VOLVO EW160B-8 Machinery House, Cab, Exterior Trim Parts Anywhere

Service Information
Document Title: Function Group: Information Type: Date:

Superstructure covering, 802 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [GB]
Superstructure covering, description

The superstructure covering refers to the sheet metal parts of the machine as well as hatches and frame parts around tanks
and the cab. The superstructure covering can be dismantled in sections.
Service Information

Cab, removal 810 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Cab, removal
Op nbr 8102-01
Lifting eyes 2 pcs. (M12)
WARNING
The work involves handling heavy components - failure to stay alert may result in severe crushing injuries.
1. Turn off the voltage with the battery disconnector.
2. Remove the floor mat.
3. Remove the operator's seat, see 852 Operator's seat, removal.
4. Remove the plastic cap for the cab fan filter behind the operator's seat.
Figure 1
5. Unplug connectors for the VECU and the right wall panel.
NOTE!
Mark the connections before dismantling.
Loosen the washer hose in the joint below the VECU.

Figure 2
6. Loosen the ventilation hoses and junction for the inlet air on the ventilation unit. These come away with the cab
when lifting.
Figure 3
7. Loosen the radio panel and lay it over the ventilation unit (is left behind when lifting).
Figure 4
8. Remove the intermediate wall behind the operator's seat.
9. Loosen the washer fluid reservoir and lay it to the side.
10. Disconnect the electrical distribution box from the rear cab wall and lay it to the side. The bracket for the handle
should be loosened (not removed) from the frame to facilitate removal.
Figure 5
11. Fit the lifting eyes in the cab roof and connect the lifting device.
Figure 6
12. Remove the cab's retainer bolts. These are located at the leading edge of the cab (4 pcs.) and at the trailing edge of
the cab (2 pcs., one in each corner) as well as one at the trailing edge of the door opening.
Figure 7
13. Lift off the cab.

Figure 8
Service Information

Cab, installation 810 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Cab, installation
Op nbr 8102-01
Lifting eyes 2 pcs. (M12)
WARNING
The work involves handling heavy components - failure to stay alert may result in severe crushing injuries.
1. Carefully lift the cab into place.
Figure 1
2. Fit and tighten down the cab's retainer bolts. These are located at the leading edge of the cab (4 pcs.) and at the
trailing edge of the cab (2 pcs., one in each corner) as well as one at the trailing edge of the door opening.
Figure 2
3. Remove the lifting eyes from the cab roof.

Figure 3
4. Fit the electrical distribution box. Tighten down the bracket for the handle against the frame.
Figure 4
5. Fit the washer fluid reservoir.
6. Fit the intermediate wall behind the operator's seat.
7. Fit the radio panel.
Figure 5
8. Fit the ventilation hoses and junction for the inlet air on the ventilation unit.
Figure 6
9. Plug in connectors for the VECU and fit the right wall panel.
Fit the washer hose in the joint below the VECU.
Figure 7
10. Fit the plastic cap for the cab fan filter behind the operator's seat.
Figure 8
11. Fit the operator's seat, see 852 Operator's seat, installation.
12. Refit the floor mat.
13. Turn on the voltage with the battery disconnector.

Service Information

Cab door, removal of door 831 Service Information 2014/5/7 0
catch
Profile:
EXC, EW180B [GB]
Cab door, removal of door catch

Op nbr 8315-01
1. Remove the operator's seat, see 852 Operator's seat, removal.
2. Remove the plastic casing with the radio part.
Figure 1
Plastic casing with radio part
3. Remove the rubber casing over the door catch by loosening the attaching bolts that are located on the inside of
the cab.
Figure 2
4. Remove the pin and the screw so that the wire is exposed.
Figure 3
5. Remove the bolts on the door catch.

Remove the door catch.
Figure 4
6. If the wire is damaged - remove it from the front mounting and fit a new wire.
Service Information

Cab door, installation of 831 Service Information 2014/5/7 0
door catch
Profile:
EXC, EW180B [GB]
Cab door, installation of door catch

Op nbr 8315-02
1. Fit the door catch and tighten down with the attaching bolts. Seal around the door catch with sealant.
Figure 1
2. Fit the wire with the pin and the screw.
Figure 2
Door catch inside cab
1. Pin
2. Screw
3. Wire
3. Fit the rubber casing over the door catch on the cab's outside by tightening it down with the attaching bolts that
are located on the inside of the cab.
Figure 3
4. Fit the plastic casing with the radio part.
Figure 4
5. Fit the operator's seat, see 852 Operator's seat, installation.

Service Information

Window pane, replacement 843 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Window pane, replacement

Op nbr 843-03
Sika Primer 206G+P (recommended)
Sika-Aktivator
Sika Tack Drive
Sikaflex Remover 208 (recommended)
1. Cover the body surfaces around the window pane with masking tape to protect the paintwork during continued
work.
Figure 1
Masking
2. Cut out the window pane with a cutting wire or a knife.

Figure 2
Cutting out window pane
3. Remove the window pane using a suction cup holder.

NOTE!
In order to get adhesion to the old adhesive, it must be a polyurethane product. If the old adhesive consists of
another product with a different chemical base, Volvo will not guarantee the results.
NOTE!
Lowest application temperature is +5 °C.
NOTICE
Always follow the technical spec. sheets and safety instructions for use of Sika products.
4. Repair any paint damage that has been caused by the work with a quick-drying genuine touch-up paint. For minor
damage, Sika Primer 206G+P can be used.
Figure 3
Touch-up of paintwork
5. Cut down the old adhesive bead on the body flange to 1-2 mm so that the new adhesive surface is optimal. Use a
razor blade knife or a sharpened chisel.
NOTE!
Make sure that the paintwork is not damaged.
Figure 4
Trimming adhesive bead
6. Fit and check the new window pane. Fit spacers and support blocks as required. In order to achieve best and most
accurate fit, we also recommend making alignment marks with masking tape on the window pane and body.
Figure 5
Preparations
A. Spacer
B. Support block
7. Clean the adhesion surface on the body flange with a clean, lint-free cloth dampened with Sika-Aktivator. Wipe
down with a dry and clean cloth. Venting time min. 10 minutes, max. 2 hours (the lower the temperature, the longer
the time).
Figure 6
Cleaning body flange
8. Clean the ceramic-coated adhesion surface on the window pane with a clean, lint-free cloth dampened with Sika-
Aktivator. Wipe down with a dry and clean cloth. Venting time min. 10 minutes, max. 2 hours (the lower the
temperature, the longer the time).
Figure 7
Cleaning window pane
9. Open the diaphragm in the top of the SikaTack Drive cartridge. Insert the cartridge into the gun. The point is pre-
cut so that the adhesive bead is V-shaped, height approx. 12 mm.
NOTE!
Keep the height of the body flange in mind. Sharpen the point if required.
10. Apply adhesive on the edges of the window pane or the body.
NOTE!
The window pane must be mounted within 10 minutes of applying the adhesive.
Figure 8
Applying adhesive
11. Fit the new window pane using a suction cup holder. Press lightly along the entire edge of the pane for good
adhesion.
Figure 9
Installing window pane
12. Remove any extra new adhesive with Sikaflex Remover 208.
13. The hardening process is dependent on moisture. In order to speed up adhesive hardening at low temperatures,
moisture can be added by placing a bucket of hot water in the cab or by placing dampened cloths against the
adhesive bead after a surface has formed on it.
Service Information

Window pane with locking 843 Service Information 2014/5/7 0
strip, replacing
Profile:
EXC, EW180B [GB]
Window pane with locking strip, replacing
Op nbr
14211207 Installation tool
1. Remove all bits left of the old window pane, locking strip and rubber moulding.
2. Install the new rubber moulding.
3. Install the new window pane.
4.
Figure 1
Installing locking strip using installation tool.
Lubricate the new locking strip with soap. Then use the installation tool for installing the locking strip.
Service Information

Upper windshield, 844 Service Information 2014/5/7 0
removing
Profile:
EXC, EW180B [GB]
Upper windshield, removing

Op nbr 8431-01
1. Make sure that the windscreen wiper is hooked in the support.
2. Depress the pedal on the steering wheel column and pull the steering wheel away from the windscreen.
3. Release the catches (2 pcs.) at the upper corners of the windscreen.
Figure 1
4. Grasp the handles and move the windscreen backward until the front wheels slide out of the rails.
5. Remove the plastic caps and fit cable ties in the eyes of the cords. Remove the cords from the rollers.
Figure 2
WARNING
Be careful so that the window pane doesn't fall down.
6. Move the windscreen forward until the upper rollers slide out of the rails.
Figure 3
V1011195
7. Lift away the windscreen through the cab entrance.
8. Remove the windscreen according to 843 Window pane, replacement.

Service Information

Upper windshield, 844 Service Information 2014/5/7 0
installing
Profile:
EXC, EW180B [GB]
Upper windshield, installing

Op nbr 8431-02
1. Install the windscreen according to 843 Window pane, replacement.
2. Lift in the windscreen through the cab entrance.
Figure 1
3. Lift up the windscreen and move it backward in the rails until the cords can be hooked on.
Figure 2
4. Remove the cable tie and fit the plastic cap.
5. Pull the windscreen backward with the handles and press up the lower part in the rails.
NOTE!
Work carefully so that the windscreen wiper is not damaged.
6. Move the windscreen forward to a position where the catches can be fitted in the rails.
Figure 3
Service Information

Operator's seat, removal 852 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Operator's seat, removal

Op nbr 8521-01
1. Move the operator's seat to the front position.
2. Remove the bolts 1 for the belt.
Figure 1
Behind operator's seat
1. Bolts for belt
3. Unplug the cabling for seat heating.
4. Remove the bolts 1 behind the operator's seat.

Move the operator's seat to the rear position.
Figure 2
Rear mountings for operator's seat
1. Attaching bolts
5. Remove the front attaching bolts.

6. Remove the wire 1 for position adjustment of the lower part.
NOTE!
Mark up how the wire is adjusted.
Figure 3
Underside seat
1. Wire for position adjustment, lower part
WARNING
Heavy and awkward lift. Work carefully when the operator's seat is lifted out.
7. Lift out the operator's seat.

NOTE!
Weight approx. 30 kg.
Service Information

Operator's seat, installation 852 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Operator's seat, installation

Op nbr 8521-02
WARNING
Heavy and awkward lift. Work carefully when the operator's seat is lifted in.
1. Lift in the operator's seat.

NOTE!
Weight approx. 30 kg.
2. Fit the wire 1 for position adjustment of the lower part.
Figure 1
Underside of operator's seat
1. Wire for position adjustment of lower part.
3. Fit the front attaching bolts for the operator's seat.
4. Move the operator's seat to the front position.
5. Fit the rear attaching bolts 1 for the operator's seat.

Figure 2
Rear mountings for operator's seat
1. Bolts
6. Fit the cabling for seat heating.
7. Fit the attaching bolts 1 for the belt.
Figure 3
Behind operator's seat
1. Attaching bolts for belt

Service Information

Air conditioning unit, 870 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [GB]
Air conditioning unit, description

Air cooling and heating type
Figure 1
Structure, air conditioning system
1 Foot 4 Indoor air

2 Defrost 5 Face
3 Outdoor air
The advanced integrated air conditioning system, with the heating and the cooling system installed in a single unit is
designed to provide a comfortable indoor environment in all seasons.
The integrated system is ergonomically designed for the most efficient air flow distribution. The easy to use control panel
provides a selection of cooling/heating and indoor/outdoor air through 8 levels and 4 fan speeds.
According to the indoor and outdoor air condition, indoor or outdoor air circulation can be selected. All fresh air is drawn
through the air filter installed between the duct and the cab vent.
Air cooling type
The air cooling type is used only for cooling. If heating is required, use the integrated system with heating and cooling
systems.
Air conditioning (AC), basic principles
The AC unit conducts heat away from the cab air to the surrounding atmosphere. At the same time as the temperature is
lowered, the air is also dehumidified as the moisture in the air condenses on the cold fins while it passes through the
evaporator.
In order to conduct heat away from the cab air, a medium with a lower temperature than the air is required, since heat
always moves from a warmer object to a colder one.
If water is heated to 100 °C (212 °F), it begins to boil since the water has reached its limit for storing heat. If you continue to
heat the water, it must release an amount of heat equal to the heat that is added. This is accomplished by boiling which
means that some of the water is converted to steam. The steam carries excess heat with it as it leaves the water.
However, the boiling point of water is too high to be used in an AC unit. A liquid that is converted into gas at a considerably
lower temperature is required. This liquid, so called refrigerant, must also fulfill other requirements in addition to converting
to a gas at a low temperature. Refrigerant R134a fulfills these requirements.
NOTICE
Use only refrigerant (R134a). Do not use any other refrigerant. Use the correct refrigerant pressure measuring gauge
set. Do not use any other refrigerant pressure gauges.
R134a has a constant pressure-temperature ratio. This means that when the temperature is increased or decreased, the
pressure also either increases or decreases. Likewise, if the pressure is increased or decreased, then the temperature is either
increased or decreased. At normal atmospheric pressure, R134a boils at 26 °C (79 °F). Somewhat simplified, the AC unit can
be said to consist of two heat exchangers, one (evaporator) being located in the cab and the other (condenser) located next
to the hydraulic oil cooler radiator or separately. Both heat exchangers are connected with hoses to a system. The system is
charged with refrigerant, R134a, which is pumped through the system by the compressor.
The cab fan circulates the cab air through the evaporator where the heat from the air is transferred to the refrigerant. The
compressor pumps refrigerant to the condenser, where the heat is dissipated to the outdoor air which is blown through the
condenser by the engine radiator fan or a separate fan.
Figure 2
Diagram, air conditioning system
1 Engine 7 Heater core A Indoor air

2 Compressor 7-1 Cooling position B Outdoor air
3 Condenser 7-2 Heating position C Face
4 Filter 8 Door D Foot
5 Blower motor 9 Diesel heater (option) E Defrost
6 Evaporator
Air conditioning unit, related components

Figure 3
Location of components, principle picture
A Ambient temperature sensor D Air conditioning control switch G Compressor

B Incar temperature sensor E Ambient Filter H Charging hose
C Air conditioning unit F Condenser I Intake hose
- Tightening torque:
 Charging hose (H): 15-20 Nm (11-14 lbf·ft)

 Intake hose (I): 15-20 Nm (11-14 lbf·ft)
Components of the air conditioning unit

The air conditioning unit components, with their hose connections, make up a closed system where the refrigerant is
circulated by a compressor. The cooling process operates continuously, with the refrigerant alternating between gaseous
and liquid states, depending on the temperature and the pressure changes.
Figure 4
Refrigerant flow, principle picture
1 Air conditioning unit 8 Ambient temperature sensor 15 Condenser

2 Blower motor 9 Evaporator 16 Dual switch
3 Relay 10 Air mix driver 17 Receiver drier
4 Water temperature sensor 11 Heater core 18 Compressor
5 Duct temperature sensor 12 Battery 19 Electromagnetic clutch
6 Expansion valve 13 Air conditioning switch (auto) 20 Relief valve
7 Incar temperature sensor 14 Engine 21 Service valve
The air conditioning unit is of the compressor type, that is, the refrigerant is circulated by a compressor.
The air conditioning unit consists of the following main components:
1. Air conditioning unit

Air conditioning unit consists of a evaporator, a heater core, an expansion valve, a blower motor, actuators, relays
and sensors.
2. Blower motor
The blower motor circulates the air in the cab where indoor and outdoor air is transferred to the cab. Outlet air flow
regulated by the motor speed.
3. Relay
The relay is located outside the air conditioning unit and is driven the blower motor and electromagnetic clutch.
4. Water temperature sensor
The water temperature sensor is located in the heater core and is activated by sensing the temperature, of the
coolant flowing into the heater core.
When the coolant temperature is lower than 25 °C (77 °F), the blower motor does not operate for 150 seconds.
5. Duct temperature sensor
The duct temperature sensor is installed in the evaporator core at intervals of 5 mm.
NOTE!
If the sensor is out of order, the air conditioning switch turns off the compressor clutch.
6. Thermostatic expansion valve

Controls the quantity of refrigerant supplied to the evaporator. The valve is directly connected to the inlet pipe on
the evaporator.
7. Incar temperature sensor
The incar temperature sensor is installed at the right sides the driver's seat.
8. Ambient temperature sensor
The ambient temperature sensor is located in the tool box. When the ambient temperature is lower than 1 °C (34 °
F), the compressor clutch is shut-off and when the ambient temperature is higher than 25 °C (77 °F), the
compressor clutch is energized.
9. Evaporator
Transfers the heat, from the cab air and the outdoor air supplied to the cab, to the refrigerant. The evaporator is
located in the air conditioning unit in front of or in parallel with the heater core, and consists of a coiled pipe with
fins for heat absorption. To prevent ice formation in the evaporator, there is a switch which interrupts the power
supply to the compressor's magnetic clutch when the temperature becomes too low. The thermostat closes the
power circuit once again when the temperature increases.
10. Air mix door driver (actuator)
The air mix door (actuator) is located at the air conditioning unit and regulates the opening/closing angle of the
mix door according to the system conditions (ambient, indoor and setting temperature).
11. Heater core
Always hot coolant flows through the heater core and gives off heat before returning to the engine.
12. Battery
The battery supplies the power to the air conditioning system.
13. Air conditioning control switch
The air conditioning switch is located at the driver's seat left side and maintains the proper indoor temperature by
operating the air conditioning unit.
14. Engine
The air compressor is installed to the engine. The engine also provides hot coolant to the heater core. The hydraulic
oil cooler fan draws air through the condenser core which cools the refrigerant.
15. Condenser
Transfers heat to the outdoor air. Located next to the hydraulic oil cooler radiator, using the radiator fan for air
flow.
16. Dual switch
A dual switch is fitted to the high pressure line of receiver drier top side. Its function is to protect the system by
interrupting the power to the compressor's magnetic clutch if the pressure should become too high or too low.
17. Receiver drier
Contains a filter and a desiccant which absorbs any moisture in the system. Also serves as a reservoir for the
refrigerant and is located on the front side of condenser.
18. Compressor
Circulates the refrigerant in the system. Located beside the engine and is driven by V belt from the engine
crankshaft pulley. An electromagnetic clutch on the compressor pulley connects or disconnects the compressor
drive.
19. Electromagnetic clutch
An electromagnetic clutch on the compressor pulley connects or disconnects the compressor drive.
20. Relief valve
The relief valve is located in the rear end plate of the compressor. Its function is to prevent damage in case of
excessive pressure if the high pressure monitor is not functioning. The safety valve opens at 3.5-4.1 MPa (35-41 bar,
508-595 psi) and closes when the pressure has dropped to approx. 2.5 MPa (25 bar, 363 psi). Refrigerant escapes
during the time that the valve is open.
21. Service valve
The service valve is installed into the hose, which is mounted to the compressor. This valve provides a way to check
the pressure and supply refrigerant.
Service Information

Air conditioning switch 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Air conditioning switch
Figure 1
Air conditioning switch
A. Front side
B. Back side
1 Display window 6 Indoor/outdoor selection switch

2 Temperature and display item select switch 7 Fan speed selection switch
3 Trouble check switch 8 Power OFF switch
4 Compressor ON/OFF switch 9 Auto/Manual mode selection switch
5 Air flow selection switch
Connector
Connector 111 (12 pins) Connector 112-1 (16 pins) Connector 112-2 (12 pins)
No Description No Description No Description
1 Compressor ON/OFF 1 - 1 Receiver drier pressure switch
2 Fan speed step 4 2 - 2 Ambient temperature sensor
3 Fan speed step 3 3 Face open 3 Ambient temperature sensor
4 Battery +24 V 4 Left foot1/4 open 4 Start switch (ACC)
5 Actuator +24 V 5 Left foot open 5 Diesel heater timer
6 Relay +24 V 6 Right foot 1/2 open 6 Air mix door position sensor ground
7 Fan speed step 2 7 Indoor air 7 Air mix door position sensor (signal)
8 Fan speed step 1 8 - 8 Water temperature sensor
9 Illumination 9 Face close 9 Incar temperature sensor
10 Ground earth 10 Face 1/2 open 10 Air mix door driver - warm air
11 Battery ground 11 Left foot close 11 Air mix door driver - cool air
12 Actuator ground 12 Left foot 1/2 open 12 Air mix door position sensor (+5 V)
13 Right foot close
14 Right foot open
15 Outdoor air
16 -
Functions of the air conditioning switches
1. Display window
A. Auto mode
The auto mode displays the value of the setting temperature.
When the trouble check switch is pressed and then the temperature & display item selection switch
pressed, the display window shows the value of the ambient and setting temperature, and if the air
conditioning system is faulty the error code value shows repeatedly.
B. Manual mode
The manual mode is used when operator requires.
According to the operation of the temperature and the display item selecting, the switch displays the
value as a C4, C3, C2, C1, H0, H1, H2, H3 and H4.
When the trouble check switch is pressed and then the temperature & display item selection switch
pressed, the display window shows the value of the ambient and setting temperature, and if the air
conditioning system is faulty the error code value shows repeatedly.
C. Emergency mode
This displays when the air conditioning system is faulty.
Fault code
No Error code System check Fault cause

1 E1 Incar temperature sensor Abnomal input
2 E2 Ambient temperature sensor Abnomal input
3 E3 Air mix door position sensor Abnomal input
4 E4 Water temperature sensor Abnomal input
5 E5 Duct temperature sensor Abnomal input
6 E6 Mix driver Abnormal operation of mix actuator
2. Temperature and display item select switch
A. Temperature selection mode
 Auto mode
The setting temperature in cab can control at 16-32 °C (61-90 °F). When setting temperature is
set at 16 °C, temperatue select mode operates to maximum cooling condition (air flow 4 steps,
face door control) and when setting temperature is set at 32 °C (90 °F), temperatue select mode
operates to maximum heating condition (air flow 4 steps, direction - foot).
 Manual mode
C1 to H4 can be adjusted.
- C1 ~ C4: cooling mode - H1 ~ H4: heating mode - H0: intermediate mode
 Emergency mode
1 to 9 can be adjusted.
- 1 ~ 4: cooling mode - 6 ~ 9: heating mode
- 5: intermediate mode
B. Display selection mode

When the trouble check switch is pressed the ambient temperature, setting temperature and error code
are shown repeatedly.
3. Trouble check switch

The switch is used to display the operator’s mode and the service mode. The switch should be pressed at least 5
seconds to shift to the service mode.
4. Compressor ON/OFF switch
This switch is used to turn the compressor ON/OFF, when the power switch is ON.
This switch locates at ON or OFF position automatically in the auto mode.
5. Air flow selection switch
This switch can select the power modes of ventilation.
6. Indoor/outdoor selection switch
Indoor or outdoor air can be selected.
When indoor air, the indicator light is ON.
Indoor air: 90% of indoor air + 10% of outdoor air
Outdoor air: 50% of outdoor air + 50% of indoor air
7. Fan speed selection switch
This switch can select the four fan speed steps.
Auto mode: can be selected automatically.
Manual mode: to be changed by operator.
8. Power OFF switch
This switch is used to turn off the air conditioning unit.
9. Auto / Manual selection switch
 Auto mode
Indicating lamp is "ON".
 Manual mode
Indicating lamp is "OFF".
Service Information

Control system, description 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Control system, description

Auto air conditioning system operation consists of auto mode and manual mode.
When the switch is operated except temperature setting switch and trouble checking switch in auto mode, the control
system transfers to the manual mode.
If the control system is faulty, air conditioning system transfers to the emergency mode automatically.
In the auto mode, control the blower fan speed, compressor operation and all doors control function automatically
according to the system condition.
In manual mode, the blower fan speed and all mix doors are controlled by the individual switches.
Figure 1
Auto air conditioning control system
Temperature setting
Figure 2
Temperature setting
1. Display window
2. Temperature and display selection switch
The setting temperature for the cab can control at 16-32 °C (61-90 °F) at intervals of 1 °C, using a temperature & display
selection switch.
NOTE!
When installed initially, the setting temperature is 25 °C (77 °F).
Initial heating mode
 When diesel heater timer is at ON position and water temperature is over 25 °C (77 °F), the blower 1 step, foot
mode and mix door are set initially the full open position.
The blower step and mode can be changed by the operator.
 This function operates regardless of the engine running.
Air mix door control

Auto mode
 The mix door regulates the opening/closing angle of the mix door according to the system conditions (ambient,
indoor and setting temperature, etc).
Manual mode
See 870 Function of manual air conditioning switch.

Blower fan speed control
Auto mode
The blower motor regulates the blower fan speed according to the system conditions.
Minimum conversion time of an interval of each blower step is 2 seconds.
Manual mode
Manual mode
OFF Step 1 Step 2 Step 3 Step 4

0% 40% 60% 80% 100%
(stop) (max. speed)
 Warm up control
 When the coolant temperature is lower than 25 °C (77 °F), the bower motor does not operate for 150
seconds.
 Limit the maximum step operation
 When the air conditioner is working at heating operation and the difference between the coolant and the
setting temperature is less than 5 °C (41 °F), the air conditioning switch limits the maximum blower step to
2.
 Maximum step operation
 When the setting temperature is set to 16 °C (61 °F) or 32 °C (90 °F), the air conditioning switch set blower
fan speed to 4 step.
Mode door control

Manual mode
Mode door open rate
OFF Face Foot (left) Foot (right)

Face 100% 0% 0%
Bi level 100% 100% 100%
Foot 0% 100% 100%
Defrost 0% 0% 0%
Auto mode
 The change of the face, foot and Bi level mode can be selected according to the ambient, indoor and setting
temperature.
Intake door control

Manual mode
Manual mode
Indoor Outdoor
Indoor circulation 90% 10%
Outdoor inflow 50% 50%
Auto mode
 Heating mode
Inflow outdoor air
 Cooling mode
Indoor circulation mode and outdoor inflow mode are automatically selected according to indoor, outdoor and
setting temperature.
Memory and playback

When the start switch is turned to OFF position, the air conditioning switch memorizes the current air conditioner condition
(indoor, outdoor and setting temperature, mode door condition). When the start switch is turned to ON position, the
controller resets a previous memory state, reading to memory.
Compressor protection
 Auto mode
 This is automatically controlled according to indoor, outdoor and setting temperature.

 If the duct temperature sensor is out of order, the air conditioning switch turns off the compressor clutch.
 Manual mode
 See 870 Function of manual air conditioning switch.
Self diagnosis and system status indication
 The air conditioning switch shows the fault code to the operator via the display window, when checking the air
conditioning system.
 The status display of air conditioning system classifies the operator"s mode and service mode. Press the trouble
check switch above 5 seconds to change to the service mode. (the LED blinks)
Fault code
No Error code System check Fault cause

1 E1 Incar temperature sensor Abnormal input
2 E2 Ambient temperature sensor Abnormal input
3 E3 Air mix driver position sensor Abnormal input
4 E4 Water temperature sensor Abnormal input
5 E5 Duct temperature sensor Abnormal input
6 E6 Air mix driver Abnormal operation of Mix actuator
System status indication item
No Description Identificatio Display Unit Remark

n code
1 Target temperature 25 °C Manual mode: C4 ~ H4
(setting temperature) Emergency mode: 1 ~ 9
2 Ambient temperature A A24 °C
3 Error code E E1 - If no error skip through the items.
4 Water temperature c c27 °C
5 Duct temperature d d10 °C
6 Air mix driver F F60 % 0% (Full close) ~ 99% (Full open)
7 Compressor clutch 1 10/1 - 1: ON, 0: OFF
8 Pressure switch 2 20/1 - 1: ON, 0: OFF
9 Air mix actuator drive direction 3 30/1/2 - 0: Stop, 1: Cold air, 2: Hot air
NOTE!
Items 4 to 9 display in the service mode.
Emergency mode
 When the air conditioning system detect any errors, the system transfers to emergency mode.
NOTE!
The control function of emergency mode is the same as manual air conditioning system.
Service Information

Manual air conditioning, 870 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [GB]
Manual air conditioning, description

The blower fan speed control, mode door control, intake door control and temperature are controlled by the manual
operation of each switch.
Figure 1
Manual air conditioning control system
Service Information

Function of manual air 870 Service Information 2014/5/7 0
conditioning switch
Profile:
EXC, EW180B [GB]
Function of manual air conditioning switch

Initial heating mode
See Auto air conditioning 870 Control system, description.
Compressor and air mix door control
Compressor and air mix door control
Temperature control switch Description Remark

Step 1 Compressor clutch control Less then 1 °C: OFF, more than 6 °C: ON
Step 2 according to the duct Less then 3 °C: OFF, more than 10 °C: ON
temperature
Step 3 Less then 6 °C: OFF, more than 15 °C: ON
Step 4 Less then 9 °C: OFF, more than 17 °C: ON
Step 5 Neutral
Step 6 Air mix door control Air mix door opened 25%
Step 7 Air mix door opened 50%
NOTE!
Compressor clutch controls for over step 5: the same as step 4.
Air mix door controls for under step 5: air mix door is fully closed.
Blower fan speed control

See 870 Control system, description.
Mode door control
Intake door control
Memory and playback
When the start switch is turned to OFF position, the air conditioning switch memorizes the current air conditioning condition
(setting temperature, mode door condition). Again when the start switch is turned to ON position, the controller resets the
previous memory state reading to memory.
Manual air conditioning switch
Figure 1
Switch, air conditioning
1. Air flow selection switch

3. Fan speed select switch
4. Indoor/outdoor select switch
5. Cool and heat temperature control switch
Air flow select switch and compressor ON/OFF switch
 Pressing the air flow selection switch, the upper LED lights and the air direction is selected.
 When the compressor ON/OFF switch is pressed, the upper LED lights. But the cooling system operates only when
the fan speed control switch is operated.
Figure 2
Switch, air flow select and compressor ON/OFF
1. Face
2. Bi level
3. Foot
4. Defrost
Fan speed select switch
Figure 3
Switch, fan speed select
 Pressing the fan speed selection switch, the upper LED lights.
 Heating and cooling system operate only when the fan speed control switch is operated.
 The air conditioning system stops when the OFF switch is pressed.
Temperature control switch
Figure 4
Switch, temperature control
A. Cooling
B. Heating
 Cooling and heating operations are composed of 4 steps respectively.

 By pressing the right or left switch, temperature control moves by 1 step. Two LEDs light to indicate the current
position.
Indoor or outdoor air select switch
Figure 5
Switch, air select
 Indoor or outdoor air can be selected.

 Indoor air: 90% of Indoor air + 10% of outdoor air
 Outdoor air: 50% of outdoor air + 50% of Indoor air
Method of operation
Operation, air conditioning system
Function Air direction Temperature Indoor or outdoor air Fan Compressor

control
Quick cooling Cool 4 step High speed ON
Cooling Cool 1 ~ 3step Lower or ON

medium
speed
Defrost in the Cool 4 step High or ON

summer medium
speed
Defrost in the Heat 2 ~ 3 step medium ON
spring & fall speed
Quick heating Heat 4 step High speed OFF
Heating Heat 2 ~ 3 step medium OFF

speed
Ventilation Neutral Low or OFF

medium
NOTE!
The above chart represents the normal method of operation. Choose the air selection mode according to the ambient
condition.
Service Information

Expansion valve, 870 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [GB]
Expansion valve, description

 The expansion valve regulates refrigerant flow from the receiver drier to the evaporator.
 As the high temperature/high pressure liquid passes through the valve it is restricted and sprayed into the
evaporator side where it changes state and becomes a gas.
 The rapid expansion of the refrigerant can cause moisture to freeze in the valve outlet port.
Figure 1
Expansion valve
1 Diaphragm 8 Spring 15 Body

2 Center disk 9 Housing 16 O-ring
3 O-ring 10 Pad 17 Adjusting screw
4 Spring 11 Stopper A From receiver drier
5 Washer 12 Ring B To evaporator
6 Ball valve 13 O-ring C From evaporator
7 Valve support 14 Shaft D To compressor
Expansion valve, operation

Figure 2
Expansion valve open
A From receiver drier

B To evaporator
C From evaporator
D To compressor
E Orifice
The expansion valve is used to regulate the amount of refrigerant flowing into the evaporator. At this point in this system,
the high pressure/high temperature liquid is sprayed into the evaporator where it changes state and becomes a gas.
When the refrigerant temperature flowing from C to D is high, diaphragm (1) pushes down stem (14) due to high
temperature transmit to diaphragm (1) via stem (14). Ball (6) is moved downward by stem (14) and the refrigerant of port A
flows through orifice (E) to port B.
Figure 3
Expansion valve closed
A From receiver drier

B To evaporator
C From evaporator
D To compressor
E Orifice
When the refrigerant temperature flowing from C to D is low, diaphragm (1) pulls up stem (14) due to low temperature
transmit to diaphragm (1) via stem (14). Ball (6) pushed upward by spring (8) force, blocks orifice (E), and the refrigerant of
port A can not flow to port B.
Service Information

Evaporator, description 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Evaporator, description
 The refrigerant passing through the expansion valve is converted to a low pressure liquid as it is sprayed into the
evaporator.
 The mist flowing through the core tubing evaporates as it absorbs heat from the indoor/outdoor air passing over
the evaporator fins. This process cools and dehumidifies the air, any moisture contained in the air is converted to
water which collects on the fins and is then drained from the evaporator housing.
Figure 1
Evaporator
1. Connection for high pressure hose from receiver drier

2. Connection for low pressure hose to compressor
3. To evaporator
4. From evaporator
5. Expansion valve
Service Information

Compressor, description 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Compressor, description
The compressor is the main working part of the air conditioning unit. It functions as a pump in the system when it draws
vaporized refrigerant from the evaporator and feeds it to the condenser. The compressor has seven cylinders with the
pistons located in a circular array. The pistons work horizontally towards one end of the compressor housing. The piston
motion is transmitted from the drive shaft via a rotating cam, a piston rod plate and piston rods. The pistons rods are
journalled in the pistons and have ball bearings in the piston rod plate. The pistons are made of aluminium and have two
teflon piston rings.
The compressor housing and valve housing are made of aluminium and the pistons operate directly in the compressor
housing.
Figure 1
Structure, compressor
1 AMP econo seal "J" series, Connector (mark II), Cap housing 1P
2 AVX 1.25 (black)
Figure 2
Suction phase
1 Rotating cam 3 Piston rod 5 Outlet valve 7 Piston

2 Piston rod plate 4 Piston ring 6 Inlet valve 8 Oil plug
Figure 3
Pressure phase
The valve plate is made of steel and has drilled channels for the outlet and inlet valves. The valves are of the reed type and
are bolted to the plate. The reed valves are controlled by the suction and pressure action of the pistons.
There is a drive shaft seal in the front end plate. The seal consists of an o-ring, a lip seal and a graphite seal. There is an oil
filler plug on the upper side of the compressor housing.
Service Information

Condenser, description 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Condenser, description
 The condenser mounted in front of the oil cooler, consists of tubes, refrigerant passing through, and cooling fins,
radiating heat rapidly.
 The condenser will condense the refrigerant gas which is under high pressure, high temperature condition into a
high pressure liquid, by cooling it with the air flow from the oil cooler fan.
 Insufficient cooling of the condenser retards the conversion of the high pressure gas into a high pressure liquid, this
causes the circuit pressure to rise which increases the system load and reduces the cooling capacity.
 Therefore, it is very important that the airflow is not obstructed and there is no foreign material on the condenser
fins.
Service Information

Drying filter, description 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Drying filter, description

Receiver drier
 The drier installed between the condenser outlet and evaporator inlet, consists of the body, desiccant, strainer,
filter, sight glass, safety plug and pressure switch.
 The receiver/drier is a reservoir to store excess liquid refrigerant in the system. Excess refrigerant is required for two
reasons: Outdoor air temperature and humidity have an effect on the minimum quantity of refrigerant required in
the system for the air conditioning to operate at maximum efficiency. The higher the temperature and humidity, the
more refrigerant required in the system. More refrigerant is required due to the expansion valve opening farther
allowing more refrigerant into the low pressure side of the system.
 The strainer and filter remove particles caused by component failure, or corrosion due to acids and moisture in the
system.
 The desiccant is used to absorb moisture from the refrigerant. Moisture combined with refrigerant oil forms a
sludge which prevents adequate lubrication. Moisture combined with refrigerant creates hydrofluoric and
hydrochloric acids which are very corrosive to metal surfaces.
NOTE!
Evacuating the system will not remove the moisture from the desiccant. The receiver drier must be replaced.
 The safety plug is designed to protect the system from excessive pressure and temperature. It will release above
105 °C (221°F) or 3.4 MPa (34 bar, 498 psi).
 A sight glass is installed so the condition of the flow of refrigerant can be checked.
Pressure switch
A pressure monitor is fitted to the high pressure side. Its function is to protect the system by interrupting the power to the
compressor's magnetic clutch if the pressure should become too high or too low.
Safety Valve
The safety valve is located in the rear end plate of the compressor or on the high pressure line. Its function is to prevent
damage in case of excessive pressure if the high pressure monitor is not functioning. The safety valve opens at 3.2-4.1 MPa
(32-41 bar, 464-595 psi) and closes when the pressure has dropped to approx. 2.5 MPa (25 bar, 363 psi). Refrigerant escapes
during the time that the valve is open.
Service Information

Refrigerant hoses 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Refrigerant hoses
The refrigerant hoses have an inner tube of polyamide in order to reduce refrigerant leakage from the system.
NOTE!
The polyamide inner tube makes the hoses prone to breakage, see minimum allowed bend radius in the table below.
Each hose has unions with o-rings at the ends, and lengths and dimensions are tailored to the specific location in the unit.
NOTE!
Hoses and O-rings must not be replaced by parts with different rubber quality.
When disconnecting hoses, protective plugs must be fitted immediately on the ends of the hoses and components to
protect the system from any contaminants.
Figure 1
Refrigerant hose with unions
A side B side
1 Hose Compressor Air conditioning unit
2 Hose Receiver drier Air conditioning unit
3 Hose Compressor Condenser
Service Information

Blower motor 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Blower motor
This circulates the air in the cab where indoor and outdoor air is transferred to the cab.
Specification
No-load Load
Rated voltage DC 24 V
Rotational direction Counter clockwise
Current (A) 1.0 ~ 0.8 Less than 5.4
Speed (rpm) More than 4200 More than 3800
Service Information

Ceramic resistor 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Ceramic resistor
This regulates the blower motor fan speed according to the resistance value.
Specification
Operating temperature -38 ~ 80 °C (-36 ~ 176 °F)
Short-circuit time HI ~ LOW HI ~ ML HI ~ MH
Within 240 seconds Within 150 seconds Within 600 seconds
Figure 1
Ceramic resistor
View A View B Circuit diagram

A Terminal "A" L Speed 1 1 4.5 ± 10% Ω
B Terminal "B" ML Speed 2 2 2.1 ± 10% Ω
C Terminal "C" MH Speed 3 3 0.85 ± 10% Ω
D Terminal "D" HI Speed 4 4 Temperature of fuse melting
5 183 ± 7 °C
Service Information

Three point relay 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Three point relay

This is installed at left side of the air conditioning unit, 5 pieces in a row in order number.
Specification
Lamp load 150 W
Resistor load 12.5 A
Motor load 12.5 A
Figure 1
Three point relay
A Fan speed 1 D Fan speed 4

B Fan speed 2 E Compressor ON/OFF relay
C Fan speed 3
Service Information

Actuator, foot/face driver 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Actuator, foot/face driver

This is located in the air conditoner unit and regulates the air flow in the cab.
Specification
Item Specification
Rated load 1.5 Nm (13.3 lbf in)
Rated current Initial 0,1 A or less
Operating time (90°) Initial 2.5 ± 1 sec
Operating torque (at DC 24 V) Initial 6 Nm (53 lbf in)
Lock current Initial 0.55 or less
Stopping angle P1~ P5 Initial 90 ± 1°
Figure 1
Actuator, foot/face driver
1 Fan speed 1 5 Air compressor ON/OFF relay

2 Fan speed 2 A Controller
3 Fan speed 3 B Close
4 Fan speed 4 C Face
Service Information

Actuator, air mix door 870 Service Information 2014/5/7 0
driver
Profile:
EXC, EW180B [GB]
Actuator, air mix door driver

This is located in the air conditoner unit and regulates a proper temperature the cool/warm air.
Specification
Item Specification
Rated load 1.5 Nm (13.3 lbf in)
Rated current Rated 0.1 A less
Operating time Rated, 90° 2.5 ± 1 sec
Operating torque DC 24 V 6 Nm (53 lbf in)
Lock current Rated voltage, lock 0.4 A less
Limit current off point P1 89 ± 2.5°
(at no load, 5V) P2 38 ± 2.5°
PBR (Position) residence Vcc - GND 3 KΩ ± 30%
PBR (Position) output characteristic V1 10 ± 3.5%
V2 90 ± 3.5%
V3 ± 3.5 %
Figure 1
Actuator, air mix door driver
1 Fan speed 1 4 Fan speed 4

2 Fan speed 2 5 Air compressor ON/OFF relay
3 Fan speed 3
Service Information

Water temperature sensor 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Water temperature sensor

The water temperature sensor is installed in heater core. When the coolant temperature is lower than 25 °C (77 °F), the
bower motor does not operate for during 150 seconds.
Specification
Item Specification
Sensor characteristic R25 10 KΩ ± 5%
B (0/50) 3880 ± 2%
Figure 1
Water temperature sensor
R Resistance
T Temperature
Service Information

Duct temperature sensor 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Duct temperature sensor

The duct temperature sensor is installed in the evaporator core at intervals of 5 mm, positioning at 5 mm apart from
evaporator fin.
When the air conditioning a switch is turned to ON position and the blower motor is operated over 1 step, duct temperature
sensor detects the air temperature passed over the evaporator.
When the duct temperature is lower than 1 °C (34 °F), the compressor clutch is shut-off and when the duct temperature is
higher than 6 °C (43 °F), the compressor clutch is energized.
This protects the compressor from overload.
Specification
Sensor characteristic Ro 8 KΩ ± 1%
B (0/50) 3880 ± 2%
Figure 1
Duct temperature sensor
R. Resistance
T. Temperature
Service Information

In-car temperature sensor 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
In-car temperature sensor

This is installed between the driver's seat and right side console box, and transmits a signal to the controller (air conditioning
switch) in order to reach the setting temperature by sensing the indoor temperature.
Specification
Item Specification
Sensor characteristic Ro 2.5 KΩ ± 3%
B (0/50) 3880 ± 2%
Figure 1
In-car temperature sensor
Service Information

Ambient temperature 870 Service Information 2014/5/7 0
sensor
Profile:
EXC, EW180B [GB]
Ambient temperature sensor

This sensor is locked in the battery box, and is transmits a signal to the controller (air conditioning switch) in order to reach
the setting temperature by sensing the outdoor temperature.
Specifications
Item Specifications
Sensor characteristic Ro 2.5 KΩ ± 3%
B (0/50) 3880 ± 2%
Figure 1
Ambient temperature sensor
1 Thermistor R Resistance
2 Terminal T Temperature
Service Information

Receiver drier, changing 870 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Receiver drier, changing

Op nbr
The receiver drier must be changed if the system has been open for a long time without protective plugs, for example, in
case of a hose rupture. Also change receiver drier if you suspect that there is moisture in the system.
WARNING
Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.
1. Empty the refrigerant from the unit,

See 870 Air conditioning unit, refrigerant check and recharging.
2. Disconnect and remove the hoses from the receiver drier.

Use protective plugs.
Figure 1
Receiver drier
3. Fit the new receiver drier.
4. Remove the protective plugs, install new o-rings on the hoses.
5. Remove the protective plugs from the receiver drier, apply oil to all o-rings and connect the hoses.
Tightening torque: 20 Nm (15 lbf·ft)
6. Fill the system with refrigerant.

See 870 Air conditioning unit, refrigerant check and recharging.
Service Information

maintenance
Profile:
EXC, EW180B [GB]
Air conditioning unit, maintenance

Periodic inspection
 If the cooling or heating system are not used for a long time, refer to the periodic maintenance table and perform
the required inspections.
 During the off-season operate the air conditioner 2 ~ 3 times per month for 5 ~ 10 minutes to lubricate the
compressor components.
 In the summer season close the valve installed in the engine block to cut off the flow of coolant to the heater.
Check item
Proper refrigerant handling
Worldwide environmental protection regulations prohibit the discharge of any refrigerant into the atmosphere, and require
that refrigerant be recovered using the approved recovery equipment.
NOTICE
Use correct refrigerant recovery, recycling and charging stations, DO NOT use refrigerant, hoses, fittings,
components or refrigerant oils intended for use with other refrigerants.
Recovery, recycling and charging stations for R134a and other refrigerants MUST NOT be interchanged. Systems containing
other refrigerants use a different oil than systems using R134a. Certain seals are not compatible with both types of
refrigerants.
R12 and R134a refrigerant precautions
WARNING
Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear
goggles, gloves and protective clothing. Repair and refilling of the refrigerant system must only be done by trained
personnel. Contact your authorized Volvo Construction Equipment workshop. If liquid refrigerant contacts eyes or
skin, do not rub the area. Splash large amounts of cool water on affected area. Go to a physician or hospital
immediately for treatment. Do not allow refrigerant to contact open flames or very hot surfaces such as electric
welding arc, electric heating element and lighted smoking materials. Do not heat refrigerant over 52 °C (125 °F) in a
closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant
containers away from heat sources. Store refrigerant in a cool place. do not handle a damp refrigerant container
with your bare hands. Skin may freeze to the container. Wear gloves. If skin freezes to the container, pour cool water
over container to free the skin. Go to a physician or hospital immediately for treatment.
Periodic maintenance table

Periodic maintenance items
Component Check item Check period

Compressor Operating condition 12 month
Condenser Condenser Contamination 6 month
Motor Operating condition 6 month
Evaporator Contamination 12 month
Refrigerant (R-134a) Charging capacity 6 month
Idler pulley Operating condition 12 month
V-belt Looseness, damage, aging 6 month
Tube Hose Aging 12 month
Tube connection Damage 6 month
Attached parts Leakage, looseness, contacting damage 6 month
Heater core Contamination 12 month
Blower motor Operating condition 12 month
Heater valve Leakage, operating condition 12 month
Outdoor filter Contamination 6 month
Indoor filter Contamination 6 month
Check method
Check for gas leakage on refrigerant hose joint.
 When oil is found on the pipe joint, gas leakage could be occurring.
 Check the union and tighten to the proper torque.
Check the tension of V-belt for driving compressor.
Figure 1
Check, belt looseness
A. Compressor
B. Crank pulley
 Check the belt for looseness by pressing with your fingers. When a force of approximately 10 kg is applied to the
belt center, allowable limit is 8 ~ 10 mm. After about 40 hours, recheck the belt tension.
Check the compressor.
 After operating air conditioner for 5 ~ 10 minutes, check the high pressure pipe and low pressure pipe by hand. In
normal condition the high pressure pipe is hot and low pressure is cold.
Check the condenser.
 When the condenser is contaminated, the radiating efficiency is lowered significantly. Clean the condenser to
improve cooling.
NOTICE
DO NOT use steam to clean the condenser core. The refrigerant can overheat! When cleaning with water, protect the
electrical components.
Service Information

refrigerant check and
recharging
Profile:
EXC, EW180B [GB]
Air conditioning unit, refrigerant check and recharging

WARNING
DO NOT disassemble the compressor relief valve. The refrigerant in the circuit is rapidly ejected and may cause
injury.
Special tools
Figure 1
Tools for refrigerant charging
1. Quick coupler
2. Low pressure hose
3. Gauge manifold
4. High pressure hose
5. Quick coupler
6. Center filler hose
Quick coupler connecting method

Figure 2
Quick coupling, connection
 Remove the filler valve cap.

 Insert the quick coupler onto the filler valve, and press firmly sleeve (A) until a click sound is heard.
NOTE!
When connecting, take care not to bend pipes.
Quick coupler disconnecting method
Figure 3
Quick coupling, disconnection
Hold body (A) of quick coupler and lift sleeve (B).

After removing the quick coupler, install the filler valve cap.
Pressure check procedure
 Close both the low and high pressure valves on the gauge manifold.
 Connect the appropriate quick coupler of the gauge set to the low (suction) pressure and high (discharge) pressure
side of the compressor.
 Connect the center filler hose to the refrigerant canister.
 Open (1/2 turn) and close each pressure valve to release the air from the hoses and gauge set.
 Start the engine and idle at approx. 1500 rpm for about 10 minutes to stabilize the system.
 Turn on the air conditioning switch and select the temperature selection switch to maximum cooling at maximum
fan speed.
 Open all system vents for maximum air distribution.
 After 5 minutes, read the gauge dial.
 After checking, stop the engine, and then remove the gauge set.
Troubleshooting by gauge measured value

Operating condition
 Vents: Open all duct vents.

 Indoor, outdoor selection: Indoor circulating
 Fan speed: The highest speed
 Temperature: Maximum cooling
 Ambient temperature at air conditioning intake port: 30-35 °C (86-95 °F).
NOTE!
The pressure valve may change according to the ambient temperature.
Abnormal pressure gauge readings, causes

NOTE!
The pressure gauge valve must be completely closed, that is, fully turned in.
Figure 4
Reading pressure gauge
Pressure reading Possible causes
 Low pressure gauge (blue), low 1. Defective thermostat

 High pressure gauge (red), normal 2. Moisture in system
3. Expansion valve closed if low pressure gauge shows negative
pressure
Figure 5
 Low pressure gauge (blue), high 1. Expansion valve not working

 High pressure gauge (red), normal 2. Compressor not working
Figure 6
 Low pressure gauge (blue), high 1. Compressor valve not working

 High pressure gauge (red), low 2. Compressor not working
Figure 7
 Low pressure gauge (blue), normal 1. Air in system or too much refrigerant
 High pressure gauge (red), high 2. Condenser air passage clogged
3. Too much oil in system
Figure 8
 Low pressure gauge (blue), high 1. Compressor clutch air passages closed
 High pressure gauge (red), high 2. System overfilled with refrigerant
3. Condenser fan not working
Figure 9
 Low (blue) and high pressure 1. Compressor clutch not working

gauge (red) show the same 2. Compressor not working
pressure 3. Electrical malfunction, breaker or pressure switch not working
Troubleshooting (for ambient temperature 30-35 °C (86-95 °F) at air con intake port)
Troubleshooting
Refrigerant Pressure Phenomenon Cause Check, Repair

Mpa (bar, psi)
Low High
Normal 0.15-0.25 1.37-1.57 - - -
(1.5- 2.5, (14-16,
218-363) 2031-2320)
Low 0.05-0.1 0.69-0.98 High/low pressure are low. Refrigerant is low Check and repair the
(0.5-1.0, (7-10, Bubbles pass continuously in and has leaked. refrigerant leak.
7.3-14.5) 100-142) sight glass. Fill with refrigerant.
Air conditioning outlet air is not
cold.
Refrigerant is 0- (–) 0.5-0.6 If clogged completely, low Air conditioning Check and replace
not circulated. (5-6, pressure is indicated refrigerant circuit receiver drier and
73-87) immediately to (–). is clogged. expansion valve, etc.
If clogged a little, low pressure
is indicated slowly to (–).
Moisture is 0- (–) 0.69-0.98 Start up operation is normal, Expansion valve is Check expansion
mixed into (7-10, and after a while, low pressure frozen moisture valve.
refrigerant 100-142) drops to (–). mixed. Replace receiver
circuit. drier.
Low 0.4-0.6 0.69-0.98 Low pressure is higher than Faulty compressor Check and replace
compression of (4-6, (7-10, normal. compressor.
compressor. 58-87) 100-142) If air conditioner is turned off, (When compression
immediately High/Low pressure is poor, the outside is
are the same. not hot to touch).
Excessive 0.25-0.35 1.96 - 2.45 High/low pressure are high, Excessive Check the amount of
refrigerant. (2.5-3.5, (20-25, simultaneously. refrigerant. refrigerant.
36.6-50.8) 284-355) Engine rpm is lowered, but Poor cooling of Check and correct the
bubbles on sight glass are not condenser. cooling fin of
visible. condenser.
Air is mixed 0.25-0.3 1.96-2.45 High/low pressure are high, Air is mixed. Refill with refrigerant.
into circuit. (2.5-3.0, (20-25, simultaneously.
36.3-43.5) 284-355) High/low pressure pipes are
warm.
A lot of bubbles in sight glass
are visible.
Excessive 0.3-0.4 1.96-2.45 High/low pressure are high, Faulty expansion Check expansion
opening of (3-4, (20-25, simultaneously. valve. valve.
expansion 43.5-58) 284-355) Frost on low pressure pipe is Check the mounting
valve. visible. of heat sensing tube
and bulb.
Replace
expansion valve.
Refrigerant fill procedure
NOTICE
Use only refrigerant (R134a). Do not use any other refrigerant. Use the correct refrigerant pressure measuring gauge
set. Do not use any other refrigerant pressure gauges.
Special tools
Gauge set, vacuum pump, refrigerant.
Figure 10
Tools for refrigerant filling
1. Quick coupler
2. Vacuum pump
3. Filler hose
4. Refrigerant service canisters
Refrigerant draining
 To drain the refrigerant, connect the gauge set with the valves closed to the compressor lines and the center filler
hose to the service canisters.
 Open the valve at the service canister, then open the manifold valve for the low pressure side, and if the high
pressure side gauge reads below 0.3 MPa (3 bar, 43.5 psi), open the high pressure side valve to drain both circuits
simultaneously.
 When the manifold gauges read 0 MPa pressure, close both manifold valves and the service canister valve.
Evacuating
 Connect the center filler hose to the vacuum pump.

 Open both high/low manifold valves and start the vacuum pump.
 Evacuate the system until the low pressure side reads 710 mmHg vacuum, then close both manifold valves and stop
the vacuum pump.
 If the vacuum decreases more than 25 mmHg in 5 minutes, there is a leak in the system. Repair the leak and re-
evacuate the system.
 If there is no change in the vacuum reading, restart the vacuum pump and continue evacuating until the gauge
registers 760 mmHg.
 Close both the high/low manifold valves and stop the vacuum pump.
Refrigerant filling
 After removing the vacuum pump, connect the center filler hose to the service canister.
 First open the high pressure side valve, and the refrigerant will automatically fill to the pipes.
 If the filling rate is slow, close the high pressure side valve and leave for 5 ~ 10 minutes, and check for possible gas
leakage. After repairs continue the recharging cycle.
 Add refrigerant until the system is charged with the correct amount and close the manifold high pressure valve.
 Start the engine, and idle at 1000 ~ 1500 rpm.
WARNING
Do not open the high pressure side valve during the air conditioner running. At this time, reverse flow phenomenon
of refrigerant may occur.
 Open the low pressure side valve to fully fill the refrigerant system.
 If the refrigerant is fully filled, close the low pressure side valve.
 Observe the refrigerant flow in the sight glass, check the pressure and inspect for leakage.
 Stop the engine and remove the gauge set from the compressor.
 Install with the filler valve cap.
Service Information

Electrical circuit, air 870 Service Information 2014/5/7 0
conditioner/heater
Profile:
EXC, EW180B [GB]
Electrical circuit, air conditioner/heater
Figure 1
45 Diesel heater timer 50b Face actuator 50j Compressor relay

46 Relay 50c Foot actuator, left 50k Relay, blower motor speed
47 Diesel heater 50d Foot actuator, right 51 Ambient temperature sensor
47a Water pump 50e Mix actuator, left 52 In-car temperature sensor
48 Fuel pump 50f Duct temperature sensor 53 Pressure switch
49 Air conditioning switch 50g Water temperature sensor 54 Compressor, electromagnetic clutch
50 Air conditioning unit 50h Resistor
50a Intake actuator 50i Blower motor
Service Information

Heating system, 873 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [GB]
Heating system, description

With the engine running, the heat is transmitted to the heater core via the hot coolant circulating between the engine block
and heater core. The blower motor transfers heat from the heater core by moving the indoor/outdoor air through the heater
core transferring it to the cab.
The air mix door is installed in the air conditioning unit in order to regulate the indoor temperature according to the setting
temperature.
Figure 1
Heating unit, principle illustration
1 Blower motor 6 Mix door lever 11 Outdoor air

2 Foot 7 Face door actuator 12 Intake door actuator
3 Heater hose 8 Mix door actuator 13 Hot water port (to heater)
4 Heater hose 9 Face 14 Cool water port (from heater)
5 Heater core 10 Indoor air
Service Information

Heater fan, changing 873 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Heater fan, changing

Op nbr 873-03
1. Turn off the voltage with the battery disconnector.
2. Move the operator's seat to the front position. Fold the backrest forward.
3. Remove the cover over the cab filter.

Remove the plastic casing over the cab fan.
Remove the wall.
Figure 1
Plastic casing, behind operator's seat
1. Cover over cab filter

2. Plastic casing over cab fan
3. Wall
4. Remove the bolts and remove the cross stay.

Figure 2
Cab behind operator's seat
1. Bolts
2. Cross stay
5. Disconnect the cabling and remove the plastic casings.
Figure 3
Fan unit, casing
1. Plastic casing
2. Plastic casing
3. Cabling
6. Remove the air filter over the fan motor.
Figure 4
Fan unit, air filter
1. Air filter
7. Remove the plastic casings over the fan motor.

Figure 5
Fan unit, fan casing
1. Fan casing
8. Unplug the connector and remove the fan motor.
Figure 6
Fan motor
1. Connector
2. Fan motor
9. Fit the fan motor and plug in the connector.
Figure 7
Fan motor
1. Connector
2. Fan motor
10. Fit the plastic casings over the fan motor.
Figure 8
Fan unit, fan casing
1. Fan casing
11. Fit the air filter over the fan motor.
Figure 9
Fan unit, air filter
1. Air filter
12. Fit the plastic casings and fit the cabling.

Figure 10
Fan unit, casing
1. Plastic casing
2. Plastic casing
3. Cabling
13. Fit the cross stay an install the bolts.
Figure 11
1. Bolts
2. Cross stay
14. Fit the wall.

Fit the plastic casing over the cab fan.
Fit the cover over the cab filter.
Figure 12
Plastic cover, behind operator's seat
1. Cover over cab filter

2. Plastic casing over cab fan
3. Wall
15. Return the operator's seat to the position it was in before work was started.
Service Information

Heating coil, removal 873 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Heating coil, removal

Op nbr 8732-01
1. Park the machine in the service position.
2. Turn off the electric power with the battery disconnector.
3. Open the radiator cap and release any high pressure.
4. Remove the bolts 1 and remove the plastic casing 2.

Remove the bolts 3 and the plastic casing 4.
Figure 1
1. Bolts
2. Plastic casing
3. Bolts
4. Plastic casing
5. Remove the bolts 1 and 2. Remove the wall 3.

Figure 2
Wall behind operator's seat
1. Bolts
2. Bolts
3. Wall
6. Remove the bolts 1 for the belt.
Figure 3
Bolts for belt
1. Bolts for belt
7. Unplug the cabling for seat heating.
8. Remove the rear attaching bolts 1 for the operator's seat.
Figure 4
Rear attaching bolts for operator's seat
1. Attaching bolts
9. Move back the operator's seat, both upper and lower part.
10. Remove the front attaching bolts for the operator's seat (2 pcs.).
11. Remove the wire 1 for the lower part.

NOTE!
Mark up how the wire is adjusted.
Figure 5
Underside operator's seat
1. Wire for adjusting position of lower part of operator's seat
12. Lift out the operator's seat.

NOTE!
Heavy and awkward lift. Weight approx. 30 kg.
13. Remove the bolts 1 and remove the cross stay 2.
Figure 6
1. Bolts
2. Cross stay
14. Disconnect the cabling 3 and remove the plastic casings 1 and 2.
Remove the filter over the fan.
Figure 7
Fan unit
1. Casing
2. Casing
3. Cabling
15. Remove the fan casing's attaching bolts 1 (6 pcs.) and remove the relays 2. Unplug the connector 3 for the fan
motor.
Figure 8
Fan casing
1. Attaching bolts
2. Relays
3. Connector
16. Remove the hose clamps 1 and 2 and remove the attaching bolts 3. Disconnect the cabling 4. Remove the pipe
sleeve 5.
Figure 9
Heater unit
1. Hose clamp
2. Hose clamp
3. Attaching bolts
4. Cabling
5. Pipe sleeve
17. Mark up and disconnect the cable harnesses from the casing over the heating coil.
18. Remove the attaching bolts for the casing over the heating coil.
Figure 10
Casing over heating coil
19. Loosen the lock 1 and disconnect the stay 2 for the heater shutter.
Figure 11
Stay for heater shutter
1. Lock
2. Stay
20. Lift away the casing over the heating coil.

NOTE!
Do not damage the stay for the heater shutter.
21. Clamp shut hoses 1 and 2 with welding pliers and loosen the hoses. Disconnect the cabling 3.
Figure 12
Heating coil
1. Hose
2. Hose
3. Cabling
22. Lift out the heating coil.
Service Information

Heating coil, installation 873 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Heating coil, installation

Op nbr 8732-02
1. Lift in the heating coil.
2. Fit hoses 1 and 2 and loosen the welding pliers. Fit the cabling 3.
Figure 1
Heating coil
1. Hose
2. Hose
3. Cabling
3. Lift the casing into place over the heating coil.

NOTE!
Do not damage the stay for the heater shutter.
4. Fit the cross stay 2 for the heater shutter and lock the lock 1.
Figure 2
Stay for heater shutter
1. Lock
2. Stay
5. Fit the attaching bolts for the casing over the heating coil.
Figure 3
Casing over heating coil
6. Fit the cable harnesses on the casing over the heating coil.
7. Fit the pipe sleeve 5 and fit the hose clamps 1 and 2. Fit the attaching bolts 3 and fit the cabling 4.
Figure 4
Heater unit
1. Hose clamp
2. Hose clamp
3. Attaching bolts
4. Cabling
5. Pipe sleeve
8. Fit the fan casing's attaching bolts 1 (6 pcs.) and fit the relays 2. Plug in the connector 3 for the fan motor.
Figure 5
Fan casing
1. Attaching bolts
2. Relays
3. Connector
9. Fit the filter over the fan.

Fit the plastic casings 1 and 2 and fit the cabling 3.
Figure 6
Fan unit
1. Casing
2. Casing
3. Cabling
10. Fit the cross stay 2 and fit the bolts 1.
Figure 7
1. Bolts
2. Cross stay
11. Lift in the operator's seat.

NOTE!
Heavy and awkward lift. Weight approx. 30 kg.
12. Fit the wire 1 for the lower part.
Figure 8
Underside operator's seat
1. Wire for adjusting position of lower part of operator's seat
13. Fit the front attaching bolts for the operator's seat (2 pcs.).
14. Move the operator's seat forward.
15. Fit the rear attaching bolts 1 for the operator's seat.
Figure 9
Rear attaching bolts for operator's seat
1. Attaching bolts
16. Plug in the cabling for seat heating.
17. Fit the bolts 1 for the belt.

Figure 10
Bolts for belt
1. Bolts for belt
18. Fit the wall 3 and fit the bolts 1 and 2.
Figure 11
Wall behind operator's seat
1. Bolts
2. Bolts
3. Wall
19. Fit the plastic casing 4 and the bolts 3.

Fit the plastic casing 2 and fit the bolts 1.
Figure 12
1. Bolts
2. Plastic casing
3. Bolts
4. Plastic casing
20. Run the engine until it is warm and check the coolant level. Top up if needed.
Service Information

Diesel coolant heater 875 Service Information 2014/5/7 0
(5kw), description
Profile:
EXC, EW140B, EW160B, EW180B [GB]
Diesel coolant heater (5kw), description

The diesel coolant heater is used for heating the engine coolant by a fuel combustion unit while the engine is stopped. It
consists of the fuel pump, the water pump, the timer and the heating unit. The heating unit has the control unit, the electric
motor, the glow plugs, the fuses and the sensors in it.
The heated coolant is circulated through the engine block ⇒ the diesel coolant heater ⇒ the air conditioner heating core ⇒
the engine block.
The diesel coolant heater facilitates the engine start and heating the cab in severe cold weather.
Diesel coolant heater, related components
Figure 1
Diesel coolant heater, component
1 Fuel pump 6 Water inlet 11 Fuel inlet from fuel pump
2 Heater 7 Water outlet (to air conditioner heater line) 12 Air suction
3 Water pump 8 Exhaust gas outlet 13 Heater hose (from engine)
4 Timer 9 Fuel suction from fuel tank 14 Heater hose (to engine)
5 Muffler 10 Fuel supply to diesel heater 15 Fuel line
NOTE!
The above illustration explains the case of EC460B. Regarding the ports for heater supply and return, please see Section 2
Engine.
Diesel coolant heater operation

Switching on
The pilot in the operating element (timer module, switch, etc.) comes on when the diesel heater is switched on. The water
pump starts up, and after a defined pre-rinsing and pre-glow program has been completed the combustion air blower, glow
plug and metering pump come on. Once a flame has been detected and the combustion process has stabilized, a time
control switches the glow plug off.
Heating mode
Depending on heater demand, the diesel coolant heater alternates between "HIGH" and "LOW" settings. The temperature
thresholds are permanently programmed in the electronic control unit. If the heat demand in the "LOW" setting is so low
that the cooling water reaches a temperature of 85 °C (185 °F), the heater switches to the "OFF" setting, then continues to
run for about 130 seconds. The pilot lamp is also lit while the heater is in the "OFF" setting, and the water pump continues to
run until the heater is restarted.
Switching off
When the heater is switched off, the pilot light goes out and fuel feed is shut off. Also the glow plug is switched on for 20
seconds. The combustion air blower and the water pump run on after the heater is switched off for 120 seconds and are
then switched off automatically.
Diagnosis
If the control unit detects a fault at start-up of the diesel heater or while the diesel coolant heater is in operation, it is
indicated on the timer module display within 15 seconds in the form of a fault code (F + 2 digit number).
Safety devices
The flame is monitored by the flame sensor and the maximum permissible temperature by the overheat sensor. Both
influence the control unit, when shuts down the diesel coolant heater in the event of faults.
 If the diesel coolant heater does not ignite within 90 seconds after the start of fuel feed, start-up is repeated. If the
diesel coolant heater does not ignite repeatedly within 90 seconds after the start of fuel feed, a fault shutdown
takes place.
 If the flame goes out by itself while the heater is in operation, a restart is initially carried out. If the diesel coolant
heater does not ignite within 90 seconds after the start of fuel feed, or if it ignites but goes out again, a fault
shutdown takes place. The fault shutdown can be cancelled by briefly switching the heater off and on again.
 In the event of overheat (e. g. shortage of water, poorly ventilated coolant circulation system), the overheat sensor
is tripped, fuel feed is shut off, then a fault shutdown is activated. Once the cause of the overheat has been
eliminated, the diesel coolant heater can be restarted by switching it off and on again (prerequisite: the diesel
coolant heater has cooled down sufficiently).
 If the voltage drops below approximately 10 Volts or 20 Volts or rises above 15 Volts or 30 Volts, a delayed fault
shutdown is activated.
 If the glow plug is defective or an electrical lead running to the metering unit is broken, the diesel coolant heater
does not start.
 The blow motor speed is monitored continuously. If the blower motor does not start or becomes blocked, a fault
NOTE!
 The diesel coolant heater must not be operated in garage.

 When performing electric welding work on the vehicle, disconnect the plus terminal of the battery and connect to
GND in order to protect the control unit.
 Also switched on the diesel coolant heater briefly for approximately 10 seconds once a month outside the heating
period in order to prevent the water pump and burner motor seizing up.
 Before switching on or pre-programming the heating mode, move the heating lever of the vehicle to the
"WARM" (maximum) setting and the blower to the "slow setting" (low power consumption).
Service Information

Diesel heater, description 875 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Diesel heater, description

The diesel heater is used for heating the engine coolant by a fuel combustion unit while the engine is stopped. It consists of
the fuel pump, the water pump, the timer and the heating unit. The heating unit has the control unit, the electric motor, the
glow plugs, the fuses and the sensors in it.
The heated coolant is circulated through the engine block ⇒ the diesel heater ⇒ the air conditioner heating core ⇒ the
engine block.
The diesel heater facilitates the engine start and heating the cab in severe cold weather.
Diesel heater, related components
Figure 1
Diesel heater, component
1 Fuel pump 6 Water inlet 11 Fuel inlet from fuel pump
2 Heater 7 Water outlet (to air conditioner heater line) 12 Air suction
3 Water pump 8 Exhaust gas outlet 13 Heater hose (from engine)
4 Timer 9 Fuel suction from fuel tank 14 Heater hose (to engine)
5 Muffler 10 Fuel supply to diesel heater 15 Fuel line
NOTE!
The above illustration explains the case of EC460B. Regarding the ports for heater supply and return, please see Section 2
Engine.
Diesel heater operation

Switching on
The pilot in the operating element (timer module, switch, etc.) comes on when the diesel heater is switched on. The water
pump starts up, and after a defined pre-rinsing and pre-glow program has been completed the combustion air blower, glow
plug and metering pump come on. Once a flame has been detected and the combustion process has stabilized, a time
control switches the glow plug off.
Heating mode
Depending on heater demand, the diesel heater alternates between "HIGH" and "LOW" settings. The temperature thresholds
are permanently programmed in the electronic control unit. If the heat demand in the "LOW" setting is so low that the
cooling water reaches a temperature of 85 °C (185 °F), the heater switches to the "OFF" setting, then continues to run for
about 130 seconds. The pilot lamp is also lit while the heater is in the "OFF" setting, and the water pump continues to run
until the heater is restarted.
Switching off
When the heater is switched off, the pilot light goes out and fuel feed is shut off. Also the glow plug is switched on for 20
seconds. The combustion air blower and the water pump run on after the heater is switched off for 120 seconds and are
then switched off automatically.
Diagnosis
If the control unit detects a fault at start-up of the diesel heater or while the diesel heater is in operation, it is indicated on
the timer module display within 15 seconds in the form of a fault code (F + 2 digit number).
Safety devices
The flame is monitored by the flame sensor and the max. permissible temperature by the overheat sensor. Both influence
the control unit, when shuts down the diesel heater in the event of faults.
 If the diesel heater does not ignite within 90 seconds after the start of fuel feed, start-up is repeated. If the diesel
heater does not ignite repeatedly within 90 seconds after the start of fuel feed, a fault shutdown takes place.
 If the flame goes out by itself while the heater is in operation, a restart is initially carried out. If the diesel heater
does not ignite within 90 seconds after the start of fuel feed, or if it ignites but goes out again, a fault shutdown
takes place. The fault shutdown can be cancelled by briefly switching the heater off and on again.
 In the event of overheat (e. g. shortage of water, poorly ventilated coolant circulation system), the overheat sensor
is tripped, fuel feed is shut off, then a fault shutdown is activated. Once the cause of the overheat has been
eliminated, the diesel heat can be restarted by switching it off and on again (prerequisite: the diesel heater has
cooled down sufficiently).
 If the voltage drops below approximately 10 Volts or 20 Volts or rises above 15 Volts or 30 Volts, a delayed fault
 If the glow plug is defective or an electrical lead running to the metering unit is broken, the diesel heater does not
start.
 The blow motor speed is monitored continuously. If the blower motor does not start or becomes blocked, a fault
NOTE!
 The diesel heater must not be operated in garage.

 When performing electric welding work on the vehicle, disconnect the plus terminal of the battery and connect to
GND in order to protect the control unit.
 Also switched on the diesel heater briefly for approximately 10 seconds once a month outside the heating period in
order to prevent the water pump and burner motor seizing up.
 Before switching on or pre-programming the heating mode, move the heating lever of the vehicle to the
"WARM" (maximum) setting and the blower to the "slow setting" (low power consumption).
Service Information

Diesel heater, principles 875 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Diesel heater, principles
Figure 1
Diesel heater, structure
1 Timer 10 Interface / 8 pins plug A From engine

2 Water pump 11 Control unit B To heat exchanger
3 From relay and fuse 12 Electric motor C Water inlet
4 Earth 13 Combustion air hose D Fuel
5 Combustion air blower 14 Flame sensor E Exhaust gas
6 Combustion chamber 15 Glow plug F Combustion air
7 Temperature sensor 16 Fuel pump
8 Overheat sensor 17 Exhaust pipe with silencer
9 Heat exchanger
Timer
The timer controls the diesel heater, and displays the operating status. The functions the timer displays current date, current
time and operating time. It also controls the manual operation, the reserved operation and the ON/OFF function of the
diesel heater.
Figure 2
Timer
A Front side B Rear side

1 Symbol for remote control 5 Temperature display 9 Heating ON / OFF switch
2 Memory indicator 6 Heating indicator 10 Backward switch
3 Program day 7 Time adjusting switch 11 Forward switch
4 Current time / program time 8 Program switch
Fuel pump
The fuel pump supplys the diesel heater with the fuel from the tank.
Figure 3
Fuel pump
A. From fuel tank

B. To diesel heater
Water pump
The water pump is located between the diesel heater and the engine block, and supplys the diesel heater with the coolant
from the engine block.
Figure 4
Water pump
A. From engine block

B. To diesel heater
Heating unit
The heating unit raises the temperature of the coolant using the fuel combustion unit, consists of the glow plug, the
thermostats, the flame sensor, the controller, the electric motor and the fuse. The case of the unit has the fuel supplying
port, the coolant inlet/outlet port, the air inlet port and the exhaust port.
Figure 5
Heating unit
Connector - D
No Color Remark
A Fuel inlet 1 Red B+
B Water outlet 2 Brown GND
C Water inlet 3 Red / Black Air conditioning fan "ON"
D Connector 4 Green Fuel pump
E Air inlet 5 Blue / White
F Exhaust 6 Blue
G Case 7 Yellow Timer "ON"
8 Black / White
Service Information

Electrical circuit, air 875 Service Information 2014/5/7 0
conditioner/heater
Profile:
EXC, EW160B, EW180B [GB]
Figure 1
45 Diesel heater timer 50b Face actuator 50j Compressor relay

46 Relay 50c Foot actuator, left 50k Relay, blower motor speed
47 Diesel heater 50d Foot actuator, right 51 Ambient temperature sensor
47a Water pump 50e Mix actuator, left 52 In-car temperature sensor
48 Fuel pump 50f Duct temperature sensor 53 Pressure switch
49 Air conditioning switch 50g Water temperature sensor 54 Compressor, electromagnetic clutch
50 Air conditioning unit 50h Resistor
50a Intake actuator 50i Blower motor
Many thanks for your purchase.
Happy every day.
file:///C|/Users/yeqiwen/Documents/QIWEN-YE-END.txt[2014/5/7 22:07:30]

VOLVO EW160B-8 Machinery House, Cab, Exterior Trim Parts Anywhere

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Service Information

Document Title: Function Group: Information Type: Date:

Superstructure covering, description

Document Title: Function Group: Information Type: Date:

Lifting eyes 2 pcs. (M12)

1. Turn off the voltage with the battery disconnector.

2. Remove the floor mat.

3. Remove the operator's seat, see 852 Operator's seat, removal.

Loosen the washer hose in the joint below the VECU.

8. Remove the intermediate wall behind the operator's seat.

9. Loosen the washer fluid reservoir and lay it to the side.

13. Lift off the cab.

Document Title: Function Group: Information Type: Date:

Lifting eyes 2 pcs. (M12)

1. Carefully lift the cab into place.

3. Remove the lifting eyes from the cab roof.

5. Fit the washer fluid reservoir.

6. Fit the intermediate wall behind the operator's seat.

7. Fit the radio panel.

Fit the washer hose in the joint below the VECU.

12. Refit the floor mat.

13. Turn on the voltage with the battery disconnector.

Document Title: Function Group: Information Type: Date:

Cab door, removal of door catch

1. Remove the operator's seat, see 852 Operator's seat, removal.

2. Remove the plastic casing with the radio part.

5. Remove the bolts on the door catch.

Document Title: Function Group: Information Type: Date:

Cab door, installation of door catch

2. Fit the wire with the pin and the screw.

4. Fit the plastic casing with the radio part.

5. Fit the operator's seat, see 852 Operator's seat, installation.

Document Title: Function Group: Information Type: Date:

Window pane, replacement

Sika Primer 206G+P (recommended)

Sika Tack Drive

Sikaflex Remover 208 (recommended)

2. Cut out the window pane with a cutting wire or a knife.

3. Remove the window pane using a suction cup holder.

Document Title: Function Group: Information Type: Date:

Window pane with locking strip, replacing

14211207 Installation tool

2. Install the new rubber moulding.

3. Install the new window pane.

Document Title: Function Group: Information Type: Date:

Upper windshield, removing

1. Make sure that the windscreen wiper is hooked in the support.

3. Release the catches (2 pcs.) at the upper corners of the windscreen.

7. Lift away the windscreen through the cab entrance.

8. Remove the windscreen according to 843 Window pane, replacement.

Document Title: Function Group: Information Type: Date:

Upper windshield, installing

1. Install the windscreen according to 843 Window pane, replacement.

2. Lift in the windscreen through the cab entrance.

4. Remove the cable tie and fit the plastic cap.

Document Title: Function Group: Information Type: Date:

Operator's seat, removal

1. Move the operator's seat to the front position.

2. Remove the bolts 1 for the belt.

1. Bolts for belt

3. Unplug the cabling for seat heating.

4. Remove the bolts 1 behind the operator's seat.

5. Remove the front attaching bolts.

1. Wire for position adjustment, lower part