Volvo EC160 Excavator Repair Service Manual

Table of Content EC160 Service Information

• GENERAL
  • SPECIFICATIONS
    • General
      • Tightening torques, general tolerances
  • STANDARD TIME

• STANDARD PARTS, SERVICE
  • LUBRICANT; FUEL; OTHER FLUID
  • SERVICE
    • Emergency measures
      • Jump starting
        • Jump starting of machine, description
        • Jump starting of machine, connection of cables
    • Miscellaneous
      • Vacuum suction, hydraulic systems
        • Vacuum pump, connection
      • Hydraulic system, cleanliness when handling hydraulic components
      • Hydraulic system, repair of hydraulic components in workshop
      • Hydraulic system, storage and transport of hydraulic components

• ENGINE WITH MOUNTING AND EQUIPMENT
  • ENGINE
    • General, common info about 211 – 218
      • Complete unit, removal
      • Engine specifications, general
    • Engine mounting
      • Engine mounting, right front, removal
  • FUEL SYSTEM
    • Fuel tank; fuel filling pump
      • Fuel filling pump, connections included
        • Fuel filling pump, removal
    • Injection pump; regulator; pump companion
  • COOLING SYSTEM
    • Radiator, mounting and connections included
    • Coolant pump; thermostat
      • Coolant pump
        • Coolant pump, removal
    • Fan; fan shroud; fan coupling
      • Fan drive, mechanical
  • ENGINE CONTROL
    • Speed control
      • Engine speed control, replacement of throttleł cylinder
      • Engine speed control, setting of throttle control

• ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
  • • Comprehensive info, electrical system
      • Information system, overview
      • Main electrical components, description
      • Wiring diagram, list of components and index
  • BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
    • Battery
  • ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
    • General, common info about 321 – 322
      • Charging system, checking the charging voltage
    • Alternator inclusive drive
      • Alternator, removal
  • STARTING SYSTEM
    • General, common info about 331 – 334
    • Starter motor inclusive solenoid
      • Starter motor
        • Starter motor incl. start relay, removal
    • Starter lock
      • Ignition lock, removal
  • OTHER ELECTRICAL EQUIPMENT
    • General, common info about 361 – 367
      • Other equipment, control unit
      • Other equipment, replacement of upper windscreen wiperł motor
    • Automatic control/blocking function, lacking a function group of its own
  • CABLE; FUSE; RELAY
    • General, common info about 371 – 379
    • Cable; battery disconnector
      • Battery cable, battery disconnector
        • Battery disconnector
          • Battery disconnector, removal
    • Electrical distribution box; fuse box; junction box
      • Electrical distribution box
        • Distribution box 1
          • Distribution box A1, fuses and relays
  • INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
    • General, common info about 383 – 387
      • Information system, description
    • Sender, monitoring system
      • Sensors and monitors, air filter pressure monitor
      • Sensors and monitors, engine speed (rpm) sensor
      • Sensors and monitors, engineł oil pressure monitor
      • Sensors and monitors, replacement of air filter pressure monitor
      • Sensors and monitors, replacement of auto decelerator pressure monitor
      • Sensors and monitors, replacement of cold start temperature monitor
      • Sensors and monitors, replacement of engine oil pressure monitor
      • Sensors and monitors, replacement of engine speed (rpm) sensor
      • Sensors and monitors, replacement of fuelł levelł sensor
      • Sensors and monitors, replacement of hydraulic oil filter pressure monitor
      • Sensors and monitors, replacement of overload pressure monitor
      • Sensors and monitors, replacement of safety bar
      • Sensors and monitors, replacement of temperature sensor for coolant
      • Sensors and monitors, replacement of temperature sensor for hydraulic oil
      • Sensors and monitors, replacement of travel pedal pressure monitor
      • Sensors and monitors, replacement of windscreenł position monitor
      • Sensors and monitors, temperature sensor for hydraulic oil
      • Sensors and monitors, travelł pedal pressure monitor
      • Sensors and monitors, windscreen position monitor
      • Sensors and monitors, overload pressure monitor
    • Warning/information unit, display unit
      • Warning/information unit, display unit
        • Information display unit, description
      • Central computer
        • Central unit A3, removal
      • Display unit

• POWER TRANSMISSION
  • • General, common info about 410 – 436
  • GEARBOX,
    • Gearbox
      • Track gearbox, crawler machine
        • Travel gearbox for track machine, removal
  • HYDROSTATIC DRIVE
    • Hydraulic motor incl. operating system.
      • Hydraulic motor 1, traveling
      • Hydraulic motor, swing of superstructure
    • Centre passage; lines
      • Centre passage
  • MISCELLANEOUS
    • Swing system upper part
      • Swing ring
        • Slew ring, measurement of axial play
      • Slew system for superstructure, measurement of rotational play
      • Slew system for superstructure, specifications

• BRAKE
  • TRACK BRAKE
    • Track brake
      • Brake disc
        • Brake discs, removal

• FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
  • FRAME
    • Counterweight
      • Counterweight, removal
    • Frame, excavator
      • Undercarriage (crawler machine)
  • WHEELS; TRACKS; TYRE; HUB; DRUM
    • Crawler unit
      • Front idler, incl. fork
      • Sprocket
      • Steel track
        • Track chain
          • Track chain, measurement of wear between chain pin and bushing
          • Track chain, renovation of tracks with link set
      • Top rollers; skid rails
        • Topp rollers
      • Bottom rollers
      • Spring pakage; adjusting cylinder
        • Spring package
          • Spring package with tensioning cylinder, removal

• MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
  • • Framework, machine house
  • CAB, NAKED; CANOPY
    • • Cab body
  • DOORS; HATCH; COVER PLATE, (all)
    • Door, complete with catch, hinges (no glass)
      • Cab door, removal of door catch
  • CAB INTERIOR/UPHOLSTERY
    • Driver’s seat, complete; instructor’s seat
      • seat, Driver’s
        • OperatorŢ€™s seat, removal
  • AIR CONDITIONING UNIT
    • Heating unit
      • Heating radiator
        • Heater coil, removal
      • Heating control valve

• HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
  • WORKING HYDRAULICS; SERVO HYDRAULICS
    • General, common info about 911 – 917
      • Hydraulic diagram, component list
      • Hydraulically driven oil cooler fan, description
    • Tank; line; oil cooling; filter; breather; filling pump
      • Tank
      • Oil cooling system
    • Working hydraulics
      • Directional valve; control valve
        • Directional valve, slewing
          • Directional valve for slew, removal of spring
        • Directional valve, removal of spring
      • Pressure limiting valve (relief valves)
        • Chock valve
          • Shock valve, removal
        • Pressure limiting valve, removal
      • Hydraulic lock; line rupture valve
        • Line rupture valve, boom
          • Hose rupture valve for boom cylinder, description
          • Hose rupture valve for boom cylinder, removal
        • Line rupture valve, dipper
          • Hose rupture valve for dipper arm cylinder, description
          • Hose rupture valve for dipper arm cylinder, removal
      • Block for valve assembly
      • Refilling valve (anti-caviation valve)
        • Anti cavitation valve, removal
      • Shock and anti cavitation valve, removal
    • Pump, working hydraulics
    • Servo hydraulic system
      • Pump
      • Pressure accumulator
        • Servo pressure accumulator, description
        • Servo pressure accumulator, removal
      • Control pressure valve, except brake valve
        • Control pressure valve, adjustment
      • Solenoid valve, on/off function
    • Other hydraulic equipment
      • Hammer and shears, hydraulic diagram
  • MECHANICAL EQUIPMENT/ATTACHMENT
    • Attachment bracket, mechanical and hydraulic Quickfit
      • Cylinder, hydraulic
        • Cylinder for hydraulic quickfit, removal
  • UNIT, DIGGING
    • General, common info about 971 – 975
      • Bearings, measurement of radial play
      • Digging equipment sinking, specifications
    • Boom with links
      • Boom
      • Cylinder, boom lifting
        • Boom cylinder, left, removal
    • Dipper arm with links
      • Dipper arm
        • Dipper arm, replacement of pin between dipperł armł and boom
      • Cylinder, dipper arm
        • Dipper arm cylinder, removal
      • Cylinder, bucket
        • Bucket cylinder, removal