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Komatsu PW160-7H Hydraulic Excavator Shop Manual (H50051 and up) - PDF DOWNLOAD
Komatsu PW160-7H Hydraulic Excavator Shop Manual (H50051 and up)
FILE DETAILS:
Komatsu PW160-7H Hydraulic Excavator Shop Manual (H50051 and up)
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : VEBM390100
Total Pages : 956
DESCRIPTION:
Komatsu PW160-7H Hydraulic Excavator Shop Manual (H50051 and up)
FOREWORD:
GENERAL:
This shop 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 shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters: these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs , as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling eachr component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PW160-7H Hydraulic Excavator Shop Manual (H50051 and up)
VEBM390100 SHOP MANUAL................................................................................................... 1 TITLE................................................................................................................ 1 GENERAL.............................................................................................................. 5 SAFETY............................................................................................................... 3 SAFETY NOTICE.................................................................................................... 3 IMPORTANT SAFETY NOTICE...................................................................................... 3 GENERAL PRECAUTIONS.......................................................................................... 3 PREPARATIONS FOR WORK........................................................................................ 3 PRECAUTIONS DURING WORK...................................................................................... 4 SECTION 10........................................................................................................... 35 H50051 AND UP.................................................................................................... 1 HOW TO READ THE SHOP MANUAL...................................................................................... 6 volumes...................................................................................................... 6 DISTRIBUTION AND UPDATING.................................................................................... 6 FILING METHOD................................................................................................ 6 REVISED EDITION MARK......................................................................................... 6 REVISIONS.................................................................................................... 6 SYMBOLS...................................................................................................... 6 HOISTING INSTRUCTIONS............................................................................................ 7 HOISTING..................................................................................................... 7 WIRE ROPES................................................................................................... 7 PUSH-PULL TYPE COUPLERS.......................................................................................... 8 COATING MATERIALS................................................................................................ 10 STANDARD TIGHTENING TORQUE....................................................................................... 12 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS................................................................. 12 TIGHTENING TORQUE OF HOSE NUTS............................................................................... 13 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...................................................................... 13 TIGHTENING TORQUE FOR FLARED NUTS............................................................................ 13 Tightening torque for 102 engine series (bolts and nuts)..................................................... 14 Tightening torque for 102 engine series (eye joints)......................................................... 14 Tightening torque for 102 engine series (tapered screws)..................................................... 14 ELECTRIC WIRE CODE............................................................................................... 15 CLASSIFICATION BY THICKNESS.................................................................................. 15 CLASSIFICATION BY COLOR AND CODE............................................................................. 15 CONVERSION TABLES................................................................................................ 16 METHOD OF USING THE CONVERSION TABLE......................................................................... 16 UNITS............................................................................................................ 22 WORKING RANGES................................................................................................... 26 1 PIECE BOOM................................................................................................. 26 2 PIECE BOOM................................................................................................. 27 SPECIFICATION DIMENSION DRAWINGS................................................................................. 24 DIMENSIONS....................................................................................................... 24 1 pIECE BOOM................................................................................................. 24 DIMENSIONS....................................................................................................... 25 2 PIECE BOOM................................................................................................. 25 SPECIFICATIONS................................................................................................... 28 WEIGHT TABLE..................................................................................................... 30 1 piece boom................................................................................................. 31 2 piece boom................................................................................................. 32 FUEL, COOLANT AND LUBRICANTS..................................................................................... 33 ENGINE RELATED PARTS............................................................................................. 36 RADIATOR . OIL COOLER . charge air cooler........................................................................ 37 POWER TRAIN...................................................................................................... 38 SWING CIRCLE..................................................................................................... 40 SWING MACHINERY & motor.......................................................................................... 42 SWING MOTOR...................................................................................................... 46 Operation of swing lock...................................................................................... 50 RELIEF VALVE PORTION......................................................................................... 51 Operation.................................................................................................... 51 UNDERCARRIAGE.................................................................................................... 52 TRANSMISSION..................................................................................................... 54 TRAVEL MOTOR..................................................................................................... 57 oPERATION OF TRAVEL MOTOR.................................................................................... 59 CLUTCH CONTROL CIRCUIT........................................................................................... 61 AXLE............................................................................................................. 64 sUSPENSION LOCK CYLINDER......................................................................................... 68 Braking System................................................................................................... 70 brake/steer pump................................................................................................. 72 PRIORITY VALVE................................................................................................... 73 POWER BRAKE VALVE................................................................................................ 74 SPECIFICATIONS............................................................................................... 74 FUNCTION..................................................................................................... 75 ACCUMULATOR for brake system..................................................................................... 76 STEERING SYSTEM.................................................................................................. 77 STEERING COLUMN.................................................................................................. 78 ORBITROL VALVE................................................................................................... 79 hydraulic equipment layout drawingS.............................................................................. 80 hydraulic CIRCUIT dIAgRAM........................................................................................ 82 HYDRAULIC TANK................................................................................................... 83 HYDRAULIC PUMP................................................................................................... 84 HPV125....................................................................................................... 84 LS VALVE..................................................................................................... 89 PC VALVE..................................................................................................... 89 LS(pc)-EPC VALVE.............................................................................................102 PILOT PRESSURE CONTROL (PPC) SYSTEM..............................................................................105 CONTROL VALVE....................................................................................................106 PW160-7H.....................................................................................................106 CLSS.............................................................................................................116 OUTLINE OF CLSS..............................................................................................116 1. Unload valve..................................................................................................121 2. Introduction of LS pressure...................................................................................124 3. LS Bypass plug................................................................................................125 4. Pressure compensation valve...................................................................................126 5. Area ratio of pressure compensation valve.....................................................................128 6. Boom regeneration circuit.....................................................................................129 7. Arm regeneration circuit......................................................................................131 8. Swing bleeding valve..........................................................................................133 9. Variable type pressure compensation valve (for service).......................................................134 10. LS select valve..............................................................................................135 CENTre SWIVEL JOINT..........................................................................................136 travel ppc pedal.............................................................................................138 WORK EQUIPMENT . SWING PPC VALVE.............................................................................140 SERVICE PPC VALVE............................................................................................144 solenoid valve MANIFOLD......................................................................................147 SOLENOID VALVE BLOCK.....................................................................................148 2 Position 3 way valve...............................................................................148 2 Position 4 way valve...............................................................................150 attachment epc valve.....................................................................................152 Boom safety valve............................................................................................156 HYDRAULIC CYLINDER...........................................................................................158 BOOM CYLINDER............................................................................................158 ARM CYLINDER.............................................................................................158 BUCKET CYLINDER..........................................................................................158 ADJUST CYLINDER..........................................................................................159 Outrigger CYLINDER...........................................................................................160 dozer CYLINDER...............................................................................................162 work equipment...............................................................................................164 Work Equipment...........................................................................................165 1. DIMENSION OF ARM......................................................................................166 2. Dimension of bucket...................................................................................167 air conditioner..............................................................................................168 air conditioner piping...................................................................................168 electrical wiring diagram....................................................................................169 engine control system........................................................................................170 Governor motor...........................................................................................172 Engine throttle and pump controller......................................................................174 ELECTRONIC CONTROL SYSTEM....................................................................................176 machine control system diagram...........................................................................178 MACHINE MONITOR SYSTEM.......................................................................................202 MONITOR PANEL............................................................................................204 LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH.................................................................223 OVERLOAD WARNING DEVICE......................................................................................230 OUTLINE..................................................................................................230 SENSOR.......................................................................................................231 1st attachment circuit hydraulic performance (main valve bypassed)...........................................238 travel system................................................................................................240 TRAVEL CIRCUIT...........................................................................................240 oPERATIONAL AND CONTROL FEATURES.........................................................................241 SteeRING system..............................................................................................262 Operating principles.....................................................................................262 SERVICE BRAKE AND SUSPENSION SYSTEM..........................................................................275 bRAKING SYSTEM...........................................................................................275 operation................................................................................................278 SECTION 20...........................................................................................................281 INSPECTION AND ADJUSTMENT OF ENGINE RPM..........................................................................298 MEASUREMENT OF EXHAUST GAS COLOUR................................................................................300 ADJUSTMENT OF VALVE CLEARANCE....................................................................................303 MEASUREMENT OF COMPRESSION PRESSURE..............................................................................305 MEASUREMENT OF BLOW-BY PRESSURE..................................................................................306 INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING...............................................................307 MEASUREMENT OF ENGINE OIL PRESSURE...............................................................................309 ADJUSTMENT OF ENGINE SPEED SENSOR............................................................................310 INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION.....................................................310 EMERGENcy sEtting iF FAILURE occurs IN ENGINE CONTROL SYSTEM.....................................................312 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS................................................................313 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL....314 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE........................................................318 INSPECTION AND ADJUSTMENT OF PUMP PC (Valve INLET) CONTROL OIL PRESSURE..........................................320 INSPECTION AND ADJUSTMENT OF PUMP LS valve CONTROL OIL PRESSURE..................................................324 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE....................................................................328 7 - Stage solenoid block.....................................................................................330 4 - Stage solenoid block.....................................................................................332 2 - Stage solenoid block.....................................................................................333 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE.........................................................................334 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE.................................................................336 testing travel motor relief pressure.............................................................................337 adjusting travel motor relief pressure...........................................................................338 Testing propshaft speed..........................................................................................339 tESTING TRANSMISSION CLUTCH CONTROL CIRCUIT......................................................................340 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................342 RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT...........................................................344 MEASUREMENT OF OIL LEAKAGE AMOUNT................................................................................346 AIR BLEEDING OF VARIOUS PARTS....................................................................................348 INSPECTION PROCEDURES FOR DIODE..................................................................................350 SPECIAL FUNCTION OF MONITOR PANEL................................................................................352 OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE)............................................................354 TABLE FOR ERROR AND FAILURE CODE NO..........................................................................360 OPERATION AND DISPLAY OF SERVICE MENU........................................................................364 Way of switching to Service Menu.........................................................................364 Table for Monitoring Items...............................................................................367 PM - Tune up service.............................................................................................382 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM...............................................................386 TROUBLESHOOTING..................................................................................................387 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....................................................................541 TROUBLESHOOTING OF ELECTRICAL SYSTEM.............................................................................589 (Error checking of items without Monitor codes)..................................................................589 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)......................................................679 SECTION 30...........................................................................................................703 HOW TO READ THIS MANUAL..........................................................................................705 REMOVAL AND INSTALLATION OF ASSEMBLIES.......................................................................705 DisassemblY and assemblY OF assemblIES.......................................................................706 SPECIAL TOOLS....................................................................................................707 SKETCHES.....................................................................................................707 LIST OF TOOLS................................................................................................708 PRECAUTIONS WHEN PERFORMING OPERATION............................................................................709 GOVERNOR MOTOR ASSEMBLY..........................................................................................711 REMOVAL AND INSTALLATION OF Assembly.............................................................................712 STARTING MOTOR ASSEMBLY..........................................................................................712 REMOVAL AND INSTALLATION OF Assembly.............................................................................713 FUEL INJECTION PUMP ASSEMBLY.....................................................................................713 ENGINE FRONT SEAL................................................................................................718 ENGINE REAR SEAL.................................................................................................721 CYLINDER HEAD ASSEMBLY...........................................................................................723 COMBINATION COOLER...............................................................................................729 ENGINE AND HYDRAULIC PUMP ASSEMBLIES.............................................................................732 TRAVEL MOTOR ASSEMBLY............................................................................................737 TRAVEL MOTOR ASSEMBLY............................................................................................740 REMOVAL AND INSTALLATION OF......................................................................................744 SWING MOTOR AND SWING MACHINERY ASSEMBLY.........................................................................744 SWING MACHINERY ASSEMBLY.........................................................................................745 SWING MOTOR ASSEMBLY.............................................................................................753 FRONT AXLE ASSEMBLY..............................................................................................762 FRONT AXLE ASSEMBLY..............................................................................................764 REAR AXLE AND TRANSMISSION ASSEMBLY..............................................................................814 REAR AXLE ASSEMBLY...............................................................................................817 TRANSMISSION ASSEMBLY............................................................................................848 PROPSHAFT ASSEMBLY...............................................................................................876 WHEEL ASSEMBLY...................................................................................................878 SUSPENSION LOCK CYLINDER ASSEMBLY................................................................................879 SUSPENSION LOCK ASSEMBLY.........................................................................................880 OUTRIGGER ASSEMBLY...............................................................................................881 OUTRIGGER ASSEMBLY...............................................................................................882 DOZER BLADE ASSEMBLY.............................................................................................883 DOZER BLADE ASSEMBLY.............................................................................................884 SWING CIRCLE.....................................................................................................885 ASSEMBLY.........................................................................................................885 REVOLVING FRAME ASSEMBLY.........................................................................................886 CENTRE SWIVEL JOINT ASSEMBLY.....................................................................................889 CENTRE SWIVEL JOINT ASSEMBLY.....................................................................................892 HYDRAULIC TANK ASSEMBLY..........................................................................................894 FUEL TANK ASSEMBLY...............................................................................................898 CONTROL VALVE ASSEMBLY...........................................................................................900 LS SEPARATION VALVE ASSEMBLY.....................................................................................904 PRESSURE COMPENSATION VALVE ASSEMBLY.............................................................................905 MAIN RELIEF VALVE ASSEMBLY.......................................................................................906 LS CONTROL EPC VALVE ASSEMBLY....................................................................................907 EPC SOLENOID VALVE ASSEMBLY......................................................................................908 PPC SOLENOID VALVE BLOCK ASSEMBLY................................................................................909 MANIFOLD BLOCK ASSEMBLY..........................................................................................911 OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT...........................................................................912 WORK EQUIPMENT PPC VALVE ASSEMBLY................................................................................913 HYDRAULIC CYLINDER ASSEMBLY......................................................................................914 MONOBOOM WORK EQUIPMENT ASSEMBLY.................................................................................920 2 PIECE BOOM WORK EQUIPMENT ASSEMBLY.............................................................................923 AIR CONDITIONER UNIT ASSEMBLY....................................................................................926 COUNTERWEIGHT ASSEMBLY...........................................................................................930 OPERATOR CAB ASSEMBLY............................................................................................932 MONITOR ASSEMBLY.................................................................................................935 GOVERNOR / PUMP CONTROLLER ASSEMBLY..............................................................................937 90 OTHERS............................................................................................................939 Hydraulic circuit diagram 1/3....................................................................................941 Hydraulic circuit diagram 2/3....................................................................................943 Hydraulic circuit diagram 3/3....................................................................................945 Electrical circuit diagram 1/5...................................................................................947 Electrical circuit diagram 2/5...................................................................................949 Electrical circuit diagram 3/5...................................................................................951 Electrical circuit diagram 4/5...................................................................................953 Electrical circuit diagram 5/5...................................................................................955
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