Komatsu PW160-7E0 Hydraulic Excavator Service Repair Shop Manual (H55051 and up) - VEBM395100
Komatsu PW160-7E0 Hydraulic Excavator Service Repair Shop Manual (H55051 and up) - VEBM395100
This Complete Service Repair Workshop Manual PDF Download for the PW160-7E0 Komatsu Hydraulic Excavator (S/N: H55051 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu PW160-7E0 - S/N: H55051 and up
TABLE OF CONTENTS :
01 GENERAL 10 STRUCTURE, FUNCTION AND 20 TESTING AND ADJUSTING 30 DISASSEMBLY AND ASSEMBLY 90 OTHERS
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Product Code : VEBM395100 Total Pages : 1140
This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
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VEBM395100 PW160-7E0
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE GENERAL PRECAUTIONS PRECAUTIONS DURING WORK
01 GENERAL SPECIFICATION DIMENSION DRAWINGS DIMENSIONS 1 pIECE BOOM WORKING RANGES 1 PIECE BOOM 2 PIECE BOOM SPECIFICATIONS WEIGHT TABLE 1 piece boom 2 piece boom FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE, FUNCTION AND ENGINE RELATED PARTS RADIATOR . OIL COOLER . CHARGE AIR COOLER POWER TRAIN SWING CIRCLE SWING MACHINERY & MOTOR SWING MOTOR Operation of swing lock RELIEF VALVE PORTION Operation UNDERCARRIAGE TRANSMISSION ATT EPC VALVE ASSEMBLY QUICK COUPLER CONTROL VALVE TRAVEL MOTOR OPERATION OF TRAVEL MOTOR CLUTCH CONTROL CIRCUIT AXLE SUSPENSION LOCK CYLINDER BRAKING SYSTEM BRAKE/STEER PUMP PRIORITY VALVE POWER BRAKE VALVE SPECIFICATIONS FUNCTION ACCUMULATOR for brake system STEERING SYSTEM STEERING COLUMN ORBITROL VALVE HYDRAULIC EQUIPMENT LAYOUT DRAWINGS HYDRAULIC CIRCUIT DIAGRAM HYDRAULIC TANK HYDRAULIC PUMP HPV125 LS VALVE PC VALVE LS(pc)-EPC VALVE PILOT PRESSURE CONTROL (PPC) SYSTEM CONTROL VALVE PW160-7E0 CLSS OUTLINE OF CLSS CENTre SWIVEL JOINT TRAVEL PPC PEDAL WORK EQUIPMENT . SWING PPC VALVE SOLENOID VALVE MANIFOLD SOLENOID VALVE BLOCK 2 Position 3 way valve 2 Position 4 way valve attachment epc valve BOOM SAFETY VALVE HYDRAULIC CYLINDER BOOM CYLINDER ARM CYLINDER BUCKET CYLINDER ADJUST CYLINDER OUTRIGGER CYLINDER DOZER CYLINDER WORK EQUIPMENT Work Equipment 1. DIMENSION OF ARM 2. Dimension of bucket AIR CONDITIONER air conditioner piping ELECTRICAL WIRING DIAGRAM ELECTRICAL SYSTEM Engine Control Engine controller CN-CE01 (*: Never connect to NC as malfunctions and errors occur) CN-CE01 (*: Never connect to NC as malfunctions and errors occur) CN-CE02 (*: Never connect to NC as malfunctions and errors occur) CN-CE03(*: Never connect to NC as malfunctions and errors occur) Engine throttle and pump controller ELECTRONIC CONTROL SYSTEM machine control system diagram MACHINE MONITOR SYSTEM MONITOR PANEL LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH OVERLOAD WARNING DEVICE OUTLINE SENSOR 1st ATTACHMENT CIRCUIT HYDRAULIC PERFORMANCE (MAIN TRAVEL SYSTEM TRAVEL CIRCUIT oPERATIONAL AND CONTROL FEATURES Operator’s Input via travel mode switch OVERRUN PROTECTION. This is dealt with through the action of the counterbalance spool in the motor control block.When the machin... STEERING SYSTEM Operating principles Dynamic Steering 2 - stage principle SERVICE BRAKE AND SUSPENSION SYSTEM bRAKING SYSTEM operation KOMTRAX terminal system KOMTRAX terminal
20 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Flow control characteristic of PC valve (STD) TESTING AND ADJUSTING Measuring engine speed Measuring intake air pressure (boost pressure) MEASUREMENT OF EXHAUST GAS COLOUR Adjusting valve clearance Measuring compression pressure MEASUREMENT OF BLOW-BY PRESSURE Measuring engine oil pressure CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION Replacing the fan belt Handling fuel system parts Releasing residual pressure from fuel system Measuring fuel pressure Measuring fuel discharge, return and leakage Bleeding air from fuel circuit Checking fuel circuit for leakage MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE Procedure for pressure reducing adjustment INSPECTION AND ADJUSTMENT OF PUMP PC (Valve INLET) CONTROL OIL PRESSURE INSPECTION AND ADJUSTMENT OF PUMP LS valve CONTROL OIL PRESSURE MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE 6 - Stage solenoid block 4 - Stage solenoid block 2 - Stage solenoid block MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE Measuring and adjusting quick coupler control valve output pressure testing travel motor relief pressure adjusting travel motor relief pressure Testing propshaft speed TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT MEASUREMENT OF OIL LEAKAGE AMOUNT AIR BLEEDING OF VARIOUS PARTS INSPECTION PROCEDURES FOR DIODE SPECIAL FUNCTION OF MONITOR PANEL OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE) TABLE FOR FAILURE CODE NO. OPERATION AND DISPLAY OF SERVICE MENU Way of switching to Service Menu Table for Monitoring Items Procedure for turning on KOMTRAX terminal KOMTRAX terminal lamp indications Preparation work for troubleshooting of electrical system PM - Tune up service TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE CHECKS BEFORE TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING Failure-looking Phenomenon and Troubleshooting No. How to read electric wire code CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM CONNECTOR LOCATIONS CONNECTION TABLE FOR CONNECTOR PIN NUMBERS TROUBLESHOOTING WHEN FAILURE CODE IS INDICATED Before carrying out troubleshooting when failure code is displayed INFORMATION CONTAINED IN TROUBLESHOOTING TABLE Relative Electrical Circuit Diagram Failure code [CA111] EMC Critical Internal Failure Failure code [CA115] Engine Neutral and Backup Speed Sensor Error Failure code [CA122] Chg Air Press Sensor High Error Failure code [CA123] Chg Air Press Sensor Low Error Failure code [CA131] Throttle Sensor High Error Failure code [CA132] Throttle Sensor Low Error Failure code [CA144] Coolant Temp Sens High Error Failure code [CA145] Coolant Temp Sens Low Error Failure code [CA153] Chg Air Temp Sensor High Error Failure code [CA154] Chg Air Temp Sensor Low Error Failure code [CA155] Chg Air Temp High Speed Derate Failure code [CA187] Sens Supply 2 Volt Low Error Failure code [CA221] Ambient Press Sens High Error Failure code [CA222] Ambient Press Sens Low Error Failure code [CA227] Sens Supply 2 Volt High Error Failure code [CA238] Ne Speed Sens Supply Volt Error Failure code [CA271] IMV/PCV1 Short Error Failure code [CA272] IMV/PCV1 Open Error Failure code [CA322] Inj #1 (L#1) Open/Short Error Failure code [CA324] Inj #3 (L#3) Open/Short Error Failure code [CA331] Inj #2 (L#2) Open/Short Error Failure code [CA332] Inj #4 (L#4) Open/Short Error Failure code [CA342] Calibration Code Incompatibility Failure code [CA351] Injectors Drive Circuit Error Failure code [CA352] Sensor Supply 1 Volt Low Error Failure code [CA386] Sens Supply 1 Volt High Error Failure code [CA428] Water in Fuel Sensor High Error Failure code [CA429] Water in Fuel Sensor Low Error Failure code [CA435] Eng Oil Press Sw Error Failure code [CA441] Battery Voltage Low Error Failure code [CA442] Battery Voltage High Error Failure code [CA449] Rail Press Very High Error Failure code [CA451] Rail Press Sensor High Error Failure code [CA452] Rail Press Sensor Low Error Failure code [CA488] Chg Air Temp High Torque Derate Failure code [CA553] Rail Press High Error Failure code [CA559] Rail Press Low Error Failure code [CA689] Eng Ne Speed Sensor Error Failure code [CA731] Eng Bkup Speed Sens Phase Error Failure code [CA757] All Continuous Data Lost Error Failure code [CA778] Eng G Speed Sensor Error Failure code [CA1633] KOMNET Datalink Timeout Error Failure code [CA2185] Throttle Sensor Supply Voltage High Error Failure code [CA2186] Throttle Sensor Supply Voltage Low Error Failure code [CA2249] Rail Press Very Low Error Failure code [CA2311] IMV Solenoid Error Failure code [CA2555] Grid Htr Relay Volt High Error Failure code [CA2556] Grid Heater Relay Volt Low Error Failure Code [D110KB] (Short-circuiting in battery relay) Failure code [D862KA] GPS Antenna Disconnection Configuration diagram of KOMTRAX system Failure Code [DA22KK] (Abnormality in pump pressure sensor) Failure code [DA25KP] Press. Sensor Power Abnormality Failure code [DA2RMC] Pump Comm. Abnormality Failure Code [DA2SKQ] (Abnormality in inputting model code) Failure Code [DA2SKQ] (Abnormality in inputting model code) Failure code [DAFRMC] Monitor Comm. Abnormality Failure code [DDC3KZ] Outrigger Switch Select Abnormality Failure Code [DDP4KX] (Abnormality in travel PPC pressure switch) Failure Code [DDWCKZ] (Abnormality in travel direction control switch) Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality Failure code [DFB3L8] Service Lever 1 Potentio Error Failure code [DFB4L8] Service Lever 2 Potentio Error Failure code [DGH2KB] Hydr Oil Sensor Short Failure Code [DH1OKS] (Abnormality in Pressure sensor power source) Failure code [DHPAMA] F Pump Press Sensor Abnormality Failure Code [DHS5KX] (Abnormality in travel PPC sensor) Failure Code [DHX1MA] (Abnormality in overload caution sensor) Failure Code [DLT4KA] (Disconnection in transmission speed sensor in pump controller system) Failure Code [DW27KA] (Disconnection in Transmission Clutch solenoid) Failure Code [DW27KB] (Short-circuiting in Transmission Clutch solenoid) Failure Code DW4AKA (Disconnection in suspension lock solenoid) Failure Code [DW4AKB] (Short circuiting in suspension lock solenoid) Failure Code [DW4CKA] (Disconnection in PPC lock solenoid) Failure code [DW4CKB] PPC Lock Sol. S/C Failure Code [DW4MKA] (Disconnection in Creep solenoid) Failure Code [DW4MKB] (Short-circuiting in Creep solenoid) Failure Code [DW44KA] (Disconnection of Travel F/R solenoid) Failure Code [DW44KB] (Short-circuiting of Travel F/R solenoid) Failure Code [DW45KA] (Disconnection in Swing Parking Brake solenoid) Failure code [DW45KB] Swing Brake Sol. S/C Failure Code [DW91KA] (Disconnection in Travel Neutral solenoid) Failure Code [DW91KB] (Short-circuiting in Travel Neutral Solenoid) Failure Code [DWK0KA] (Disconnection in 2-stage Relief solenoid) Failure Code [DWK0KB] (Short-circuiting in 2-Stage Relief Solenoid) Failure Code [DWK2KA] (Disconnection in 2-stage Back Pressure solenoid) Failure Code [DWK2KB] (Short circuiting in 2-stage back pressure solenoid) Failure Code [DXA0KA] (Disconnection in PC-EPC solenoid system) Failure Code [DXA0KB] (Short-circuiting in PC-EPC solenoid) Failure Code [DXE0KA] (Disconnection in LS-EPC solenoid system) Failure Code [DXE0KB] (Short-circuiting in LS-EPC solenoid) Failure code [DXE4KA] Service Current EPC1 Discon Failure code [DXE4KB] Service Current EPC1 Short Failure code [DXE7KA] Service Current EPC2 Discon Failure code [DXE7KB] Service Current EPC2 Short Failure code [DXE8KA] Service Current EPC3 Discon Failure code [DXE8KB] Service Current EPC3 Short Failure code [DXE9KA] Service Current EPC4 Discon Failure code [DXE9KB] Service Current EPC4 Short Failure code [DY20KA] Wiper Working Abnormality Failure code [DY20MA] Wiper Parking Abnormality Failure code [DY2CKB] Washer Drive S/C Failure code [DY2DKB] Wiper Drive (For) S/C Failure code [DY2EKB] Wiper Drive (Rev) S/C TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) INFORMATION CONTAINED IN TROUBLESHOOTING TABLE E-1 Engine does not start (Engine does not rotate) E-5 Auto-decelerator does not work E-6 Auto engine warm-up device does not work E-7 Preheater does not operate E-8 All work equipment, swing and travel do not move E-9 One-touch Power Max Switch does not work E-10 No display in monitor panel at all E-11 Part of display on monitor panel is missing E-12 Monitor panel displays contents irrelevant to the model E-13 Fuel level monitor red lamp lights up while engine is running E-14 Engine coolant temperature gauge does not indicate normally E-15 Hydraulic oil temperature gauge does not display correctly E-16 Fuel gauge does not display correctly E-17 Swing lock monitor does not display correctly E-18 When the monitor switch is operated, no display appears E-19 Windshield wiper and window washer do not operate E-20 Alarm buzzer cannot be stopped E-21 "Boom/Stabiliser RAISE" is not correctly displayed in monitor function E-22 "Boom/Stabiliser LOWER" is not correctly displayed in monitor function E-23 "Arm DIGGING" is not correctly displayed in monitor function E-24 "Arm DUMPING" is not correctly displayed in monitor function E-25 "Bucket DIGGING" is not correctly displayed in monitor function E-26 "Bucket DUMPING" is not correctly displayed in monitor function E-27 "SWING" is not correctly displayed in monitor function E-28 "TRAVEL" is not correctly displayed in monitor function E-29 "2 Piece Boom" is not correctly displayed in monitor function E-30 Air Conditioner does not work E-31 Travel reverse alarm does not sound E-32 KOMTRAX system does not operate normally TROUBLESHOOTING OF ELECTRICAL SYSTEM (Error checking of items without Monitor codes) Relative Electrical Circuit Diagram Radio Cassette & Telephone Socket Electrical Circuit Diagram For Radio Cassette & Telephone Socket PPC Lock Circuit Circuit Diagram for PPC Lock Circuit Brake Light Circuit Circuit Diagram for Brake Light Circuit Undercarriage Attachments - Mode Selection Circuit Diagram for Undercarriage Attachments - Mode Selection Undercarriage Attachments - Front Left Outrigger Circuit Diagram for Undercarriage Attachments - Front Left Outrigger Undercarriage Attachments - Front Right Outrigger Circuit Diagram for Undercarriage Attachments - Front Right Outrigger Undercarriage Attachments - Rear Left Outrigger Undercarriage Attachments - Rear Right Outrigger Circuit Diagram for Undercarriage Attachments - Rear Right Outrigger Heated Seat Does Not Warm Up Circuit Diagram for the Heated Seat Suspension Lock Circuit Diagram for Suspension Lock Lower Wiper Does Not Work (Optional Fitment) Circuit Diagram for Lower Wiper Work Lights (Operator Cab Front Left) Work Lights (Operator Cab Front Right) Work Lights (Operator Cab Rear) Circuit Diagram for Work Lights Worklights (Boom, Arm & Counterweight) Circuit Diagram for Worklights (Boom & Counterweight) Cab and Counterweight Beacon Light Circuit Diagram for Cab & Counterweight Beacon Light Air Seat Compressor (Option - Air Suspension Seat) Circuit Diagram for Air Seat Compressor (Option - Air Suspension Seat) Operator Cab Interior Light Circuit Diagram for Operator Cab Interior Light Cigar Lighter Circuit Diagram for Cigar Lighter Park Brake (Not Activating) Circuit Diagram for Park Brake Park Brake (Displayed Symbol) Circuit Diagram for Park Brake RH PPC Lever Clamshell Roller Switch Pushed to the LH Position Circuit Diagram for Clamshell Control RH PPC Lever Clamshell Roller Switch Pushed to the RH Position Circuit Diagram for Clamshell Control RH PPC Lever Clamshell Roller Switched Pushed to the RH or LH Circuit Diagram for Clamshell Control Horns Circuit Diagram for Horn Swing Lock - Normal Operation Circuit Diagram for Swing Lock Swing Lock - Emergency Operation Circuit Diagram for Swing Lock - Emergency Operation Neutral Start (Engine) Neutral Start (Engine) cont’d (A) Neutral Start (Engine) cont’d (B) Neutral Start (Engine) cont’d (C) Circuit Diagram for Neutral Start (Engine) Emergency Travel Control - Forward Circuit Diagram for Travel Direction Control Emergency Travel Control - Neutral Circuit Diagram for Travel Direction Control Emergency Travel Control - Reverse Emergency Travel Control - Reverse cont’d Circuit Diagram for Travel Direction Control Driving Lights - Main Beam Circuit Diagram for Driving Lights Driving Lights - Main Beam Flash Circuit Diagram for Driving Lights Driving Lights - Main Beam Dipped Circuit Diagram for Driving Lights Driving Lights - Position Lights Circuit Diagram for Driving Lights Driving Lights - Position Lights cont’d (1) and (2) Circuit Diagram for Driving Lights Indicators - Right Hand Circuit Diagram for Indicators & Hazard Warning Indicators - Left Hand Circuit Diagram for Indicators & Hazard Warning Hazard Warning Lights Circuit Diagram for Indicators & Hazard Warning Hazard Warning Lights cont’d (A) Circuit Diagram for Indicators & Hazard Warning Swing Lock Proximity Switch Brake and Swing Lock Proximity Switches TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS INFORMATION CONTAINED IN TROUBLESHOOTING TABLE Quick coupler
30 DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL REMOVAL AND INSTALLATION OF ASSEMBLIES DisassemblY and assemblY OF assemblIES SPECIAL TOOLS SKETCHES LIST OF TOOLS PRECAUTIONS WHEN PERFORMING OPERATION STARTING MOTOR ASSEMBLY FUEL Supply PUMP assembly FUEL INJECTOR ASSEMBLY FRONT OIL SEAL REAR OIL SEAL CYLINDER HEAD ASSEMBLY COMBINATION COOLER FUEL COOLER ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES TRAVEL MOTOR ASSEMBLY TRAVEL MOTOR ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY SWING MACHINERY ASSEMBLY SWING MOTOR ASSEMBLY FRONT AXLE ASSEMBLY FRONT AXLE ASSEMBLY REAR AXLE AND TRANSMISSION ASSEMBLY REAR AXLE ASSEMBLY TRANSMISSION ASSEMBLY PROPSHAFT ASSEMBLY WHEEL ASSEMBLY SUSPENSION LOCK CYLINDER ASSEMBLY SUSPENSION LOCK CYLINDERS ASSEMBLY OUTRIGGER ASSEMBLY OUTRIGGER ASSEMBLY DOZER BLADE DOZER BLADE ASSEMBLY SWING CIRCLE ASSEMBLY REVOLVING FRAME ASSEMBLY CENTRE SWIVEL JOINT ASSEMBLY CENTRE SWIVEL JOINT ASSEMBLY HYDRAULIC TANK ASSEMBLY FUEL TANK ASSEMBLY CONTROL VALVE ASSEMBLY LS SEPARATION VALVE ASSEMBLY PRESSURE COMPENSATION VALVE ASSEMBLY MAIN RELIEF VALVE ASSEMBLY LS CONTROL EPC VALVE ASSEMBLY EPC SOLENOID VALVE ASSEMBLY 4 STATION PPC SOLENOID VALVE BLOCK ASSEMBLY MANIFOLD BLOCK ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT WORK EQUIPMENT PPC VALVE ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY MONOBOOM WORK EQUIPMENT ASSEMBLY 2 PIECE BOOM WORK EQUIPMENT ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY COUNTERWEIGHT ASSEMBLY OPERATOR CAB ASSEMBLY MONITOR ASSEMBLY GOVERNOR / PUMP CONTROLLER ASSEMBLY KOMTRAX TERMINAL ENGINE CONTROLLER