Volvo EC160E L Excavator Service Repair Manual

Volvo EC160E L Excavator Service Repair Manual

Size: 542.54 MB
Format: PDF
Language: English
Machine:Excavator 
Machine Model: EC160E L 
Document: Service Repair Manual, Electrical Wiring Diagram, Hydraulic Diagram
Pages: 4234 Pages

The Bookmarks of Volvo EC160E L Excavator Service Repair Manual:
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

[Other Product]