Komatsu PW160-7H Hydraulic Excavator Service Repair Shop Manual (H50051 and up) - VEBM390100

This Complete Service Repair Workshop Manual PDF Download for the PW160-7H Komatsu Hydraulic Excavator (S/N: H50051 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 PW160-7H - S/N: H50051 and up


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- MAINTENANCE STANDARD
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : VEBM390100
Total Pages : 956


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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TITLE
GENERAL
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
GENERAL PRECAUTIONS
PREPARATIONS FOR WORK
PRECAUTIONS DURING WORK

SECTION 10
H50051 AND UP
HOW TO READ THE SHOP MANUAL
volumes
DISTRIBUTION AND UPDATING
FILING METHOD
REVISED EDITION MARK
REVISIONS
SYMBOLS
HOISTING INSTRUCTIONS
HOISTING
WIRE ROPES
PUSH-PULL TYPE COUPLERS
COATING MATERIALS
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
TIGHTENING TORQUE OF HOSE NUTS
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
TIGHTENING TORQUE FOR FLARED NUTS
Tightening torque for 102 engine series (bolts and nuts)
Tightening torque for 102 engine series (eye joints)
Tightening torque for 102 engine series (tapered screws)
ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
UNITS
WORKING RANGES
1 PIECE BOOM
2 PIECE BOOM
SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
1 pIECE BOOM
DIMENSIONS
2 PIECE BOOM
SPECIFICATIONS
WEIGHT TABLE
1 piece boom
2 piece boom
FUEL, COOLANT AND LUBRICANTS
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
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
PW160-7H
CLSS
OUTLINE OF CLSS
1. Unload valve
2. Introduction of LS pressure
3. LS Bypass plug
4. Pressure compensation valve
5. Area ratio of pressure compensation valve
6. Boom regeneration circuit
7. Arm regeneration circuit
8. Swing bleeding valve
9. Variable type pressure compensation valve (for service)
10. LS select valve
CENTre SWIVEL JOINT
travel ppc pedal
WORK EQUIPMENT . SWING PPC VALVE
SERVICE 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
engine control system
Governor motor
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 valve bypassed)
travel system
TRAVEL CIRCUIT
oPERATIONAL AND CONTROL FEATURES
SteeRING system
Operating principles
SERVICE BRAKE AND SUSPENSION SYSTEM
bRAKING SYSTEM
operation

SECTION 20
INSPECTION AND ADJUSTMENT OF ENGINE RPM
MEASUREMENT OF EXHAUST GAS COLOUR
ADJUSTMENT OF VALVE CLEARANCE
MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF BLOW-BY PRESSURE
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
MEASUREMENT OF ENGINE OIL PRESSURE
ADJUSTMENT OF ENGINE SPEED SENSOR
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
EMERGENcy sEtting iF FAILURE occurs IN ENGINE CONTROL SYSTEM
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
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
7 - 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
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 ERROR AND FAILURE CODE NO.
OPERATION AND DISPLAY OF SERVICE MENU
Way of switching to Service Menu
Table for Monitoring Items
PM - Tune up service
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(Error checking of items without Monitor codes)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)

SECTION 30
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
GOVERNOR MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF Assembly
STARTING MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF Assembly
FUEL INJECTION PUMP ASSEMBLY
ENGINE FRONT SEAL
ENGINE REAR SEAL
CYLINDER HEAD ASSEMBLY
COMBINATION COOLER
ENGINE AND HYDRAULIC PUMP ASSEMBLIES
TRAVEL MOTOR ASSEMBLY
TRAVEL MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF
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 ASSEMBLY
OUTRIGGER ASSEMBLY
OUTRIGGER ASSEMBLY
DOZER BLADE ASSEMBLY
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
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

90 OTHERS
Hydraulic circuit diagram 1/3
Hydraulic circuit diagram 2/3
Hydraulic circuit diagram 3/3
Electrical circuit diagram 1/5
Electrical circuit diagram 2/5
Electrical circuit diagram 3/5
Electrical circuit diagram 4/5
Electrical circuit diagram 5/5

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