Cylinder; troubleshooting...2953
Boom; specifications...2956
Boom; description...2957
Boom; removing...2960
Boom; installing...2965
Boom; replacing...2969
Boom lifting cylinder; specifications...2972
Boom lifting cylinder; description...2974
Boom cylinder; removing...2977
Boom cylinder; installing...2979
Boom cylinder; replacing...2981
Boom cylinder; repacking in machine...2984
Dipper arm; specifications...2987
Dipper arm; description...2988
Dipper arm; removing...2991
Dipper arm; installing...2995
Dipper arm; replacing...2998
Bucket operation_{031-27}...3000
Bucket operation_{031-06}...3002
Link; description...3004
Dipper arm connecting rod; removing...3006
Dipper arm connecting rod; installing...3010
Dipper arm connecting rod; replacing...3013
Connecting rod yoke; removing...3018
Connecting rod yoke; installing...3021
Connecting rod yoke; replacing...3024
Dipper arm cylinder; specifications...3028
Dipper arm cylinder; description...3030
Dipper arm cylinder; removing...3032
Dipper arm cylinder; installing...3035
Dipper arm cylinder; replacing...3037
Dipper arm cylinder; repacking in machine...3040
Bucket assembly; removing...3044
Bucket assembly; installing...3047
Bucket assembly; replacing...3050
Bucket cylinder; specifications...3054
Bucket cylinder; description...3056
Bucket cylinder; removing...3058
Bucket cylinder; installing...3061
Bucket cylinder; replacing...3064
Bucket cylinder; repacking in machine...3068
99 - MISCELLANEOUS...3073
Bleeding air...3074
Automatic lubrication system; specifications...3075
Automatic lubrication system; description...3077
Control unit; description...3085
Control units; software functions...3087
Troubleshooting...3093
Volvo EC160C Excavators Service Repair Manual
