Volvo EW160B Wheeled Excavator Service Repair Manual Instant Download

1
Service Information
Document Title Description D6D Function Group 200 Information Type Service Information Date 2014/7/17
Profile EXC, EW160B GB Profile EXC, EW160B GB Profile EXC, EW160B GB Profile EXC, EW160B GB
Description D6D The D6D engine is a straight six
cylinder, direct-injected four-stroke diesel
engine, with electronically controlled fuel
injection EMS (Engine Management System). The
engine meets the emission requirements according
to EURO2. The engine number is stamped on the
name plate and on the engine block's right side.
Model and serial number must always be indicated
when ordering spare parts.
2
Service Information
Document Title Engine, removal Function Group 210 Information Type Service Information Date 2014/7/17
Profile EXC, EW160B GB Profile EXC, EW160B GB Profile EXC, EW160B GB Profile EXC, EW160B GB
Engine, removal Op nbr 210-01 14360000 Vacuum
pump Lifting links, min. 1500 kg Hose with valve
WARNING
Risk of burns - stop the diesel engine and allow
it to cool down before starting any work.
WARNING
Smoking or open flames near the machine are
absolutely forbidden during refuelling or when
the fuel system is open to contact with the air.
WARNING

• Hot oil and hot engine coolant can cause severe
  burns!
• NOTE!
• Clamps that secure hoses and wiring should be
  removed and replaced when installing.
• Plug and mark all hoses and connections when
  disconnecting.
• Place the machine in service position A 091
  Service positions.
• Turn off the engine and depressurize the
  hydraulic system, see 170 Elimination of trapped
  hydraulic pressure.
• Remove the counterweight, see 716 Counterweight,
  removing.

• 3.
• Figure 1 Superstructure
• Cover
• Cover
• Remove the covers under the engine.

3
Remove the covers over the engine.

• 4.
• Figure 2 Framework
• Cover
• Framework
• Cover
• Disconnect the outer framework and lift off the
  frame with the covers.

5. Figure 3 Engine/hydraulic compartment 1. Interm
ediate wall Remove the intermediate wall .
6. Figure 4 Engine/hydraulic compartment 1. Frame
work
4
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5
Remove the remaining framework.
7. Figure 5 Draining coolant 1. Hose with
valve Connect the hose with valve (in tool
equipment) and drain the coolant from the
radiator and engine into a clean container. 8.
Connect the vacuum pump, see 900 Vacuum pump,
connection.
9. Figure 6 Working pump

1. Suction line
2. Hydraulic hose
3. Hydraulic hose

1. Hydraulic hose
2. Hydraulic hose
3. Hydraulic hose

Disconnect the suction line and hydraulic hoses
from the working pump. NOTE! Plug the suction
line from the hydraulic oil tank and the other
hoses with metal plugs, since the vacuum is
disconnected further on in the instructions.
6

• 10.
• Figure 7 Servo/steering pump
• Hydraulic hose
• Hydraulic hose
• Hydraulic hose
• Hydraulic hose
• Disconnect the hydraulic hoses from the
  servo/steering pump.
• 11. Turn off the vacuum pump and turn off the
  battery disconnector.

• 12.
• Figure 8 Engine
• Cooling hose
• Compressor
• Disconnect the cooling hose and disconnect the
  AC-compressor from the bracket.
• NOTE!
• Do not loosen the hoses for the compressor.

7

• 13.
• Figure 9 Radiator/engine
• Cooling hose
• Cooling hose
• Cooling hose
• Cooling hose
• Disconnect the cooling hoses from the engine.

• 14.
• Figure 10 Engine
• Ground cable
• Cabling
• Disconnect the ground cable from the engine and
  the cabling from the starter motor.

8

• 15.
• Figure 11 Engine
• Cooling hoses
• Cabling
• Disconnect the cooling hoses (2 pcs.) and the
  cabling from the alternator.

• 16.
• Figure 12 Engine
• Electric cable
• Electric cable
• Electric cable
• Fuel hose
• Disconnect the electric cables and the fuel hose
  , as well as the fuel hose for the fuel pump (by
  the cooling fan). Remove the clamps for hoses and
  electric cables, then place the electric cables
  and hoses on the engine member.

9

• 17.
• Figure 13
• Lifting links on engine
• Lifting links
• Lifting eyes
• Connect the lifting links in the engine's lifting
  eyes (2 pcs.) and in a lifting device.

• 18.
• Figure 14 Engine
• Bolted joint
• Bolted joint
• Remove the bolted joints and for the engine
  mounts.

19. Figure 15
10

• Inner engine mount
• Bolted joint
• Hose clamp
• Remove the bolted joint for the inner engine
  mount and loosen the hose clamp .

• 20.
• Figure 16
• Outer engine mount
• Bolted joint
• Hose
• Remove the bolted joint and the hose.
• 21. Lift the engine out of the machine and place
  the engine on stable supports.

11
Service Information
Document Title Engine, installation Function Group 210 Information Type Service Information Date 2014/7/17
Profile EXC, EW160B GB Profile EXC, EW160B GB Profile EXC, EW160B GB Profile EXC, EW160B GB
Engine, installation Op nbr 210-02 14360000
Vacuum pump Lifting links, min. 1500 kg

• 1.
• Figure 1
• Transferring components
• Muffler
• Working pump
• Transfer the working pump with drive flange and
  cap. Transfer the muffler with pipes for the
  turbo.

2. Figure 2 Transferring components
12

• Engine mount
• Servo/steering pump
• Engine heater cable
• Transfer the servo/steering pump and eventual
  engine heater cabling. Transfer the rear engine
  mounts on both sides.
• Tightening torque for engine mounts110 11 Nm.

3. Figure 3 Transfer front engine
mounts 1. Engine mount Transfer the front
engine mounts on both sides. Tightening torque
for engine mounts260 26 Nm
4. Figure 4 Transferring components 1. Alternator
Transfer the alternator.
13

• 5.
• Figure 5
• Transferring components
• Hose
• Intercooler pipe
• Transfer the hose for the turbo and the
  intercooler pipe.
• 6. Connect lifting links in the engine's lifting
  eyes and lift the engine into the machine.
• NOTE!
• Fit the hose on the turbo hose before the engine
  is lowered onto the engine mounts.

• 7.
• Figure 6
• Outer engine mount
• Bolted joint
• Intercooler hose
• Fit the bolted joint and the intercooler hose.
  Tightening torque 687 68 Nm.

14

• 8.
• Figure 7
• Inner engine mount
• Bolted joint
• Hose clamp
• Fit the bolted joint for the inner engine mount
  and tighten the hose clamp. Tightening torque
  687 68 Nm.

• 9.
• Figure 8 Engine
• Bolted joint
• Bolted joint
• Fit the bolted joint for the engine mounts.
  Tightening torque 687 68 Nm.

10.
15

• Figure 9 Engine
• Electric cable
• Electric cable
• Electric cable
• Fuel hose
• Connect the electric cables and the fuel hose, as
  well as the fuel hose for the fuel pump (by the
  cooling fan).

• 11.
• Figure 10 Engine
• Cooling hoses
• Cabling
• Connect cooling hoses (2 pcs.) and the cabling
  for the alternator. Clamp the cooling hoses and
  electric cables with clamps according to earlier
  clamping.

• 12.
• Figure 11 Engine
• Cabling
• Ground cable
• Connect the cabling to the starter motor and the
  ground cable to the engine.

16

• 13.
• Figure 12 Radiator/engine
• Cooling hose
• Cooling hose
• Cooling hose
• Cooling hose
• Connect the cooling hoses to the engine.

• 14.
• Figure 13 Engine
• Cooling hose
• AC-compressor
• Fit the AC-compressor on the bracket and the
  cooling hose.
• Turn on the battery main switch.
• Connect the vacuum pump, see 900 Vacuum pump,
  connection.

17

• 17.
• Figure 14 Servo/steering pump
• Hydraulic hose
• Hydraulic hose
• Hydraulic hose
• Hydraulic hose
• Connect the hydraulic hoses to the servo/steering
  pump.

• 18.
• Figure 15 Working pump
• Suction line
• Hydraulic hose
• Hydraulic hose
• Hydraulic hose
• Hydraulic hose
• Hydraulic hose
• Connect the suction line and the hydraulic hoses
  to the working pump.
• 19. Disconnect the vacuum pump, see 900 Vacuum
  pump, disconnection.

18
20. Figure 16 Engine/hydraulic compartment 1. Fram
ework Fit the framework .
21. Figure 17 Engine/hydraulic compartment 1. Inte
rmediate wall Fit the intermediate wall .

• 22.
• Figure 18 Framework
• Cover
• Framework
• Cover
• Fit the outer framework with the covers.

19

• 23.
• Figure 19 Superstructure
• Cover
• Cover
• Fit the covers under the engine. Fit the covers
  over the engine.
• Fit the counterweight, see 716 Counterweight,
  installation.
• Fill coolant, see 173 Maintenance service, every
  4000 hours.
• Check oil level in the engine. Fill if needed.
• Check hydraulic oil level. Fill if needed.
• Bleed the fuel system, see 233 Fuel system,
  bleeding.
• Start the engine and check for leakage.

20
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21
Service Information
Document Title Cylinder head, description Function Group 211 Information Type Service Information Date 2014/7/17
Profile EXC, EW160B GB Profile EXC, EW160B GB Profile EXC, EW160B GB Profile EXC, EW160B GB
Cylinder head, description The cylinder head is
made of cast iron and is common for all
cylinders. The induction air enters vertically
(A) and the exhausts leave horizontally (B).
Inlets and exhaust outlets are located on the
same side of the cylinder block. On order for the
engine to fulfill governing emission standards,
there are 3 cylinder head gaskets of different
thicknesses between the cylinder head and the
piston.
Figure 1
22
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the link into your browser. The full manual is
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