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Volvo Excavator EC160E L Service Repair Manual
Format: PDFTotal Size: 542.54 MB
Language: English
Brand: Volvo
Machine Type: Excavator
Model: EC160E L
Manual Type:
- Service Repair Manual
- Electrical Wiring Diagram
- Hydraulic Diagram
Number of Pages:
- 4234 Pages
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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