Volvo EW160E Excavator Service and Repair Manual

Volvo EW160E Excavator Service and Repair Manual

Size: 332.34 MB
Format: PDF
Language: English
Machine:Excavator
Document: Service and Repair Manual, Electric and Hydraulic Diagram
Machine Model: EW160E

File List:
Volvo EW160E Diagrams.pdf (421 Pages)
Control system diagram
Control system diagram 1
Explanations to hydraulic diagram
Hydraulic diagram, boom float valve-1
Hydraulic diagram, boom float valve-1
Hydraulic diagram, Boom Suspension System-1
Hydraulic diagram, Boom Suspension System-1
Hydraulic diagram, complete-1
Hydraulic diagram, complete-2
Hydraulic diagram, cruise control-1
Hydraulic diagram, cruise control-1
Hydraulic diagram, dozer blade and outrigger-1
Hydraulic diagram, dozer blade and outrigger-1
Hydraulic diagram, elevating cab-1
Hydraulic diagram, elevating cab-1
Hydraulic diagram, elevating cab-2
Hydraulic diagram, elevating cab-2
Hydraulic diagram, grab piping-1
Hydraulic diagram, grab piping-1
Hydraulic diagram, line rupture valves-1
Hydraulic diagram, line rupture valves-1
Hydraulic diagram, offset boom-1
Hydraulic diagram, offset boom-1
Hydraulic diagram, offset boom-2
Hydraulic diagram, quick fit-1
Hydraulic diagram, quick fit-1
Hydraulic diagram, quick fit-2
Hydraulic diagram, single acting trailer hydraulic-1
Hydraulic diagram, single acting trailer hydraulic-1
Hydraulic diagram, single acting trailer hydraulic-2
Hydraulic diagram, travel (low speed)-1
Hydraulic diagram, travel (low speed)-1
Hydraulic diagram, with reversible cooling fan-1
Hydraulic diagram, with reversible cooling fan-1
Hydraulic diagram, X1 with pressure control-1
Hydraulic diagram, X1 with pressure control-1
Hydraulic diagram, X3-1
Hydraulic diagram, X3-1
Wiring diagram WD120-1
Wiring diagram WD120-1
Wiring diagram WD120-2
Wiring diagram WD120-2
Wiring diagram WD201-1
Wiring diagram WD201-1
Wiring diagram WD201-2
Wiring diagram WD201-2
Wiring diagram WD202-1
Wiring diagram WD202-1
Wiring diagram WD202-2
Wiring diagram WD202-2
Wiring diagram WD203-1
Wiring diagram WD203-1
Wiring diagram WD203-2
Wiring diagram WD203-2
Wiring diagram WD204-1
Wiring diagram WD204-1
Wiring diagram WD204-2
Wiring diagram WD204-2
Wiring diagram WD205-1
Wiring diagram WD205-1
Wiring diagram WD205-2
Wiring diagram WD205-2
Wiring diagram WD206-1
Wiring diagram WD206-1
Wiring diagram WD206-2
Wiring diagram WD206-2
Wiring diagram WD207-1
Wiring diagram WD207-1
Wiring diagram WD207-2
Wiring diagram WD207-2
Wiring diagram WD208-1
Wiring diagram WD208-1
Wiring diagram WD208-2
Wiring diagram WD208-2
Wiring diagram WD209-1
Wiring diagram WD209-1
Wiring diagram WD209-2
Wiring diagram WD209-2
Wiring diagram WD300-1
Wiring diagram WD300-1
Wiring diagram WD300-2
Wiring diagram WD300-2
Wiring diagram WD301-1
Wiring diagram WD301-1
Wiring diagram WD301-2
Wiring diagram WD301-2
Wiring diagram WD302-1
Wiring diagram WD302-1
Wiring diagram WD302-2
Wiring diagram WD302-2
Wiring diagram WD303-1
Wiring diagram WD303-1
Wiring diagram WD303-2
Wiring diagram WD303-2
Wiring diagram WD304-1
Wiring diagram WD304-1
Wiring diagram WD304-2
Wiring diagram WD304-2
Wiring diagram WD305-1
Wiring diagram WD305-1
Wiring diagram WD305-2
Wiring diagram WD305-2
Wiring diagram WD306-1
Wiring diagram WD306-1
Wiring diagram WD306-2
Wiring diagram WD306-2
Wiring diagram WD307-1
Wiring diagram WD307-1
Wiring diagram WD307-2
Wiring diagram WD307-2
Wiring diagram WD308-1
Wiring diagram WD308-1
Wiring diagram WD308-2
Wiring diagram WD308-2
Wiring diagram WD309-1
Wiring diagram WD309-1
Wiring diagram WD309-2
Wiring diagram WD309-2
Wiring diagram WD310-1
Wiring diagram WD310-1
Wiring diagram WD310-2
Wiring diagram WD310-2
Wiring diagram WD311-1
Wiring diagram WD311-1
Wiring diagram WD311-2
Wiring diagram WD311-2
Wiring diagram WD312-1
Wiring diagram WD312-1
Wiring diagram WD312-2
Wiring diagram WD312-2
Wiring diagram WD401-1
Wiring diagram WD401-1
Wiring diagram WD401-2
Wiring diagram WD401-2
Wiring diagram WD402-1
Wiring diagram WD402-1
Wiring diagram WD402-2
Wiring diagram WD402-2
Wiring diagram WD501-1
Wiring diagram WD501-1
Wiring diagram WD501-2
Wiring diagram WD501-2
Wiring diagram WD801-1
Wiring diagram WD801-1
Wiring diagram WD801-2
Wiring diagram WD801-2
Wiring diagram WD802-1
Wiring diagram WD802-1
Wiring diagram WD802-2
Wiring diagram WD802-2
Wiring diagram WD803-1
Wiring diagram WD803-1
Wiring diagram WD803-2
Wiring diagram WD803-2
Wiring diagram WD901-1
Wiring diagram WD901-1
Wiring diagram WD901-2
Wiring diagram WD901-2
Wiring diagram WD902-1
Wiring diagram WD902-1
Wiring diagram WD902-2
Wiring diagram WD902-2
Wiring diagram WD903-1
Wiring diagram WD903-1
Wiring diagram WD903-2
Wiring diagram WD903-2
Wiring diagram WD904-1
Wiring diagram WD904-1
Wiring diagram WD904-2
Wiring diagram WD904-2
Wiring diagram WD905-1
Wiring diagram WD905-1
Wiring diagram WD905-2
Wiring diagram WD905-2
Wiring diagram WD906-1
Wiring diagram WD906-1
Wiring diagram WD906-2
Wiring diagram WD906-2
Wiring diagram WD907-1
Wiring diagram WD907-1
Wiring diagram WD907-2
Wiring diagram WD907-2
Wiring diagram WD908-1
Wiring diagram WD908-1
Wiring diagram WD908-2
Wiring diagram WD908-2
Wiring diagram WD909-1
Wiring diagram WD909-1
Wiring diagram WD909-2
Wiring diagram WD909-2
Wiring diagram WD910-1
Wiring diagram WD910-1
Wiring diagram WD910-2
Wiring diagram WD910-2
Wiring diagram WD911-1
Wiring diagram WD911-1
Wiring diagram WD911-2
Wiring diagram WD911-2
Wiring diagram WD990-1
Wiring diagram WD990-1
Wiring diagram WD990-2
Wiring diagram WD990-2
Wiring diagram WD992-1
Wiring diagram WD992-1
Wiring diagram, electrical distribution box
Wiring diagram, electrical distribution box 1
Wiring diagram, general
Volvo EW160E Excavator Shop Manual.pdf (1287 Pages)
2-piece boom, installing
2-piece boom, removing
91603-3 Cruise Control
91604-3 X1 Hydraulic Pressure
91607-3 X1 Hydraulic Flow
91618-3 Tiltrotator calibration
91620-3 Boom suspension system, solenoid valve
91623-3 X1 max hydraulic flow
91624-3 X3 Hydraulic flow
Accumulator precharge pressure, checking and adjusting
Accumulator removed, checking
Automatic lubrication pump, installing
Automatic lubrication pump, removing
Back-up valve, checking and adjusting
Boom cylinder, rupture valve, replacing
Boom suspension accumulator, checking and adjusting
Boom suspension system, changing accumulator
Cab elevating cylinder, replacing
Control lever, changing
Cooling fan speed, checking and adjusting
Cylinder for hydraulic quickfit S1, installing
Cylinder for hydraulic quickfit S1, removing
Cylinder for hydraulic quickfit S6, installing
Cylinder for hydraulic quickfit S6, removing
Cylinder for hydraulic quickfit Universal, installing
Cylinder for hydraulic quickfit Universal, removing
Digging equipment bearings, shimming
Dipper arm cylinder, rupture valve, replacing
Dipper arm, installing
Dipper arm, removing
Dozer blade cylinder check valve, replacing
E-tool Sleeve
Float position valve, checking and adjusting
Float position valve, replacing
Hydraulic oil cooler, installing
Hydraulic oil cooler, removing
Hydraulic oil tank, installing
Hydraulic oil tank, releasing pressure
Hydraulic oil tank, removing
Hydraulic pump (removed), changing shaft seal
Hydraulic pump regulator, replacing
Hydraulic quickfit cylinder, installing
Hydraulic quickfit cylinder, removing
Hydraulic system, flushing
Hydraulic system, warming up
Line rupture valve pressure, checking and adjusting
Line rupture valve relief pressure (arm), adjusting
LS-pressure relief valve, replacing
Main control valve section
Main control valve, installing
Main control valve, removing
Maintenance service, general
Pump, installing
Pump, removing
Quickfit, function check
Quickfit, replacing
Reversible cooling fan, checking and adjusting
Rupture valve, replacing (2pcs boom tilt cylinder)
Servo accumulator, installing
Servo accumulator, removing
Servo pressure, checking and adjusting
Servo pump, installing
Servo pump, removing
Servo valve, installing
Servo valve, removing
Shock and anti-cavitation valve, checking and adjusting
Stabilisers, hydraulic cylinder, installing
Stabilisers, hydraulic cylinder, removing
Unload valve, checking and adjusting
Unload valve, replacing
Working pressure, checking and adjusting
X1 pressure relief valve, adjusting
X1 pressure relief valve, replacing
X3 pressure and flow, adjusting
(0) GENERAL
88830268 User Instruction
88830540 User Instruction
E-3508
E-3509
E-tool, 3500 Support plate for travel gearbox and motor
E-tool, 3502 Plate for turning crankshaft
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
Coasting left and right swing
Creeping of hydraulic cylinder
Cylinder speed
Measuring condition
Measuring of swing bearing clearance
Swing speed
Travel Speed
(2) ENGINE WITH MOUNTING AND EQUIPMENT
ACM (Aftertreatment control module) non-programmed, replacing
ACM (Aftertreatment control module) pre-programmed, replacing
AdBlue®DEF dosing injector, replacing
AdBlue®DEF hoses, replacing
AdBlue®DEF mixing tube, replacing
AdBlue®DEF pump unit, flushing
AdBlue®DEF pump unit, inlet nipple, replacing
AdBlue®DEF pump unit, replacing
AdBlue®DEF quality, checking
AdBlue®DEF tank armature suction filter, replacing
AdBlue®DEF tank armature, cleaning
AdBlue®DEF tank armature, replacing (2)
AdBlue®DEF tank armature, replacing
AdBlue®DEF tank, cleaning
AdBlue®DEF tank, replacing
AdBlue®DEF, draining
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Coolant pump, replacing
Coolant valve, replacing (2)
Coolant valve, replacing
Cooling fan clutch, replacing
Cooling system pressure, checking
Crystallization of AdBlue®DEF, checking
Cylinder compression, testing
DOC (Diesel oxidation catalyst), replacing
DPF (Diesel particulate filter), checking and cleaning
EGR cooler, replacing
EGR reed valve, replacing
EGR valve, replacing
EGR venturi tube, cleaning
EGR venturi tube, replacing
Engine control module (ECM), replacing non-programmed
Engine control module (ECM), replacing pre-programmed
Engine mount front, replacing
Engine mounting rear, changing
Engine, installing
Engine, removing
Engine, replacing (2)
Engine, replacing
Exhaust aftertreatment system muffler unit, installing
Exhaust aftertreatment system muffler unit, removing
Exhaust pipe flexible tube, replacing
Expansion tank, replacing
Feed pump pressure, checking
Fuel control valve (FCV), replacing
Fuel filling pump, installing
Fuel filling pump, removing
Fuel rail pressure sensor, replacing
Fuel rail, replacing
Fuel tank, replacing
High pressure fuel pipes, replacing
High pressure fuel pump, replacing
Injector sleeves, replacing
Injectors, replacing
Inlet throttle, replacing
Lubrication oil consumption, checking
Lubrication oil pressure, checking with pressure gauge
Oil level sensor, replacing
Pressure relief valve (PRV), replacing
Radiator, assembling
Radiator, disassembling
Radiator, installing
Radiator, removing
Regeneration log, checking
SCR (Selective catalytic reduction) dosing system, checking
SCR (Selective catalytic reduction) muffler, replacing
Thermostat, replacing
Turbocharger, replacing
Valves, adjusting
Wastegate, checking
(3) ELEC.SYSTEM; WARNING SYSTEM;INFORMATION SYSTEM;INSTRUMENTS
Alternator, replacing incl function checking
Alternator, testing
Antenna, replacing
Batteries, replacing
Battery, charging
CareTrack antenna, replacing
CareTrack battery, replacing
Dig Assist accuracy, checking
Dig Assist body IMU, calibrating
Dig Assist GNSS, calibrating
Dig Assist IMU, checking
Dig Assist lift point, measuring
Dig Assist linkage, calibrating
Dig Assist Onboard Weighing system, calibrating
Dig Assist Onboard Weighing, tool weight, calibrating
Dig Assist quick coupler, measuring
Electric center passage, replacing
Electrical battery disconnect switch, replacing
Electrical distribution box, circuit board replacing
Engine oil pressure sensor, replacing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor, replacing
Fuel level sender, replacing
GNSS Antenna, replacing
GPMECU1 non-programmed, replacing
GPMECU1 pre-programmed, replacing
GPMECU2 non-programmed, replacing
GPMECU2 pre-programmed, replacing
Headlights, adjusting
HMICU non-programmed, replacing
HMICU pre-programmed, replacing
Horn, replacing
Hour meter, replacing
Hydraulic oil temperature sensor, replacing
Ignition switch, replacing
Inertial measurement unit (IMU), replacing
Instrument cluster (display unit), replacing
Laser catcher, replacing
Smart Receiver, replacing
Speaker, replacing
Starter motor, replacing
Starter motor, testing
Switch, replacing
Travel alarm, replacing
Volvo Co-Pilot Android software, updating offline (USB)
Volvo Co-Pilot Android software, updating online (OtA)
Volvo Co-Pilot SIM card, installing
Volvo Co-Pilot, replacing
Volvo Co-Pilot, software updating
W-ECU, replacing, non-programmed
W-ECU, replacing, pre-programmed
Windscreen flusher pump, replacing
Windscreen wiper front motor, replacing
X1 electronic pedal, replacing
(4) POWER TRANSMISSION
Axle, installing
Axle, removing
Center passage, disassembling and assembling
Centre passage, installing
Centre passage, removing
Front axle, installing
Front axle, removing
Input shaft seal, replacing (2)
Input shaft seal, replacing
King pin and bushing, replacing
Measuring rotational clearance
Propeller shaft front, replacing
Propeller shaft rear, replacing
Pump coupling, installing
Pump coupling, removing
Repair instructions
Retardation valve, replacing
Swing motor brake discs, replacing (motor removed)
Swing motor pressure, checking and adjusting
Swing motor, installing
Swing motor, removing
Swing ring gear inner seal, replacing
Swing ring gear outer seal, replacing
Swing ring, installing
Swing ring, measuring axial clearance
Swing ring, removing
Transmission mode, function check
Travel gearbox, installing
Travel gearbox, removing
Travel motor pressure, checking and adjusting
Travel motor regulation start, checking and adjusting
Travel motor removed, seal replacing
Travel motor, calibrating
Travel motor, installing
Travel motor, removing
(5) BRAKE
Accumulator (removed) charging pressure, checking
Accumulator, installing
Accumulator, removing
Brake accumulator charging pressure, adjusting
Brake system circuit pressure, checking and adjusting
Brake system, bleeding
Discarded accumulators
Foot brake valve, replacing
Parking brake, manually releasing
(6) STEERING
CDC control valve, checking and adjusting
Comfort drive control (CDC) angle sensor, changing
Comfort drive control (CDC) control valve, installing
Comfort Drive Control (CDC) control valve, removing
Steering control unit, installing
Steering control unit, removing
Steering system working pressure, checking and adjusting
Steering valve, installing
Steering valve, removing
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION;WHEELTRACK UNIT
Counterweight, installing
Counterweight, removing
Pivot axle lock cylinder seals, changing
Pivot axle lock cylinder, installing
Pivot axle lock cylinder, releasing for towing
Pivot axle lock cylinder, removing
Step, installing
Step, removing
Superstructure, installing
Superstructure, removing
Wheel, installing
Wheel, removing
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air conditioning unit, maintenance
Air conditioning unit, refrigerant check and recharging
Air mix door actuator, replacing
Backrest, replacing
Cab filter, replacing
Cab roof window, replacing
Cab, installing
Cab, removing
CCM non-programmed ECU, replacing
CCM pre-programmed ECU, replacing
Compressor, replacing incl draining and filling
Condenser, replacing incl draining and filling
Cooler and Heater assembly, replacing
Cooling unit, leak detection
Door window, replacing
Door, replacing
Engine hood, replacing
Evaporator, replacing incl draining and filling
Expansion valve, replacing incl draining and filling
Fan motor, replacing
Heater core, replacing
Instrument panel (left), replacing
Instrument panel (right), replacing
Intake actuator, replacing
Longitudinal adjustment cable, replacing
Longitudinal suspension cable, replacing
Mode (foot) actuator, replacing
Rear window, replacing
Receiver, replacing incl draining and filling
Refrigerant, draining
Refrigerant, filling incl vacuum pumping
Seat belt, replacing
Seat cushion, replacing
Seat heater pad, replacing
Seat heater, checking
Seat support, replacing
Seat, replacing
Side window, replacing
Troubleshooting, air conditioning unit (AC)
Vent actuator, replacing
Windscreen, replacing
(9) HYDRAULIC SYSTEM; DIGGINGHANDINGGRADING EQUIPM.;MISC.EQUIP
2-piece boom, installing
2-piece boom, removing
91603-3 Cruise Control
91604-3 X1 Hydraulic Pressure
91607-3 X1 Hydraulic Flow
91618-3 Tiltrotator calibration
91620-3 Boom suspension system, solenoid valve
91623-3 X1 max hydraulic flow
91624-3 X3 Hydraulic flow
Accumulator precharge pressure, checking and adjusting
Accumulator removed, checking
Automatic lubrication pump, installing
Automatic lubrication pump, removing
Back-up valve, checking and adjusting
Boom cylinder, rupture valve, replacing
Boom suspension accumulator, checking and adjusting
Boom suspension system, changing accumulator
Cab elevating cylinder, replacing
Control lever, changing
Cooling fan speed, checking and adjusting
Cylinder for hydraulic quickfit S1, installing
Cylinder for hydraulic quickfit S1, removing
Cylinder for hydraulic quickfit S6, installing
Cylinder for hydraulic quickfit S6, removing
Cylinder for hydraulic quickfit Universal, installing
Cylinder for hydraulic quickfit Universal, removing
Digging equipment bearings, shimming
Dipper arm cylinder, rupture valve, replacing
Dipper arm, installing
Dipper arm, removing
Dozer blade cylinder check valve, replacing
E-tool Sleeve
Float position valve, checking and adjusting
Float position valve, replacing
Hydraulic oil cooler, installing
Hydraulic oil cooler, removing
Hydraulic oil tank, installing
Hydraulic oil tank, releasing pressure
Hydraulic oil tank, removing
Hydraulic pump (removed), changing shaft seal
Hydraulic pump regulator, replacing
Hydraulic quickfit cylinder, installing
Hydraulic quickfit cylinder, removing
Hydraulic system, flushing
Hydraulic system, warming up
Line rupture valve pressure, checking and adjusting
Line rupture valve relief pressure (arm), adjusting
LS-pressure relief valve, replacing
Main control valve section
Main control valve, installing
Main control valve, removing
Maintenance service, general
Pump, installing
Pump, removing
Quickfit, function check
Quickfit, replacing
Reversible cooling fan, checking and adjusting
Rupture valve, replacing (2pcs boom tilt cylinder)
Servo accumulator, installing
Servo accumulator, removing
Servo pressure, checking and adjusting
Servo pump, installing
Servo pump, removing
Servo valve, installing
Servo valve, removing
Shock and anti-cavitation valve, checking and adjusting
Stabilisers, hydraulic cylinder, installing
Stabilisers, hydraulic cylinder, removing
Unload valve, checking and adjusting
Unload valve, replacing
Working pressure, checking and adjusting
X1 pressure relief valve, adjusting
X1 pressure relief valve, replacing
X3 pressure and flow, adjusting
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