Volvo EC160E L Excavator Service Repair Manual PDF

Volvo EC160E L Excavator Service Repair Manual PDF

Size: 542.54 MB
Language: English
Make: Volvo
Machine: Excavator
Document: Service Repair Manual, Wiring Diagram, Hydraulic Diagram
Model: Volvo EC160E L
Page: 4234 Pages

Detail Contents:
1.EC160E
Safety

• Cautions during operation
  CE-marking, EMC-directive
  Checklist after a fire or heat exposure
  Decontamination
  Environmental handling for the future
  Environmentally hazardous fluids
  Environmentally safe handling
  Fire prevention measures
  General precautions
  Health hazards with paint, plastics and rubber
  Move and operate machine safely
  Preparations for work
  Safety concerns everybody!
  Safety rules when servicing
  Safety when handling oils and fuel
  Safety when using lifting equipment
  Safety when working with air conditioning refrigerant
  Safety when working with batteries
  Safety when working with hydraulic systems
  Starting with booster batteries
  Waste handling
  Working in environmentally contaminated areas

Specifications

• 3 way selector valve, specifications
  AdBlue DEF information
  AdBlue DEF
  Adjustable boom cylinder, specifications
  Adjustable boom, specifications
  Air conditioning unit, specifications
  Alternative fuels
  Alternator, specifications
  Auxiliary heater, specifications
  Battery, specifications
  Boom cylinder, specifications
  Boom, specifications
  Bucket cylinder, specifications
  Cab, weight
  Center passage, specifications
  Change capacities
  Control lockout lever switch, specifications
  Control pattern selector valve, specifications
  Coolant with freezing and corrosion protection
  Coolant
  Cooling fan rpm, specifications
  Cooling system, specifications
  Cooling system, tightening torques
  Counterweight, specifications
  Counterweight, tightening torques
  Current pressure, specifications
  DC–DC converter, specifications
  Dipper arm cylinder, specifications
  Dipper arm, specifications
  Dozer blade cylinder, specifications
  Dozer blade, specifications
  Driver’s seat, specifications
  EGR system, tightening torques
  Electric horn, specifications
  Electrical system, specifications
  Engine – Pump control, specification
  Engine limp home switch, specifications
  Engine oil
  Engine, specifications
  Engine, tightening torques
  Frame and track unit, specifications
  Fuel system, specifications
  Fuel system, tightening torques
  Fuel
  Grease
  Hammer return filter, specifications
  Hydraulic oil cooling system, specifications
  Hydraulic oil
  Hydraulic pressure, specifications
  Hydraulic pump, specifications
  Hydraulic tank, specifications
  Ignition switch, specifications
  Inlet and exhaust system, specification
  Inlet and exhaust system, tightening torques
  Keypad, specification
  Line rupture valve (arm), specifications
  Line rupture valve (boom), specifications
  Line rupture valve (Boom), tightening torque
  Lower wiper motor, specifications
  Lubrication system, specifications
  Lubrication system, tightening torques
  Machine weight, specifications
  Main control valve, specifications
  Measurement conversion tables
  Preheating, specifications
  Pressure accumulator, specifications
  Proportional solenoid valve, specifications 2
  Proportional solenoid valve, specifications
  Radio with MP3, specifications
  Recommended hydraulic oil, specifications
  Recommended lubricants
  Relay, specifications
  Remote control valve (dozer blade), specifications
  Remote control valve (Lever), specifications
  Remote control valve (Lever), tightening torque
  Remote control valve (pedal), specifications 2
  Remote control valve (pedal), specifications
  Rotating beacon, specifications
  Rotator pump, specifications
  Servo pump, specifications
  Solenoid valve for rotator
  Solenoid valve, specifications 2
  Solenoid valve, specifications
  Standard tightening torques
  Starter motor, specifications
  Swing gearbox, specifications
  Swing motor, specifications
  Swing ring gear, specifications
  Tightening torque, specifications frame
  Tightening torque, specifications
  Tightening torques 1
  Tightening torques 2
  Tightening torques
  Track gearbox, specifications
  Track motor, specifications
  Travel alarm, specifications
  Undercarriage, tightening torque 1
  Undercarriage, tightening torque 2
  Undercarriage, tightening torque
  Upper wiper motor, specifications
  Water separator, specifications
  Windscreen flusher pump, specifications
  Work lights and extra lights, specifications
  X1 electric on off pedal, tightening torque

Repair

• 1.Standart Parts and Service
  2.Engine with Mounting and Equipment
  3.Electrical System, Warning System, Information System
  4.Power Transmission
  7.Wheels,Tracks,Tyre,Hub,Drum
  8.Cab
  9.Hydraulic System ,Digging,Handling,Grading 1

Descriptions and Troubleshooting

• 2 stage port relief valve, description
  2 stage port relief valve, disassembly and assembly
  3 way selector valve, description
  ACM, IO list
  AdBlue DEF pump unit diagnostics, description
  Adjustable boom (1st boom), description
  Adjustable boom (2nd boom), description
  Adjustable boom cylinder, description
  Adjustable boom valve, description
  Air conditioning unit, description
  Air distribution, description
  AL3201, description and measuring
  Alternator, description
  Alternator, testing
  Arm holding valve, description
  Arm regenerating valve, description
  Automatic engine shut-down
  Auxiliary heater, description
  Auxiliary heater, principles
  Auxiliary start
  BA3101, description and measuring 2
  BA3101, description and measuring 3
  BA3101, description and measuring
  Battery charging capacity, checking
  Battery, description
  Battery, storage
  BB1 Communication bus, description and measuring
  BB2 Communication bus, description and measuring
  Bearings
  Boom cylinder, description
  Boom float position, description 2
  Boom float position, description
  Boom holding valve, description
  Boom regenerating valve, description
  Boom, description
  Boost control, description
  Bottom roller, description
  Bucket cylinder, description
  Bucket flow control valve, description
  Bucket regenerating valve, description
  Cab suspension, description
  CareTrack W-ECU, description
  CareTrack with anti-theft
  CCM, IO list
  Center passage, description 2
  Center passage, description
  Charging, description
  Check valve, description
  Cleaning prior to repair
  Collection of basic data
  Conditions when checking
  Connectors, overview
  Control lever (dozer blade), replacing
  Control lockout lever switch, description
  Control pattern selector valve, description
  Coolant with anti-freeze and corrosion protection, recommendation
  Cooling fan clutch, description
  Cooling fan control
  Cooling system, component location
  Cooling system, description
  Counterweight, description
  Crankcase ventilation, description
  CU9901, description and measuring 2
  CU9901, description and measuring
  Cylinder, description
  Cylinder, troubleshooting
  DC–DC converter, description
  Description, general
  Dipper arm cylinder, description
  Dipper arm, description
  Disassembly and assembly, general
  Door, replacing
  Dozer blade cylinder, description
  Dozer blade, description
  Driver’s seat, description
  ECM (Engine Control Module), IO list
  ECO mode, description
  Electrical distribution box, circuit board replacing
  Electrical distribution box
  Electrical system, description
  Electrical system, special instructions for servicing, action when working on machine
  Electrical system, special instructions for servicing, electrical components, alternator and charging regulator
  Electrical system, special instructions for servicing, electrical components, batteries
  Electrical system, special instructions for servicing, electronic components
  Electrical system, special instructions for servicing, general
  Electrical system
  Electro hydraulic pump control, description
  Electronic control system, description
  Engine limp home switch, description
  Engine stops
  Engine system
  Engine, description
  Engine, reference values
  Error codes, build-up
  Exhaust Aftertreatment System, component location
  Exhaust Aftertreatment System, description
  Exhaust gas recirculation (EGR), component location
  Exhaust Gas Recirculation (EGR), description
  Flow control valve, description
  Frame and track unit, description
  Fuel system, component location
  Fuel system, description
  Function description 2
  Function description 3
  Function description
  FX1005, description and measuring
  FX1006, description and measuring
  FX1007, description and measuring
  FX1008, description and measuring
  FX1054, description and measuring
  FX1074, description and measuring
  FX1079, description and measuring
  General fault diagnosis information
  General purpose machine electronic control unit GPMECU, function description
  GPMECU1, IO list 2
  GPMECU1, IO list
  Grading and lifting control, description
  Hammer and shear pedal valve (RCV), replacing
  Hammer return filter, description
  HE2501, description and measuring 1
  HE2501, description and measuring
  HE2511, description and measuring
  HE2512, description and measuring
  HE2513, description and measuring
  Heating system, description
  HMICU, I O list
  HMICU, IO list 2
  HMICU, IO list
  Hoses and tubes
  Human machine interface control unit HMICU, function description
  HVAC system
  Hydraulic components, description
  Hydraulic components, storing and transporting
  Hydraulic cylinders, dieseling
  Hydraulic oil cooler, description
  Hydraulic oil cooling system, description
  Hydraulic oil, storage and handling
  Hydraulic pump, description
  Hydraulic quickfit, description
  Hydraulic system, cleanliness when handling hydraulic components
  Hydraulic system, description
  Hydraulic system, position of main components
  Hydraulic system, repair of hydraulic components in workshop
  Hydraulic system, work instructions
  Hydraulic system
  Hydraulic tank, description
  IC, IO list
  Idler, description
  Ignition switch, description and operation
  Ignition switch, replacing
  Information display, check
  Inlet and exhaust system, description
  Instrument Cluster (IC), description and measuring
  Instruments and controls, front instrument panel
  Instruments and controls, left instrument panel
  Instruments and controls, overview
  Instruments and controls, rear instrument panel
  Instruments and controls, right instrument panel
  Intermittent wiper and washer
  Keypad, description
  Lead and connector checks
  Limp home
  Line rupture valve (arm), air breathing
  Line rupture valve (arm), description
  Line rupture valve (arm), troubleshooting
  Line rupture valve (boom), air breathing
  Line rupture valve (boom), description
  Line rupture valve (boom), troubleshooting
  Line rupture valve relief pressure, adjustment
  Line rupture valve relief pressure, measurement
  Link, description
  Lower wiper motor, description
  Lubrication system, description
  MA2301-MA2304, description and measuring
  MA2517, description and measuring
  MA2519, description and measuring
  MA9109 Quickfit solenoid valve, description 1
  MA9109 Quickfit solenoid valve, description
  MA9109, description and measuring
  MA9116, description and measuring
  MA9117, description and measuring
  MA9120, description and measuring
  MA9125, description and measuring
  Main control valve troubleshooting
  Main control valve, description
  Main control valve, port size and tightening torque
  Main relief valve, description
  MO2505, description and measuring
  MO3301, description and measuring
  Mode selection, description
  Overload warning
  Port relief valve, description
  Power supply CCM, description and measuring
  Power supply ECM, description and measuring
  Power supply GPMECU 1, description and measuring 1
  Power supply GPMECU 1, description and measuring
  Power supply HMICU, description and measuring 2
  Power supply HMICU, description and measuring
  Power supply W-ECU, description and measuring 2
  Power supply W-ECU, description and measuring
  Power supply, ACM (Aftertreatment Control Module), description and measuring
  Power supply, description
  Power transmission, description
  Preheating, description
  Pressure accumulator, description
  Pressure relief valve, troubleshooting
  Pressure testing
  Product plates
  Proportional solenoid valve, description 2
  Proportional solenoid valve, description
  Proportional solenoid valve, troubleshooting
  Pump, troubleshooting
  PWM2303, description and measuring
  PWM2602, description and measuring
  PWM9109, description and measuring
  PWM9123, description and measuring
  PWM9124, description and measuring
  PWM9129, description and measuring
  PWM9141, description and measuring
  PWM9142, description and measuring
  PWM9145, description and measuring
  PWM9146, description and measuring
  PWM9156, description and measuring
  PWM9157, description and measuring
  Quickfit system, operation
  Radio with MP3, description
  Radio, replacing
  RE2501, description and measuring 2
  RE2501, description and measuring
  RE3101, description and measuring 2
  RE3101, description and measuring
  RE3102, description and measuring
  RE3502, description and measuring
  RE3507, description and measuring
  RE3508, description and measuring
  RE3511, description and measuring
  RE3607, description and measuring
  RE4206, description and measuring
  Regeneration process, description
  Regulator, description
  Regulator, disassembly and assembly
  Relay, description 2
  Relay, description
  Remote control valve (dozer blade), description
  Remote control valve (Lever), description
  Remote control valve (Lever), troubleshooting
  Remote control valve (pedal), description
  Remote control valve (pedal), replacing
  Remote control valve (pedal), troubleshooting
  Replacement parts
  Rotating beacon, replacing
  Rotator (X3 Line option), description
  Rotator pump, description
  SAE J1939-1 SubNet 1, description and measuring 1
  SAE J1939-1 SubNet 1, description and measuring
  Safety when servicing
  SE2203, description and measuring
  SE2301, description and measuring
  SE2303, description and measuring 2
  SE2303, description and measuring
  SE2309, description and measuring
  SE2511, description and measuring
  SE2512, description and measuring
  SE2513, description and measuring
  SE2515, description and measuring
  SE2516, description and measuring
  SE2519, description and measuring
  SE2521, description and measuring
  SE2522, description and measuring
  SE2533, description and measuring
  SE2543, description and measuring
  SE2544, description and measuring
  SE2603, description and measuring
  SE2604, description and measuring
  SE2606, description and measuring
  SE2701, description and measuring
  SE2703, description and measuring
  SE8701, description and measuring
  SE8702, description and measuring
  SE8705, description and measuring
  SE8706, description and measuring
  SE9105, description and measuring
  SE9121, description and measuring
  SE9122, description and measuring
  SE9123, description and measuring
  SE9124, description and measuring
  SE9125, description and measuring
  SE9126, description and measuring
  SE9127, description and measuring
  SE9128, description and measuring
  SE9130, description and measuring
  SE9131, description and measuring
  SE9132, description and measuring
  SE9136, description and measuring
  SE9138, description and measuring
  SE9141, description and measuring
  SE9142, description and measuring 1
  SE9142, description and measuring
  SE9401, description and measuring 2
  SE9401, description and measuring
  Seat belt
  Service methods 2
  Service methods
  Service mode
  Service positions
  Servo hydraulic block
  Servo pump, description
  Shuttle valve block, description
  Single pedal stopper position
  Software parameters, description
  Solenoid valve (1) for hammer and shear selection
  Solenoid valve, description 1
  Solenoid valve, description
  Solenoid valve, troubleshooting
  Special tools for troubleshooting
  Spring package, assembly dimension
  Start lock, description
  Starter motor, description
  Starter switch, testing
  Starting operation
  Stop valve
  Straight travel pedal, description
  Superstructure, installing
  Superstructure, removing
  SW2506, description and measuring
  SW3301, description and measuring
  SW3803, description and measuring
  SW9161, description and measuring 2
  SW9161, description and measuring
  SW9162, description and measuring
  Swing gearbox, description
  Swing motor, assembly
  Swing motor, description
  Swing motor, disassembly
  Swing motor, maintenance standard
  Swing ring gear inner seal, replacing
  Swing ring gear, description
  System voltage
  Tech Tool, operations 2
  Tech Tool, operations 3
  Tech Tool, operations 4
  Tech Tool, operations
  Top roller, description
  Track chain, description
  Track gearbox, description 2
  Track gearbox, description
  Track guards
  Track motor, description
  Track motor, maintenance standard
  Travel alarm, replacing
  Travel alarm
  Travel speed, description
  Travel Speed
  Troubleshooting strategy
  Troubleshooting
  Undercarriage, description
  Upper wiper motor, description
  Voltage converter, replacing
  W-ECU, IO list
  Welding on the machine
  Window limit switch, description
  Windows, general
  Windscreen wiper, description
  Wiring diagram, electrical distribution box
  Work lights and extra lights, description
  X1 control, description
  X1 Line, description
  X3 control, description

Diagrams

• Component designations
  Component list Alternator, batteries, capacitors, electronic units, voltage outlet
  Component list, fuses
  Component list, Heating coils
  Component list, lights
  Component list, Miscellaneous
  Component list, motors
  Component list, relays
  Component list, sensors
  Component list, Solenoid valves
  Component list, Switches 2
  Component list, Switches
  Electrical symbols and designations
  Explanation of wiring diagrams
  Explanations to hydraulic diagram
  Hydraulic diagram, standard fig 1
  Hydraulic diagram, standard
  Hydraulic diagram, with option components fig1
  Hydraulic diagram, with option components fig2
  Hydraulic diagram, with option components
  Wire harness layout
  Wiring diagram 2
  Wiring diagram SCH01
  Wiring diagram SCH01-2
  Wiring diagram SCH02
  Wiring diagram SCH02-2
  Wiring diagram SCH03
  Wiring diagram SCH03-2
  Wiring diagram SCH04
  Wiring diagram SCH04-2
  Wiring diagram SCH05
  Wiring diagram SCH05-2
  Wiring diagram SCH05-3
  Wiring diagram SCH07
  Wiring diagram SCH08
  Wiring diagram SCH08-2
  Wiring diagram SCH08-3
  Wiring diagram SCH10
  Wiring diagram SCH11
  Wiring diagram SCH12
  Wiring diagram SCH12-2
  Wiring diagram SCH13
  Wiring diagram SCH14
  Wiring diagram SCH14-2
  Wiring diagram SCH15
  Wiring diagram SCH16
  Wiring diagram SCH16-2
  Wiring diagram SCH17
  Wiring diagram SCH18
  Wiring diagram SCH20
  Wiring diagram SCH20-2
  Wiring diagram SCH21
  Wiring diagram SCH24
  Wiring diagram SCH30
  Wiring diagram SCH30-2
  Wiring diagram

Installation Instructions

• 1 pump single acting piping, installing new
  2 pump double acting piping, installing new 1
  2 pump double acting piping, installing new
  Boom piping with quickfit, installing new
  CareTrack, installing new
  Diesel coolant heater 5 KW, installing new
  Engine heater 120V, installing new
  Engine heater 240V, installing new
  Hammer hydraulic option, installing new
  Oil leak line boom piping, installing new
  Quick fit piping on arm, installing new 2
  Quick fit piping on arm, installing new
  Quick fit piping on Base machine-UQF
  Rear view camera, installing new
  Return filter for hammer shear, installing new
  Work light extra, installing new
  Work light front, installing new
  X3 on on dipper arm, installing new

EXC Insp Report
EXC Inspection Instruction
Inspection Program, Arrival Inspection
Inspection Program, Delivery Instructions
Service Bulletins

• Biodiesel fuel for Volvo CE
  Boom Hose Rupture Valve plug leakage
  Cab door latch
  Check method on engine oil consumption
  DEF-AdBlue-AUS32 sampling, method
  ECU, functional check
  Fuel regulator
  Fuel sampling, method
  How to update software when programming fails
  Hydraulic hose assembly leakage handling
  Hydraulic system flushing method
  Improved pressure sensor installation
  Instrument cluster improvement
  Machine model
  Modification of CareTrack wire harness
  New AdBlue® DEF tank unit (FX1079 AdBlue DEF quality, temperature and level sensor)
  New diesel auxiliary heater timer
  New fastener assortment
  New product 2
  New product 3
  New product
  New software for DPF change interval
  New TechTool VCADS Pro interface
  New X1 flow control scheme
  Oil analyses
  Oil sampling, method
  Oil sampling, sampling points
  Portable refillable O-ring kits
  Recommendations for Oil Sampling Intervals
  Reporting of product misuse & near-miss report
  Reports
  Routines for reporting cracks on Boom and Arm
  Serial number location on machine components
  Software versions for E-series
  Volvo Product incident accident report & Interview Form

Special tool Manual

• General
  Index
  Hooks
  1. Enviroment and Safety equipment
  2. Measuring equipment
  3. Tightening and Loosening tools
  4. Lifting equipment
  5. Pullers and Pressing equipment
  6. Drifts
  7. Guide pins and Guide sleeves
  8. Pliers
  9. Fixtures
  10. Tech Tool
  11. Spare parts

Special Tools
Time Guide Current generation

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