Komatsu Wheeled Excavator PW160-8 service & repair manual

Description Komatsu Wheeled Excavator PW160-8 service & repair manual

Komatsu Wheeled Hydraulic Excavator PW160-8 pdf workshop service repair manual

Serial number H60051 and up

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

MANUAL CONTENT:
FOREWORD
Safety
General
How to read the shop manual
Hoisting instructions
Coating materials
Standard tightening torque
Electric wire code
Conversion tables
Units

GENERAL
Specification dimension drawings
Working ranges
Specifications
Weight table
Fuel, coolant and lubricants

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
Engine related parts
Radiator - Oil cooler - charge air cooler
Power train
Swing circle
Swing machinery & motor
Undercarriage
Transmission
Travel motor
Clutch control circuit
Axle
Suspension lock cylinder
Braking system
Brake/steering pump
Tandem pump (brake/steering)
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
Pilot pressure control (PPC) system
Control valve
CLSS
Centre swivel joint
Travel PPC pedal
Work equipment – Swing PPC valve
Solenoid valve block
Boom safety valve
Hydraulic cylinder
Outrigger cylinder
Dozer cylinder
Work equipment
Air conditioner
Electrical wiring diagram
Electrical system
Electrical control system
Machine monitor system
Overload warning device
Sensor
1st attachment circuit hydraulic performance (main valve bypassed)
Travel system
Steering system
Service brake and suspension system
KOMTRAX terminal system
Central lubrication system (CLS)
Lubrication diagram
Quick coupler control valve
ATT EPC valve assembly
Standard value table for engine related parts
Standard value table for chassis related parts
PM clinic service

STANDARD VALUE TABLE
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 valve control oil pressure
Measurement of solenoid valve output pressure
Measurement of PPC valve output pressure
Adjustment of work equipment and swing PPC valve
Changing the lubrication interval times

TESTING AND ADJUSTING
Measuring and adjusting quick coupler control valve output pressure
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas colour
Adjusting valve clearance
Measurement of compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
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
Air bleeding of various parts
Inspection procedures for diode
Special function of monitor panel

TROUBLESHOOTING
Troubleshooting when failure code is indicated
Troubleshooting of electrical system (E-Mode)
Troubleshooting of electrical system (Error checking of items without monitor codes)
Troubleshooting of hydraulic, mechanical and central lubrication system

DISASSEMBLY AND ASSEMBLY
How to read this manual
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 front oil seal
Removal and installation of rear oil seal
Removal and installation of cylinder head assembly
Removal and installation of fuel cooler assembly
Removal and installation of combination cooler assembly
Removal and installation of engine and hydraulic pump assembly
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
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 4-station PPC solenoid 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
Removal and installation of 1 piece boom 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
General assembly advice for central lubrication system (CLS)

Hydraulic circuit diagram
Electrical circuit diagram

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