Service Information Document Title: Control units, changing
Function Group: 091
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Before changing electronic control unit Volvo CE product specialist should be consulted. NOTE! Before changing a control unit, customer parameters must be read out so that they can be programmed again.
Service Information Document Title: Hydraulic dieseling
Function Group: cylinders, 091
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo If air enters the hydraulic cylinders during work on the hydraulic system, this can lead to spontaneous ignition, an effect known as dieseling. This occurs if a favourable mixture of air and hydraulic oil is compressed when the piston approaches its end position in the cylinder. A sufficiently high temperature can be reached for the mixture to spontaneously ignite.
NOTICE The dieseling effect may result in burnt piston seals and bushings. In order to prevent dieseling, the lines for the hydraulic cylinders must be bled after work is completed, as follows: 1. 2.
No load and keep the lowest engine rpm Operate the piston slowly up to the middle of cylinder in order to remove air from inner chamber of cylinder. Repeat over 5 times. After that, operate the piston up to the end of cylinder in order to remove residual air from cylinder, pipe and hose gradually. Repeat over 5 times.
NOTICE If the cylinders are pressurized either through lifting of the machine or lifting of a load in the bucket, without first performing the mentioned bleeding movements, the seals will likely be damaged. If a cylinder is to be pressure-tested after a repair, the piston rod should be run in and out a few times before increasing the pressure to testing pressure.
Service Information Document Title: Machine view
Function Group: 000
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo
Figure 1
1
Dipper arm cylinder
15
Hydraulic tank
2
Boom
16
Fuel tank
3
Boom cylinder
17
Upper roller
4
Operator cab
18
Turning joint
5
Charged air cooler , hydraulic oil cooler and radiator 19
Bottom roller
Serial number stop
6
Swing motor and gearbox
20
Idler
7
Air cleaner
21
Bucket
8
Main control valve
22
Link
9
Engine
23
Bucket cylinder
10
Rear hood
24
Dipper arm
11
Diesel Particulate Filter (DPF)
25
Swing ring gear
12
Counterweight
26
Dozer blade
13
Main pump
27
Dozer blade cylinder
14
Track motor and gearbox
Service Information Document Title: Product plates
Function Group: 000
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Please refer to the figure below to locate the product plate, engine plate, cab plate and attachment plates. Always use the Product Identification Number (PIN) provided on the vehicle and/or engine plates for troubleshooting purposes and/or when ordering spare parts. Product plate This plate with Product Identification Number, PIN, for the complete machine indicates the model designation, serial number and when applicable, machine weight, engine power, manufacturing year and CE approval. The plate is positioned on the right side of the upper frame. Engine The engine type designation, part and serial numbers are stamped on the top of valve cover. Attachment quick coupler This nameplate is attached on the outside of the bracket and indicates the part number and weight. Bucket This nameplate is attached on the top of the bucket and indicates the bucket model order number, serial number, bucket part number, rated capacity, weight, cutting width, tooth part number, and adapter part number. Cab The nameplate is attached on the inside of the cab and indicates the product number, serial number, model type, and weight.
Service Information Document Title: Service positions
Function Group: 091
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Park the machine on a horizontal and firm surface. The suitable position is indicated in the description for the various service jobs. Before beginning any work on the machine. Turn off the engine and remove the ignition key. Depressurize all pressurized lines and pressure vessels carefully so that high pressure is released without risk. Allow the machine to cool down.
Figure 1 Service position A
Figure 2 Service position B
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Figure 3 Service position C
Figure 4 Service position D
Figure 5 Service position E
Figure 6 Service position F
Service Information Document Title: Welding on the machine
Function Group: 091
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo
NOTICE During electric welding on the machine or attachments connected to the machine, components such as bearings and electric units may be damaged if the ground cable is connected incorrectly. The following actions should be taken before starting electric welding to eliminate these risks: 1. 2.
Turn off the electric power using the battery disconnector. Disconnect the batteries. NOTE! Both the plus and minus terminal.
3.
Disconnect the following electronic units: – Vehicle electronic control unit (V-ECU) – Engine electronic control unit (E-ECU) – Instrument electronic control unit (I-ECU) – Electronic climate control unit (ECC) – Wiper control unit (CU3601) Connect the welding unit's ground connection as close as possible to the welding point, and make sure that the current does not pass across a bearing.
4.
If welding is necessary on the boom or dipper arm, the following basic rules should be followed: 1. 2. 3. 4.
Welding beads should be laid down in the longitudinal direction. If possible, weld in the middle of the metal section and never closer than 80 mm to an edge. Do not weld near the welded connections of the cylinder mounting eyes. Minimum distance from eye's weld to weld for weld lug = 100 mm. Do not weld close to where a metal plate has been bent.
Service Information Document Title: Bearings
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Removal Bearings should never be removed unless absolutely necessary. Always use the recommended puller to reduce the risk of bearing or related component damage. When bearings or bushing are removed, check that the bearings is free from discoloration, nicks, scuffing and signs of overheating. If in doubt, replace the bearing or bushing. Cleaning Bearings acceptable for service should be cleaned in a suitable solvent and immersed in a clean lubricating oil until needed. Installation Be sure bearings are installed with care during servicing, maintenance and repair. All bearings on this machine are installed as a press fit. When possible, always install the bearing into the rotating part first. Use the proper tools or a press when installing a bearing or bushing. In the absence of the proper tools or a press, cool the bearings and/or heat casing to assist in the installation.
Service Information Document Title: Cleaning prior to repair
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Clean the exterior of all parts before repairing. Dirt and abrasive dust reduce the efficient work life of the part and lead to costly replacement. Use cleaning fluids and solvents which are suitable for cleaning parts and do not risk the safety of the user. Certain types of fluids damage rubber parts and/or cause skin irritation. The following precautions must be observed to insure hydraulic cleanliness: 1. 2. 3. 4. 5. 6.
Flush hose and tube assemblies with a solvent compatible with hose assemblies. Blow out excess solvent with shop air. Cap hydraulic fittings and protect threads until installation. Cap hoses and tube assemblies until installation. Flush hydraulic reservoir, fuel tank and chain case housings with a suitable solvent to remove any foreign debris. Protect system components from airborne contaminants. Plug all cylinder, valve, reservoir, tank and pump openings until installation. Use clean, filtered motor oil when filling the system. See Recommended lubricants
Service Information Document Title: Hoses and tubes
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Inspection If the hose end connections are damaged, always replace hoses and tubes. Damaged, dented, crushed or leaking hose fittings restrict oil flow and the operation of the parts being served. Be sure hoses are in good condition. If in doubt, replace them. Replace hoses if the following occur: chafed outer cover concealed corrosion of wire reinforcement ballooning (replace immediately!) kinked, crushed, stretched or deformed. Installation When installing a new hose, loosely connect each end and take the designed position before tightening the connection. Hoses must be tightened using two wrenches. One is used to tighten the swivel nut, the other to ensure the hose flexible part is not twisted. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing. If a hose is replaced on a moving part, be sure it does not foul by moving the part through its complete range of travel. Be sure any hose which has been installed is not kinked, twisted or exposed to any sharp edges. Free moving, unsupported hoses must never touch each other or related work surfaces. This causes chafing, reducing hose life.
Service Information Document Title: Pressure testing
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo 1. 2. 3.
Prior to pressure testing, be sure all hoses are in good condition and all fittings are tight. Use a pressure gauge with a range that is high enough to measure the specified pressure. Comply with the correct procedure to prevent damage to the system or the equipment and to eliminate the possibility of injury.
Service Information Document Title: Replacement parts
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo For reference when ordering replacement parts or making service inquires, record the model and serial numbers of your machine. They are stamped on the serial number plate positioned under the boom on the superstructure frame.
Service Information Document Title: Safety when servicing
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo For Safety when servicing, see the Safety Section, Section S.
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Service Information Document Title: Service methods
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Appropriate service methods and proper repair procedures are essential for safe, reliable operation of the machines and safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will assure reliability. There are many variations in procedures, techniques, tools and parts for servicing machines, as well as work skills. This manual cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, anyone who intends to depart from the instructions in this manual must first consider personal safety and then machine integrity. NOTE! Volvo CE recommends the use of environmentally sound waste storage and disposal practises. Never drain fluids on the ground or into a sewer or catch basin. Use suitable collection containers, then store and/or dispose of waste products in an approved and safe manner. Check and obey all federal, state and/or local regulations regarding waste storage, disposal and recycling.
Service Information Document Title: Service
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo For the machine to operate safely and at the lowest possible cost, it must receive thorough and complete maintenance. Intervals for maintenance and lubrication refer to normal operating and environmental conditions. Maintenance work is described in the Operator's manual and the manual "Service and maintenance" as well as the Service program. Service Programme The checking boxes in the service program show what type of service should be done for intervals from every 10 hours up to and incl. 4000 hours. The service intervals from and incl. 4500 hours only contain the additional service points that are to be done at each interval. The additional service points that are to be done at the first 500 hours are presented in the same way. Time Guide The Time Guide for service intervals for every 10 hours up to and incl. 4000 hours shows time for the total service. Intervals from and incl. 4500 hours only show time for the additional service points. Example, 4500 hour interval: Do all maintenance according to the standard interval every 500 hours and also do the extra interval 4500 hours. Follow the same example at the first 500 hours.
Service Information Document Title: Function Group: Starting engine with booster cables
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Before connecting the booster cables check the following: Size of booster cable and clip should be suitable for the battery capacity. Check cables and clips for breaks, corroded surfaces, etc. Make sure cables and clips are firmly secured. Keep the starting switch in “OFF” position, (both machines). The battery of the running engine must be the same capacity as that of the engine to be boost started. When starting from another machine do not allow the machines to touch. Connect the booster cables in the following manner :
Figure 1 Connection, booster cables 1. 2. 3. 4.
Connect clip (1) of booster cable (A) to the battery positive (+) terminal of the machine to be boost started. Connect clip (2) to the battery positive (+) terminal of the engine which is running. Connect clip (3) of booster cable (B) to the battery negative (–) terminal of the engine which is running. Connect clip (4) to the upper structure of the machine to be boost started.
NOTICE Make sure the clips are firmly connected to battery terminals. Start the engine with the fully charged battery, then crank the engine being boost started. When connecting the cables, do not allow the positive (+) and negative (–) terminals to make contact.
NOTICE
Make sure that the booster cable connections are correct. Connect the booster cable to the engine block as far as possible from the battery. After the engine has started, the booster cables must be disconnected in the reverse order. Starting engine 1. 2. 3.
Turn the key switch to “START” position and start the engine. Cranking time maximum 30 seconds, wait minimum 2 minutes between cranking attempts. After the engine has started, the booster cables must be disconnected in the reverse order.
Disconnect the cables as follows :
Figure 2 Disconnection, booster cables 1. 2. 3. 4.
Disconnect clip (1) of booster cable (B) from the upper structure. Disconnect clip (2) from the battery negative (–) terminal of the running engine. Disconnect clip (3) of booster cable (A) from the battery positive (+) terminal of the running engine. Disconnect clip (4) from the battery positive (+) terminal of the machine which was boost started.
Service Information Document Title: VCADS Pro, Operations
Function Group: 170
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo The following VCADS Pro operations are available for function group 1. Operations used when changing or working on components are mandatory. Tests Operation
Application
17012-3 Error codes
Used when there is a suspicion of fault and/or at abnormal values/ readings.
17034-3 Vehicle information, test
Read out vehicle information
Programming Operation
Application
17030-3, Parameter programming
When changing parameters.
17055-3 Central systems, updating, replace When replacing ECU by conversion kit. control unit 17056-3 Central systems, updating, change When replacing software by conversion kit. software 17095-3 Handle component
When replacing the complete engine. This operation is to update machine data in Volvo’s central systems.
Service Information Document Title: Cooling fan description
Function Group: clutch, 263
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo
Figure 1 Cooling fan clutch 1. 2. 3. 4.
Fan clutch solenoid (PWM2601) Fan speed sensor (SE2601) Support arm Electrical connector
The cooling fan is directly driven and the fan speed is controlled by a viscous cooling fan clutch. According to the hydraulic oil, the engine coolant and the charge air temperature the vehicle control unit (V-ECU) calculates the requested cooling fan speed and send this request to the engine control unit (E-ECU), which controls the current of the fan valve and a fan speed sensor. Through the electrical connector (4) a solenoid (1) inside the cooling fan clutch is activated by a PWM-signal. The solenoid is connected with a valve, which controls the silicon oil circulation within the clutch. The silicon oil transmits the fan torque from the input side (engine) to the output side (fan). The fan speed sensor (2) in the support arm (3) gives a feedback of the actual fan speed to E-ECU.
The maximum fan speed depends on the actual engine speed. After the engine start, the fan speed is at maximum for approximate 10 seconds before it is controlled and reduced to the demanded fan speed. To avoid an overheating of the machine, the fan speed is maximum if one of the temperature sensors failed or the fan clutch solenoid is without current, e.g. in case of a broken wire. Cooling fan clutch connector Pin
Specification
1
Fan speed sensor output
2
Fan speed sensor ground
3
Coil ground
4
Coil supply
5
Fan speed sensor supply
6
not used
7
not used
Figure 2 Cooling fan clutch connector Complementary information This component is included in the following systems: —Cooling system, description For wiring diagram, see —Wiring diagram SCH16
Service Information Document Title: Cooling fan control
Function Group: 263
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Cooling fan control is classified according to the type of fan driven. Standard drive is controlled with a fan clutch, and Reversible fan drive is controlled with hydraulic cooling fan. The V-ECU adjusts the currents to the proportional valve of hydraulic oil fan motor and fan clutch. Cooling fan speed should vary with respect to the hydraulic oil temperature, coolant temperature, charged air temperature and compressor operation for the air conditioner. Input signals Pin No.
ECU
Description
VB13
V-ECU
Hydraulic oil temperature sensor, SE9105
Input messages ECU
Description
I-ECU
Compressor Status
E-ECU
Induction/charge air temperature, FX1007(SE2507)
E-ECU
Coolant temperature, SE2606
E-ECU
Ambient air temperature sensor, FX1008 (SE2501)
E-ECU
Fan clutch speed sensor, SE2601
Output signals Pin No.
ECU
Description
VC21
V-ECU
Hydraulic oil fan motor proportional valve, PWM9143
EB49
E-ECU
Fan clutch proportional valve, PWM2601
Function description
Figure 1 The current for cooling fan control can be determined by 4 factors: Hydraulic oil temperature (K ) Coolant temperature (K ) Charged air temperature (K ) Compressor operation for the air conditioning V-ECU calculates each coefficient, hydraulic oil temperature, coolant temperature and charged air temperature, and sets the maximum value for the control fan speed. K = max. (K , K , K )
Figure 2 Fan speed control curve A. B.
Maximum current Minimum current
1. 2.
Full speed Minimum speed
a. b.
Expected rotating speed of cooling fan Current for cooling fan valve
The minimum and the maximum current of the fan speed control curve will be determined with respect to the engine speed
control mode. If air conditioning compressor is ON, V-ECU selects the higher rpm between the current engine rpm and compressor rpm. If the machine has a pre-heating option and the pre-heating signal is ON, the fan speed will be minimum before the pre-heating time has elapsed for engine fuel efficiency. For the cooling fan current, see Hydraulic oil cooling system, specifications Reversible type Cooling fan speed varies with input current to the proportional valve of the hydraulic oil fan motor. The fan speed would not be controlled linearly because of its characteristic. The fan speed control curve is for understanding. Decreasing the current will increase the hydraulic pressure to the fan motor, which increases the cooling fan speed. This negative control protects the hydraulic cooling system and engine from overheating when there is a failure in the VECU. Fan clutch type Cooling fan control signals calculated by V-ECU sent to the E-ECU. Pulse Width Modulated (PWM) signal is sent to the proportional valve to control flow of fluid in the fan clutch. The fan clutch requires a fan speed feedback from speed sensor to compensate control speed. If there would be a communication error between E-ECU and V-ECU, cooling fan speed will be controlled by coolant temperature. When there is a defect in the proportional solenoid valve, the valve will be a open position and the fan will operate at maximum speed.
Service Information Document Title: Function Group: Cooling system, component 260 location
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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Figure 1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Expansion tank Charge air cooler hose Radiator assembly Charge air cooler temperature sensor Thermostat Radiator hose Stay Fan Coolant pump Engine oil cooler
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Description Cooling system, description
Service Information Document Title: Cooling system, description
Function Group: 260
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo The cooling system is a pressurized closed system. It uses a pump which pumps the coolant throughout the system. The coolant transfers heat from parts and oils that need cooling, both inside the engine as well as outside. The coolant is cooled in the radiator by an air flow generated by a cooling fan. A thermostat regulates the coolant's path. When the engine is cold, the coolant by-passes the radiator to conserve heat instead of removing it. An expansion tank is used to handle expansion of the coolant. It has a pressure relief valve integrated in its cap. Coolant is refilled via the refill nipple. NOTE! EGR system only applies to D8K enigne For information about other systems that affect the cooling system, see: Lubrication system, description Exhaust Gas Recirculation (EGR), description
Figure 1 Engine cooling system
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Radiator Coolant pump Oil cooler/oil filter housing Cylinder liner EGR-cooler EGR actuator Thermostat Expansion tank Coolant level sensor (SE2603) Coolant temperature sensor (SE2606)
The coolant pump delivers the coolant to the engine via the lubrication oil cooler and into the engine, around the cylinder liners and through the thermostat housing. The thermostat controls the coolant's flow out to the radiator or in by-pass flow back into the engine, depending on the coolant temperature. The coolant pump also forces some coolant to the EGR-cooler via internal channels inside the pump and external pipes. A small amount of the EGR coolant flow is routed through external pipes to cool the EGR actuator. After cooling the exhausts in the EGRcooler, the coolant is routed back to the engine via external pipes and then enters channels inside the engine before the thermostat. The coolant is cooled in the radiator and is then transported back into the engine's cooling system. The coolant is also transported via external pipes and hoses to parts on the machine. For example, the cab heater or the transmission oil cooler. The cab heater takes its coolant from the warm side of the engine, before the thermostat, and the return leading to the pump's suction side. The transmission oil cooler takes its coolant after its been cooled in the radiator and the return leading back to the pump’s suction side. Coolant pump The coolant pump is of impeller type and is belt-driven. The rear of the pump is bolted to the cylinder block, oil cooler, and oil filter housing, and it has channels for coolant distribution. Thermostat The coolant circulation thermostat is of the piston type and has a temperature-sensitive wax body which controls opening and closing. The thermostat begins to open when the coolant temperature reaches a level which indicates that the engine is warm and the coolant needs to transport heat away from the engine. The thermostat is located inside a thermostat housing containing channels for coolant distribution. The thermostat housing is bolted to the cylinder head. Parameters There are no parameters for this function. Supplementary information Cooling system, component location Cooling fan, description Reversible cooling fan, description Function check 28407-3 Sensor values, monitoring Diagnostics Component
Control unit
Message ID
SE2603
MID128
PID111
SE2604 (Only EXC)
MID128
PID26
SE2606
MID128
PID110
PWM2602
MID128
SID33
(Only EXC)
Service Information Document Title: Crankcase description
Function Group: ventilation, 212
Information Type: Service Information
Date: 12/3/2020
Profile: EC160D L Volvo
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EC160D L Volvo Since some of the combustion pressure enters the crankcase after passing by the pistons and piston rings (blow-by), the crankcase must be ventilated. The purpose of the crankcase ventilation is to balance the pressure in the crankcase in order to avoid damage to engine components and to prevent oil mist formation and oil leakage into the ambient air. The crankcase ventilation consists of a housing containing a filter, with connections to the oil sump and ventilation piping.
Figure 1 Crankcase ventilation housing Air containing oil particles comes from the crankcase via the cylinder head into the crankcase ventilator. The air (blue arrows) passes through the filter, while oil particles (red arrows) are caught and led back to the oil sump via a return pipe. Supplementary information Engine, description Lubrication system, component locations
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