Komatsu Wheeled Excavator PW160-10 service & repair manual

Description Komatsu Wheeled Excavator PW160-10 service & repair manual

Komatsu Wheeled Hydraulic Excavator PW160-10 pdf workshop service & repair manual

Serial number H62051 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
GENERAL
Specification dimension drawings
Working ranges
Working range: 1-piece boom
Working range: 2-piece boom
Weight table
1-piece boom
2-piece boom
Fuel, coolant and lubricants

STRUCTURE AND FUNCTION
Engine related parts
Variable Flow Turbocharger
EGR system piping drawing
EGR system circuit diagram
EGR cooler
KCCV layout drawing
KCCV ventilator
KDOC muffler
Cooling system
Power train
Swing circle
Swing machinery & motor
Operation of swing lock
Relief valve portion
Undercarriage
Transmission
Hydraulic quick coupler
Travel motor
Operation of travel motor
Clutch control circuit
Axle
Suspension lock cylinder
Braking system
Gear pump
Priority valve
Power brake valve
Accumulator for brake valve
Steering system
Steering column
Orbitrol valve
Hydraulic equipment layout drawings
Hydraulic circuit diagram
Hydraulic tank
Hydraulic pump
LS valve
PC valve
LS(PC)-EPC valve
Pilot pressure control (PPC) system
Control valve
CLSS
Outline of CLSS
Basic Principle
Operation for each function and valve
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.LS select valve
10.Variable type pressure compensation valve (for service)
Centre swivel joint
Travel PPC pedal
Work equipment – Swing PPC valve
Solenoid valve block with integrated ATT - EPC
ON / OFF Solenoid valves (3 way valve)
Attachment PPC valve
Boom safety valve
Hydraulic cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
Adjust cylinder
Outrigger cylinder
Dozer cylinder
Work equipment
1.Dimension of arm
2.Dimension of bucket
Air conditioner
Air conditioner piping
Electrical wiring diagram
Electrical system
Engine control
Engine controller
Pump controller
Electrical control system
Machine monitor system
Monitor panel
Monitor display
Caution monitor
Monitor switches
KOMTRAX system
Overload warning device
Outline
Sensor
Ambient pressure sensor
Charge (boost) pressure and temperature sensor
Coolant temperature sensor
Ne (crankshaft) speed sensor
Bkup (camshaft) speed sensor
Common rail pressure sensor
Exhaust manifold pressure sensor
EGR orifice temperature sensor
Variable flow turbocharger motor (with built-in position sensor)
EGR valve (with built-in position sensor)
Fuel level sensor
WIF (Water-In-Fuel detection) sensor
Coolant level sensor
Air cleaner clogging sensor
Overload Caution sensor
Swing proximity sensor
Travel PPC sensor
PPC pressure sensor
Park brake pressure sensor
PPC levers
Travel system
Travel circuit
Lubrication diagrams

STANDARD VALUE TABLE
Standard value table for engine related parts
Standard value table for chassis related parts
PM clinic service

TESTING AND ADJUSTING
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas colour
Measuring and adjusting valve clearance
Testing
Adjusting
Testing compression pressure
Testing
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel delivery, return and leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Checking and adjusting air conditioner compressor belt tension
Replacing the fan belt
Measurement of clearance in swing circle bearing
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 differential pressure
Measurement of solenoid 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
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
Air bleeding of various parts
Inspection procedures for diode
Special function of monitor panel
Changing the lubrication interval times

TROUBLESHOOTING
General information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
How to read electric wire code
Connector location chart and circuit diagram by system
Connection table for connector pin numbers
Troubleshooting when failure code is indicated

DISASSEMBLY AND ASSEMBLY
How to read this manual
Removal and installation of assemblies
Coating material lists
Special tools list
Sketches of special tools
List of tools
Precautions when performing operation
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of KDOC assembly
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Removal and installation of engine and main pump assembly
Removal and installation of front oil seal
Removal and installation of rear oil seal
Removal and installation of engine hood assembly
Removal and installation of travel motor
Disassembly and assembly of travel motor assembly
Removal and installation of swing motor and swing machinery
Removal of swing motor assembly
Disassembly and assembly of swing motor and swing machinery
Removal and installation of front axle assembly
Disassembly and assembly of front axle
Removal and installation of rear axle and transmission
Disassembly and assembly of rear axle assembly
Disassembly and assembly of transmission
Removal and installation of propshaft assembly
Removal and installation of wheel
Removal and installation of suspension lock cylinder assembly
Disassembly and assembly of suspension lock cylinders
Removal and installation of outrigger assembly
Disassembly and assembly of outriggers
Removal and installation of dozer blade assembly
Disassembly and assembly of dozer blade
Removal and installation of swing circle assembly
Removal and installation of revolving frame assembly
Removal and installation of centre swivel joint
Disassembly and assembly of centre swivel joint assembly
Removal and installation of fuel tank assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Removal and installation of LS separation valve assembly
Removal and installation of pressure compensation valve assembly
Removal and installation of main relief valve assembly
Removal and installation of LS control EPC valve
Removal and installation of PC EPC valve assembly
Removal and installation of PPC valve block assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve
Disassembly and assembly of hydraulic cylinder
Special tools
Removal and installation of monoboom work equipment
Removal and installation of 2 piece boom work equipment
Removal and installation of air conditioner unit
Removal and installation of counterweight
Removal and installation of operator cab assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly
Removal and Installation of KOMTRAX terminal

APPENDIX
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Air conditioner condenser
Sunlight sensor
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Input and output signals of the air conditioner controller
Parts and connectors layout
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart
Information in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil
Desiccant replacement
Tool control system
Adjusting and testing
Troubleshooting of tool control system
Tool control current [%] reference value table

OTHER
Hydraulic circuit diagram
Circuit diagram
Connector diagram

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