Volvo EW160 Excavator Repair Service Manual

Description

Table of Content EW160 Service Information

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

• STANDARD PARTS, SERVICE
  • LUBRICANT; FUEL; OTHER FLUID
    • General
  • 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

• ENGINE WITH MOUNTING AND EQUIPMENT
  • ENGINE
    • General, common info about 211 – 218
      • Complete engine,
        removal
      • Engine specifications,
        general
    • Engine mounting
      • Engine mounting,
        right front, removal
  • FUEL SYSTEM
    • Fuel tank; fuel filling pump
      • Fuel filling pump, connections included
    • 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 throttle controls
      • Engine speed control,
        setting of throttle controls

• ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
  • GENERAL
    • 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 wiper 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, brake light pressure
        monitor
      • Sensors and monitors, engine oil pressure
        monitor
      • Sensors and monitors, engine speed (rpm)
        sensor
      • Sensors and monitors, pressure monitor
        for brake pressure 50 bar
      • Sensors and monitors, pressure monitor
        for brake pressure
      • Sensors and monitors, pressure monitor
        for steering pressure
      • Sensors and monitors, replacement
        of air filter pressure monitor
      • Sensors and monitors, replacement
        of auto decelerator pressure monitor
      • Sensors and monitors, replacement
        of brake light 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 fuel level sensor
      • Sensors and monitors, replacement
        of hydraulic oil filter pressure monitor
      • Sensors and monitors, replacement
        of overload pressure monitor
      • Sensors and monitors, replacement
        of parking brake pressure monitor
      • Sensors and monitors, replacement
        of pressure monitor for brake pressure
      • Sensors and monitors, replacement
        of pressure monitor for brake pressure 50 bar
      • Sensors and monitors, replacement
        of pressure monitor for steering pressure
      • Sensors and monitors, replacement
        of safety bar
      • Sensors and monitors, replacement
        of superstructure position monitor
      • 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 windscreen position monitor
      • Sensors and monitors, temperature sensor
        for hydraulic oil
      • Sensors and monitors, travel 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
    • General, common info about 410 – 436
  • GEARBOX,
    • Gearbox
      • Gearbox, travelling, wheel machine
        • Travel gearbox,
          removal and installation
  • HYDROSTATIC DRIVE
    • Hydraulic motor incl. operating system.
      • Hydraulic motor 1, traveling
      • Hydraulic motor, swing of superstructure
    • Centre passage; lines
      • Centre passage
  • PROPELLER SHAFT
    • Propeller shaft, complete
      • Propeller
        shaft, front, replacement
  • FRONT AXLE; REAR AXLE
    • Front axle
    • Rear axle 1
  • 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
  • WHEEL BRAKE
    • Front wheel brake, dry brake
  • HYDRAULIC BRAKE SYSTEM
    • Brake valve
  • TRACK BRAKE
    • Track brake
      • Brake disc
        • Brake discs,
          removal and installation
  • PARKING BRAKE
    • General, common info about 551 – 554
  • MISCELLANEOUS
    • Retardation valve
      • Retardation valve,
        removal

• STEERING
  • STEERING AXLE
    • General
    • Steering axle; steering spindle, driving
      • Steering knuckle joint bearing
        • King pin bearing,
          removal and installation of bearing
  • STEERING
    • General, common info about 641 – 647
    • Hydraulic equipment
      • Control valve
        • Steering valve,
          removal

• FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
  • FRAME
    • Counterweight
      • Counterweight,
        removal
    • Frame, excavator
      • Undercariage (wheeled machine)
  • SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /SIDE CONTROL
    • Pivot axle lock
      • Cylinder, pivot axle locking
        • Oscillation lock cylinder, installation
          of hydraulic lock
        • Oscillation lock cylinder, removal
          of hydraulic lock
        • Oscillation lock cylinder,
          description
        • Oscillation
          lock cylinder, removal
  • WHEELS; TRACKS; TYRE; HUB; DRUM
    • Wheel
    • Spacers; stone protection ring; fastener
      • Stone protection ring
        • Stone protection rings,
          description

• MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
  • GENERAL
    • Framework, machine house
  • CAB, NAKED; CANOPY
    • General
      • 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
        • Operator’s
          seat, removal
  • AIR CONDITIONING UNIT
    • Heating unit
      • Heating radiator
        • Heater coil,
          removal
      • Heating control valve

• HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
  • GENERAL
    • General
  • 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
        • Line rupture valve, folding/side angleing cylinder
          • Hose rupture valve for tilt
            cylinder, description
          • Hose rupture valve for tilt
            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
      • 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
    • Stabiliser; stabiliser blade
      • Stabiliser without cylinder
        • Stabilisers,
          removal
      • Stabiliser blade without cylinder
        • Stabiliser blade,
          removal
    • Boom with links
      • Boom
      • Cylinder, boom lifting
        • Boom cylinder,
          left, removal
    • Dipper arm with links
      • Dipper arm
        • Dipper arm, replacement of pin between dipper arm and
          boom
      • Cylinder, dipper arm
        • Dipper arm cylinder,
          removal
      • Cylinder, knuckle/side angeling
        • Tilt cylinder,
          removal
      • Cylinder, bucket
        • Bucket cylinder,
          removal