Komatsu PW160-7K Hydraulic Excavator Service Repair Shop Manual (K40001 and up) - UEBM002500

This Complete Service Repair Workshop Manual PDF Download for the PW160-7K Komatsu Hydraulic Excavator (S/N: K40001 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 PW160-7K - S/N: K40001 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
Product Code : UEBM002500
Total Pages : 890


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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PW160-7K - K40001 AND UP

Sec 00.pdf
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
GENERAL PRECAUTIONS
PREPARATIONS FOR WORK
PRECAUTIONS DURING WORK
GENERAL
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

01.pdf
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

10.pdf
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
ACCUMULATOR for brake system
STEERING TRAIN
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
PW160-7K
CLSS
OUTLINE OF CLSS
CENTre SWIVEL JOINT
travel ppc pedal
WORK EQUIPMENT • SWING PPC VALVE
SERVICE PPC VALVE
solenoid valve MANIFOLD
Solenoid valve (2, 4 & 6-stage solenoid)
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
Overload warning device
OUTLINE
SENSOR
1st attachment circuit hydraulic performance (main valve bypassed)
1st attachment circuit hydraulic performance (VIA main valve)
travel system
TRAVEL CIRCUIT
oPERATIONAL AND CONTROL FEATURES
SteeRING system
Operating principles
SERVICE BRAKE AND SUSPENSION SYSTEM
bRAKING SYSTEM
operation

20_001.pdf
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Flow control characteristic of PC valve (STD)

20_101.pdf
INSPECTION AND ADJUSTMENT OF ENGINE RPM
MEASUREMENT OF EXHAUST GAS COLOR
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
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, SWIN...
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
MEASUREMENT OF OIL LEAKAGE AMOUNT
AIR BLEEDING OF VARIOUS PARTS
INSPECTION PROCEDURES FOR DIODE
SPECIAL FUNCTION OF MONITOR PANEL
Operation of Operator's Menu and Display (Outline)
Table for Service and Failure Code Nos.
Operation and Display of Service Menu
Way of switching to Service Menu
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM

20_201.pdf
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
Classification of troubleshooting
Steps for troubleshooting
Failure-looking Phenomenon and Troubleshooting No.
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION STEREOGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

20_301.pdf
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE IN...
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Service Code in Electrical System (Abnormal data in Error History)
Service Code in Electrical System (Disconnection of S-NET signal)
Service Code in Electrical System (Short-circuiting in Travel Neutral Solenoid)
Service Code in Electrical System (Short-circuiting of Travel F/R solenoid)
Service Code in Electrical System (Short-circuiting in 2-Stage Relief solenoid)
Service Code in Electrical System (Short-circuiting in Transmission Clutch solenoid)
Service Code in Electrical System (Short-circuiting in Creep solenoid)
Service Code in Electrical System (Disconnection in Creep solenoid)
Service Code in Electrical System (Disconnection in Travel Neutral solenoid)
Service Code in Electrical System (Disconnection of Travel F/R solenoid)
Service Code in Electrical System (Disconnection in Swing Parking Brake solenoid)
Service Code in Electrical System (Disconnection in 2-stage Relief solenoid)
Service Code in Electrical System (Disconnection in Transmission Clutch solenoid)
Service Code in Electrical System (Abnormality in inputting model code)
Service Code in Electrical System (Abnormality in inputting model code)
Service Code in Electrical System Disconnection of S-NET signal)
Service Code in Electrical System (Short-circuiting in LS-EPC solenoid)
Service Code in Electrical System (Disconnection in LS-EPC solenoid system)
Service Code in Electrical System (Abnormality in pump pressure sensor)
Service Code in Electrical System (Abnormality in Pressure sensor power source)
Service Code in Electrical System (Abnormality in engine rotation sensor in governor • pump contr...
Service Code in Electrical System (Short-circuiting in PC-EPC solenoid)
Service Code in Electrical System (Disconnection in PC-EPC solenoid system)
Service Code in Electrical System (Short circuiting in 2-stage back pressure solenoid)
Service Code in Electrical System (Disconnection in 2-stage Back Pressure solenoid)
Service Code in Electrical System (Short-circuiting in attachment oil flow rate adjusting EPC)
Service Code in Electrical System (Disconnection in attachment oil flow rate adjusting EPC)
Service Code in Electrical System (Abnormality in direction control switch)
Service Code In Electrical System (Abnormality in overload caution sensor)
Service Code in Electrical System (Abnormality in travel PPC sensor)
Service Code in Electrical System (Disconnection in transmission speed sensor in governor • pump ...
Service Code in Electrical System (Incorrect non-volatile memory data)
Service Code in Electrical System (Abnormality in travel PPC switch hydraulics)
Service Code in Electrical System (Abnormality in governor potentiometer)
Service Code in Electrical System (Abnormality in fuel dial)
Service Code in Electrical System (Short-circuiting in battery relay)
Service Code in Electrical System (Step-out in governor motor)
Service Code in Electrical System (Disconnection in governor motor Phase A and B)
Service Code in Electrical System (Short-circuiting in governor motor Phase A and Phase B)
Service Code in Electrical System ("Model Selection" function not provided yet)
Service Mode in Electrical System (Model selecting signal fault)
Failure Code in Mechanical System (Out-of-rate engine rotation at high idling)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)
Failure Code in Mechanical System (Air cleaner clogging)
Failure Code in Mechanical System (Abnormally lowered charging voltage)
Failure Code in Mechanical System (Abnormally lowered engine oil pressure)
Failure Code in Mechanical System (Abnormally lowered engine oil level)
Failure Code in Mechanical System (Engine cooling water overheating)
Failure Code in Mechanical System (Abnormally lowered radiator water level)
Failure Code in Mechanical System (Hydraulic oil overheating)

20_501.pdf
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
E-1 Engine does not start (Engine does not rotate)
E-2 Engine stops while in operation
E-3 Engine speed is irregular, or there is hunting
E-4 Engine does not stop
E-5 Auto-decelerator does not work
E-6 Auto engine warm-up device does not work
E-7 Pre heater does not work
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 cooling water temperature gauge does not indicate correctly
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 does not work
E-21 "Boom/Stabiliser RAISE" is not correctly displayed in monitor function
E-22 "Boom 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 "Service" is not correctly displayed in monitor function
E-30 Air Conditioner does not work
E-31 Travel alarm does not sound

20_601.pdf
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(Error checking of items without Monitor codes)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Radio Cassette & Telephone Socket
PPC Circuit & Brake Light Interlock
Undercarriage Attachments - Mode Selection
Undercarriage Attachments - Front Left Outrigger
Undercarriage Attacments - Front Right Outrigger
Undercariage Attachments - Rear Left Outrigger
Undercarriage Attachments - Rear Right Outrigger
Heated Seat Does Not Warm Up
Suspension Lock
Lower Wiper Does Not Work (Optional Fitment)
Work Lights (Operator Cab)
Worklights (Boom & Counterweight)
Beacon Light
Air Seat Compressor (Option - Air Suspension Seat)
Operator Cab Interior Light
Quick Coupler
Cigar Lighter
Park Brake (Not Activating)
Park Brake (Displayed Symbol)
Clamshell Control - Rotate Right (1st Service)
Clamshell Control - Rotate Left - Check Work Lever Circuit
Clamshell Control - Rotate Left - Check EPC Circuit
Horns
Swing Lock - Normal Operation
Swing Lock - Emergency Operation
Neutral Start (Engine)
Emergency Travel Control - Forward
Emergency Travel Control - Neutral
Emergency Travel Control - Reverse
Driving Lights - Main Beam
Driving Lights - Main Beam Flash
Driving Lights - Main Beam Dipped
Driving Lights - Position Lights
Driving Lights - Parking Lights
Indicators - Right Hand
Indicators - Left Hand
Hazard Warning Lights

20_701.pdf
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
H-1 All work equipment lacks power, or travel and swing speeds are slow
H-2 Engine speed sharply drops or engine stalls
H-3 No work equipment, travel or swing move
H-4 Abnormal noise is heard from around hydraulic pump
H-5 Auto-decelerator does not work
H-6 Fine control mode does not function
H-7 Boom moves slowly or lacks power
H-8 Arm moves slowly or lacks power
H-9 Bucket moves slowly or lacks power
H-10 Work equipment does not move in its single operation
H-11 Work equipment hydraulic drift is too fast
H-12 Work equipment has big time lag
H-13 Other work equipment moves when relieving single circuit
H-14 One-touch power max. switch does not operate
H-15 In compound operation, work equipment with larger load moves slowly
H-16 In swing + boom RAISE operation, boom moves slowly
H-17 In swing + travel, travel speed drops sharply
H-18 Travel speed does not switch
H-19 Travel speed does not shift, or it is too slow or fast.
H-20 Machine does not swing
H-21 Swing acceleration is poor, or swing speed is slow
H-22 Excessive overrun when stopping swing
H-23 There is big shock when stopping swing
H-24 There is loud abnormal noise caused when stopping swing
H-25 Swing natural drift is too big
H-26 Swing speed is faster than specified swing speed

30.pdf
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
TRAVEL PEDAL 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

UEBM002500_A2.pdf
hydraulic circuit diagram (1/2)
PW160-7K
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hydraulic circuit diagram (2/2)
PW160-7K
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electrical circuit diagram (1/3)
PW160-7K
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electrical circuit diagram (2/3)
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electrical circuit diagram (3/3)
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