Komatsu PW160-7E0 Wheeled Excavator Workshop Repair Service Manual PDF VEBM395100 - MKMTSPW160E0.zip
A full service and repair guide, complete with electrical wiring diagrams, for the Komatsu PW160-7E0 Wheeled Excavator—containing every technical detail needed to service, troubleshoot, fix, and rebuild the machine the way professional technicians do.
The Komatsu PW160-7E0 Wheeled Excavator workshop service repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,140 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
VEBM395100 - Wheeled Excavator PW160-7E0 Shop Manual.pdf
MAIN SECTIONS
VEBM395100 PW160-7E0.....1
SAFETY.....3
SAFETY NOTICE.....3
IMPORTANT SAFETY NOTICE.....3
GENERAL PRECAUTIONS.....3
PRECAUTIONS DURING WORK.....4
01 GENERAL.....21
SPECIFICATION DIMENSION DRAWINGS.....22
DIMENSIONS.....22
1 pIECE BOOM.....22
WORKING RANGES.....24
1 PIECE BOOM.....24
2 PIECE BOOM.....25
SPECIFICATIONS.....26
WEIGHT TABLE.....28
1 piece boom.....29
2 piece boom.....30
FUEL, COOLANT AND LUBRICANTS.....31
10 STRUCTURE, FUNCTION AND.....33
ENGINE RELATED PARTS.....34
RADIATOR . OIL COOLER . CHARGE AIR COOLER.....35
POWER TRAIN.....36
SWING CIRCLE.....38
SWING MACHINERY & MOTOR.....40
SWING MOTOR.....44
Operation of swing lock.....48
RELIEF VALVE PORTION.....49
Operation.....49
UNDERCARRIAGE.....50
TRANSMISSION.....52
ATT EPC VALVE ASSEMBLY.....55
QUICK COUPLER CONTROL VALVE.....56
TRAVEL MOTOR.....58
OPERATION OF TRAVEL MOTOR.....60
CLUTCH CONTROL CIRCUIT.....62
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.....78
STEERING COLUMN.....79
ORBITROL VALVE.....80
HYDRAULIC EQUIPMENT LAYOUT DRAWINGS.....81
HYDRAULIC CIRCUIT DIAGRAM.....84
HYDRAULIC TANK.....85
HYDRAULIC PUMP.....86
HPV125.....86
LS VALVE.....91
PC VALVE.....91
LS(pc)-EPC VALVE.....104
PILOT PRESSURE CONTROL (PPC) SYSTEM.....107
CONTROL VALVE.....108
PW160-7E0.....108
CLSS.....118
OUTLINE OF CLSS.....118
CENTre SWIVEL JOINT.....139
TRAVEL PPC PEDAL.....140
WORK EQUIPMENT . SWING PPC VALVE.....142
SOLENOID VALVE MANIFOLD.....146
SOLENOID VALVE BLOCK.....147
2 Position 3 way valve.....147
2 Position 4 way valve.....149
attachment epc valve.....151
BOOM SAFETY VALVE.....154
HYDRAULIC CYLINDER.....157
BOOM CYLINDER.....157
ARM CYLINDER.....157
BUCKET CYLINDER.....157
ADJUST CYLINDER.....158
OUTRIGGER CYLINDER.....160
DOZER CYLINDER.....162
WORK EQUIPMENT.....164
Work Equipment.....165
1. DIMENSION OF ARM.....167
2. Dimension of bucket.....168
AIR CONDITIONER.....169
air conditioner piping.....169
ELECTRICAL WIRING DIAGRAM.....170
ELECTRICAL SYSTEM.....171
Engine Control.....171
Engine controller.....173
CN-CE01 (*: Never connect to NC as malfunctions and errors occur).....174
CN-CE01 (*: Never connect to NC as malfunctions and errors occur).....174
CN-CE02 (*: Never connect to NC as malfunctions and errors occur).....175
CN-CE03(*: Never connect to NC as malfunctions and errors occur).....175
Engine throttle and pump controller.....175
ELECTRONIC CONTROL SYSTEM.....178
machine control system diagram.....179
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.....240
TRAVEL SYSTEM.....242
TRAVEL CIRCUIT.....242
oPERATIONAL AND CONTROL FEATURES.....243
Operators Input via travel mode switch.....243
OVERRUN PROTECTION. This is dealt with through the action of the counterbalance spool in the motor control block.When the machin......243
STEERING SYSTEM.....264
Operating principles.....264
Dynamic Steering.....264
2 - stage principle.....264
SERVICE BRAKE AND SUSPENSION SYSTEM.....277
bRAKING SYSTEM.....277
operation.....280
KOMTRAX terminal system.....282
KOMTRAX terminal.....283
20 TESTING AND ADJUSTING.....285
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.....286
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS.....287
Flow control characteristic of PC valve (STD).....298
TESTING AND ADJUSTING.....299
Measuring engine speed.....300
Measuring intake air pressure (boost pressure).....302
MEASUREMENT OF EXHAUST GAS COLOUR.....303
Adjusting valve clearance.....305
Measuring compression pressure.....307
MEASUREMENT OF BLOW-BY PRESSURE.....309
Measuring engine oil pressure.....310
CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.....311
Replacing the fan belt.....312
Handling fuel system parts.....313
Releasing residual pressure from fuel system.....314
Measuring fuel pressure.....315
Measuring fuel discharge, return and leakage.....317
Bleeding air from fuel circuit.....321
Checking fuel circuit for leakage.....322
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS.....323
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL.....324
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE.....327
Procedure for pressure reducing adjustment.....328
INSPECTION AND ADJUSTMENT OF PUMP PC (Valve INLET) CONTROL OIL PRESSURE.....329
INSPECTION AND ADJUSTMENT OF PUMP LS valve CONTROL OIL PRESSURE.....332
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.....336
6 - Stage solenoid block.....338
4 - Stage solenoid block.....340
2 - Stage solenoid block.....341
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE.....342
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE.....344
Measuring and adjusting quick coupler control valve output pressure.....345
testing travel motor relief pressure.....346
adjusting travel motor relief pressure.....347
Testing propshaft speed.....348
TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT.....349
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT.....351
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT.....353
MEASUREMENT OF OIL LEAKAGE AMOUNT.....354
AIR BLEEDING OF VARIOUS PARTS.....356
INSPECTION PROCEDURES FOR DIODE.....358
SPECIAL FUNCTION OF MONITOR PANEL.....359
OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE).....361
TABLE FOR FAILURE CODE NO.....368
OPERATION AND DISPLAY OF SERVICE MENU.....371
Way of switching to Service Menu.....371
Table for Monitoring Items.....374
Procedure for turning on KOMTRAX terminal.....391
KOMTRAX terminal lamp indications.....394
Preparation work for troubleshooting of electrical system.....397
PM - Tune up service.....399
TROUBLESHOOTING.....403
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....404
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....405
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....406
CHECKS BEFORE TROUBLESHOOTING.....414
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.....415
Failure-looking Phenomenon and Troubleshooting No.....416
How to read electric wire code.....419
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM.....422
CONNECTOR LOCATIONS.....430
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....451
TROUBLESHOOTING WHEN FAILURE CODE IS INDICATED.....485
Before carrying out troubleshooting when failure code is displayed.....487
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.....488
Relative Electrical Circuit Diagram.....489
Failure code [CA111] EMC Critical Internal Failure.....490
Failure code [CA115] Engine Neutral and Backup Speed Sensor Error.....491
Failure code [CA122] Chg Air Press Sensor High Error.....492
Failure code [CA123] Chg Air Press Sensor Low Error.....494
Failure code [CA131] Throttle Sensor High Error.....496
Failure code [CA132] Throttle Sensor Low Error.....498
Failure code [CA144] Coolant Temp Sens High Error.....500
Failure code [CA145] Coolant Temp Sens Low Error.....502
Failure code [CA153] Chg Air Temp Sensor High Error.....504
Failure code [CA154] Chg Air Temp Sensor Low Error.....506
Failure code [CA155] Chg Air Temp High Speed Derate.....508
Failure code [CA187] Sens Supply 2 Volt Low Error.....510
Failure code [CA221] Ambient Press Sens High Error.....512
Failure code [CA222] Ambient Press Sens Low Error.....514
Failure code [CA227] Sens Supply 2 Volt High Error.....516
Failure code [CA238] Ne Speed Sens Supply Volt Error.....518
Failure code [CA271] IMV/PCV1 Short Error.....520
Failure code [CA272] IMV/PCV1 Open Error.....522
Failure code [CA322] Inj #1 (L#1) Open/Short Error.....524
Failure code [CA324] Inj #3 (L#3) Open/Short Error.....527
Failure code [CA331] Inj #2 (L#2) Open/Short Error.....530
Failure code [CA332] Inj #4 (L#4) Open/Short Error.....533
Failure code [CA342] Calibration Code Incompatibility.....536
Failure code [CA351] Injectors Drive Circuit Error.....537
Failure code [CA352] Sensor Supply 1 Volt Low Error.....540
Failure code [CA386] Sens Supply 1 Volt High Error.....542
Failure code [CA428] Water in Fuel Sensor High Error.....544
Failure code [CA429] Water in Fuel Sensor Low Error.....546
Failure code [CA435] Eng Oil Press Sw Error.....548
Failure code [CA441] Battery Voltage Low Error.....550
Failure code [CA442] Battery Voltage High Error.....553
Failure code [CA449] Rail Press Very High Error.....555
Failure code [CA451] Rail Press Sensor High Error.....556
Failure code [CA452] Rail Press Sensor Low Error.....558
Failure code [CA488] Chg Air Temp High Torque Derate.....560
Failure code [CA553] Rail Press High Error.....561
Failure code [CA559] Rail Press Low Error.....562
Failure code [CA689] Eng Ne Speed Sensor Error.....564
Failure code [CA731] Eng Bkup Speed Sens Phase Error.....567
Failure code [CA757] All Continuous Data Lost Error.....568
Failure code [CA778] Eng G Speed Sensor Error.....570
Failure code [CA1633] KOMNET Datalink Timeout Error.....574
Failure code [CA2185] Throttle Sensor Supply Voltage High Error.....576
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error.....578
Failure code [CA2249] Rail Press Very Low Error.....580
Failure code [CA2311] IMV Solenoid Error.....582
Failure code [CA2555] Grid Htr Relay Volt High Error.....584
Failure code [CA2556] Grid Heater Relay Volt Low Error.....586
Failure Code [D110KB] (Short-circuiting in battery relay).....588
Failure code [D862KA] GPS Antenna Disconnection.....590
Configuration diagram of KOMTRAX system.....590
Failure Code [DA22KK] (Abnormality in pump pressure sensor).....592
Failure code [DA25KP] Press. Sensor Power Abnormality.....594
Failure code [DA2RMC] Pump Comm. Abnormality.....596
Failure Code [DA2SKQ] (Abnormality in inputting model code).....598
Failure Code [DA2SKQ] (Abnormality in inputting model code).....600
Failure code [DAFRMC] Monitor Comm. Abnormality.....602
Failure code [DDC3KZ] Outrigger Switch Select Abnormality.....604
Failure Code [DDP4KX] (Abnormality in travel PPC pressure switch).....606
Failure Code [DDWCKZ] (Abnormality in travel direction control switch).....608
Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality.....610
Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality.....613
Failure code [DFB3L8] Service Lever 1 Potentio Error.....616
Failure code [DFB4L8] Service Lever 2 Potentio Error.....617
Failure code [DGH2KB] Hydr Oil Sensor Short.....619
Failure Code [DH1OKS] (Abnormality in Pressure sensor power source).....620
Failure code [DHPAMA] F Pump Press Sensor Abnormality.....622
Failure Code [DHS5KX] (Abnormality in travel PPC sensor).....624
Failure Code [DHX1MA] (Abnormality in overload caution sensor).....626
Failure Code [DLT4KA] (Disconnection in transmission speed sensor in pump controller system).....628
Failure Code [DW27KA] (Disconnection in Transmission Clutch solenoid).....630
Failure Code [DW27KB] (Short-circuiting in Transmission Clutch solenoid).....632
Failure Code DW4AKA (Disconnection in suspension lock solenoid).....634
Failure Code [DW4AKB] (Short circuiting in suspension lock solenoid).....636
Failure Code [DW4CKA] (Disconnection in PPC lock solenoid).....638
Failure code [DW4CKB] PPC Lock Sol. S/C.....640
Failure Code [DW4MKA] (Disconnection in Creep solenoid).....642
Failure Code [DW4MKB] (Short-circuiting in Creep solenoid).....644
Failure Code [DW44KA] (Disconnection of Travel F/R solenoid).....646
Failure Code [DW44KB] (Short-circuiting of Travel F/R solenoid).....648
Failure Code [DW45KA] (Disconnection in Swing Parking Brake solenoid).....650
Failure code [DW45KB] Swing Brake Sol. S/C.....654
Failure Code [DW91KA] (Disconnection in Travel Neutral solenoid).....656
Failure Code [DW91KB] (Short-circuiting in Travel Neutral Solenoid).....658
Failure Code [DWK0KA] (Disconnection in 2-stage Relief solenoid).....660
Failure Code [DWK0KB] (Short-circuiting in 2-Stage Relief Solenoid).....662
Failure Code [DWK2KA] (Disconnection in 2-stage Back Pressure solenoid).....664
Failure Code [DWK2KB] (Short circuiting in 2-stage back pressure solenoid).....666
Failure Code [DXA0KA] (Disconnection in PC-EPC solenoid system).....668
Failure Code [DXA0KB] (Short-circuiting in PC-EPC solenoid).....670
Failure Code [DXE0KA] (Disconnection in LS-EPC solenoid system).....672
Failure Code [DXE0KB] (Short-circuiting in LS-EPC solenoid).....674
Failure code [DXE4KA] Service Current EPC1 Discon.....676
Failure code [DXE4KB] Service Current EPC1 Short.....678
Failure code [DXE7KA] Service Current EPC2 Discon.....680
Failure code [DXE7KB] Service Current EPC2 Short.....682
Failure code [DXE8KA] Service Current EPC3 Discon.....684
Failure code [DXE8KB] Service Current EPC3 Short.....686
Failure code [DXE9KA] Service Current EPC4 Discon.....688
Failure code [DXE9KB] Service Current EPC4 Short.....690
Failure code [DY20KA] Wiper Working Abnormality.....692
Failure code [DY20MA] Wiper Parking Abnormality.....694
Failure code [DY2CKB] Washer Drive S/C.....696