service repair manual

1. © 2004
All Rights Reserved 00-1
Printed in Belgium
UEBM002500
PW160-7K
q This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
q PW160-7K mount the SAA4D102E-2 engine.
For details of the engine, see the 102 Series Engine Shop Manual.
MACHINE MODEL SERIAL NUMBER
PW160-7K 00 K40001 AND UP 00

2. CONTENTS
00-2
No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . .10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1
90 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-1
00

3. DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR ASSEMBLY
PW160-7K 30-9
12
REMOVAL
1. Open engine hood and disconnect governor
motor electrical connectors E10 and E11.
2. Disconnect rod (1) from governor motor (2) by
removing rod locking nut (3).
3. Remove governor motor assembly (2) by remov-
ing the three securing bolts (4).
INSTALLATION OF GOVERNOR MOTOR ASSEM-
BLY
q Carry out installation in the reverse order to
removal.
a When installing the governor motor,
rotate the shaft by hand to the correct
orientation -
Do not stop the the rod rotation sud-
denly.
a Adjust the rod. For details, see TESTING
AND ADJUSTING, Testing and adjust-
ing of governor motor lever stroke.
REMOVAL AND INSTALLATION OF
ASSEMBLY
GOVERNOR MOTOR
ASSEMBLY
Disconnect the cable from the negative (-)
terminal of the battery.
1 2 4
4
3
E11 E10

4. DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF Assembly
30-10 PW160-7K
12
REMOVAL
1. Open up the engine hood.
2. Disconnect the two wires from the engine start-
ing motor at:
q Wire (1) and (2) from terminal B.
q Wire (3) from terminal C.
3. Remove two mounting bolts (4) to detach engine
starting motor assembly (5).
INSTALLATION
q Install in reverse order of removal.
REMOVAL AND INSTALLATION OF
ASSEMBLY
STARTING MOTOR
ASSEMBLY
Disconnect the cable from the negative (-)
terminal of the battery.
2
3 1
4 5
Engine starting motor Terminal B
Securing nut:
17.7 to 24.5 Nm (1.8 to 2.5 kgm)
Engine starting motor Terminal C
Securing nut:
2.6 to 4.6 Nm (0.26 to 0.46 kgm)
Both faces of engine starting motor gas-
ket: Gasket sealant (LG-1)
Engine starting motor to Engine Secur-
ing Bolt:
43 ± 6 Nm (4.38 ± 0.61 kgm)

5. DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF Assembly
PW160-7K 30-11
12
SPECIAL TOOLS
a Disconnect the fuel drain manifold. (A)
a Remove the injection pump supply. (B)
a Remove the high-pressure lines. (C)
a Disconnect the electrical wire to the fuel
shutoff valve. (D)
REMOVAL
WARNING! Do not remove the control lever. The
fuel control lever on the fuel injection pump is
indexed to the shaft during pump calibration. If the
lever has been removed and reinstalled incorrectly,
engine speed and power will be affected.
1. Disconnect all control linkage. Refer to OEM ser-
vice manual.
2. Remove the pump support bracket (1).
3. Remove the access cap (2), gear retaining nut
(3) and washer (4).
4. Locate top dead centre (TDC) for cylinder No.1
by barring engine slowly while pushing in on
TDC pin.
See “INSPECTION AND ADJUSTMENT OF
FUEL INJECTION TIMING<$paranumonly>-20 -
110
Note:Be sure to disengage the pin after locating
TDC.
REMOVAL AND INSTALLATION OF
ASSEMBLY
FUEL INJECTION PUMP
ASSEMBLY
Mark Part No.
Part
Name
Neces-
sity Qty
Distinc-
tion* Sketch
A 795-799-1390 Puller n 1
*Distinction between new and existing part.
A
C
D
B
1
2
3
4

6. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
30-12 PW160-7K
5. The special washer (5) on the fuel injection pump
must be removed so the lock screw (6) can be
tightened against the driveshaft.
6. Pull the fuel injection pump drive gear loose from
the pump driveshaft.
7. Remove the 3 mounting nuts, and take off the
fuel injection pump.
8. Remove the gasket, and clean the surface.
Installation
1. Verify cylinder No.1 is at TDC by barring engine
slowly while pushing in on TDC pin.
See “INSPECTION AND ADJUSTMENT OF
FUEL INJECTION TIMING<$paranumonly>-20 -
110
2. Install a new gasket (1).
WARNING! The driveshaft must be clean and free
of all oil before installation. Failure to make certain
the driveshaft is free of oil can result in the drive gear
slipping on the shaft.
3. Install the pump (2).
Torque value: 30Nm
5
6
1
2

7. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
PW160-7K 30-13
4. Use your hands to tighten the 3 mounting nuts.
Note:Fuel pumps on engines designed to meet
Tier 2 industrial emmissions levels have
straight holes (not kidney slots) and do not
use a timing key.
WARNING! Be sure the timing pin is disengaged
before the final torque step to avoid damage to the
timing pin.
5. Install the pump driveshaft nut (3) and rotate
washer (4). The pump will rotate slightly because
of gear helix and clearance. This is acceptable
provided the pump is free to move on the flange
slots and the crankshaft does not move.
6. If installing the orignal pump, rotate the pump to
align the scribe marks.
7. If installing a new or rebuilt pump without scribe
marks, take up gear lash by rotating the pump
against the direction of drive rotation. Tighten the
flange mounting nuts.
8. Permanently mark the injection pump flange to
match the mark on the gear housing.
Torque value: 15 - 20Nm
34
Torque value: 24Nm
Torque value: 24Nm

8. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
30-14 PW160-7K
9. The special washer is wired to the pump and
must be installed under the lockscrew.
10. Disengage the timing pin before rotating the
crankshaft.
11. Install the injection pump support bracket. Fin-
ger-tighten all capscrews before final tightening.
Note:Tighten the bracket to block mounting cap-
screw before tightening the bracket to injec-
tion pump capscrews.
12. Tighten the bracket capscrews to the cylinder
block (5).
Tighten the tail support bracket capsrew to the
fuel pump (6).
13. Tighten the pump retaining nut.
14. Install all high-pressure fuel lines and the electri-
cal wire to the fuel shutoff valve.
Install drain manifold fitting and reconnect drain
tube.
Torque value: 13Nm
Tightening torque:
M14x1.5 nut: 98Nm
M12 nut: 93Nm
5
6

9. DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
PW160-7K 30-15
15. When connecting the rod to the control lever,
adjust the length so the lever has stop-to-stop
movement.
See “Function for Governor Motor Adjustment”
on page 20-175.
16. Bleed air from the fuel system and reinstall fan
guard as intial machine condition.

10. DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
30-16 PW160-7K
Removal
a Disconnect the cable from the negative
(–) terminal of the battery.
1. Drain the coolant.
a Drain the coolant to a degree that it will
not leak when hose (1) is disconnected.
2. Remove hoses (1) and (2).
3. Remove fan guards (3) and (4).
4. Remove air conditioner compressor belt.[*1]
5. Disconnect connector E06 (16) and remove air
conditioner compressor (5) and bracket and
move them toward the counterweight.
a Do not separate the air conditioner pip-
ing.
6. Remove fan shroud (6).
a Take care that the fan shroud will not
interfere with the other parts.
7. Remove the cooling fan.
8. Install lever [1] to tensioner (7) and move the
lever in the direction of the arrow to remove fan
belt (8).
a Take care not to catch your hands
between the tensioner and pulley.
9. Remove fan pulley (9).
10. Remove 4 mounting bolts (10) and crank pulley
(11). [*2]
a Remove the crank pulley with its timing mark
(a) matched to pointer (12) or make match
marks on the crank pulley and front cover so
that you can position the crank pulley cor-
rectly when installing it.
11. Remove 20 mounting bolts (13) and front cover
(14). [*3]
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
1
2 4
36 16 5

11. DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
PW160-7K 30-17
12
12. Remove engine front seal (15) from front cover
(14). [*4]
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Install the air conditioner compressor belt.
For details, see TESTING AND ADJUSTING,
Inspection and adjustment of air compressor
belt tension.
[*2]
a Install the belt to the position from which it
was removed.
a Install the crank pulley temporarily and fan
belt, and then tighten the mounting bolts to
the specified torque.
[*3]
a Apply ThreeBond 1207D or equivalent in the
form of a continuous string 1 – 2 mm thick to
the fitting face of the front cover.
a Install the gasket to the front cover, and then
install them to the engine.
a Tighten the mounting bolts in the following
order.
[*4]
Mounting bolt:
125 ± 5 Nm {12.75 ± 0.51 kgm}
Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}

12. DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
30-18 PW160-7K
a Using the push tool, install so that dimension
b will be as follows.
q Dimension b: 21 ± 0.38 mm

13. DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
PW160-7K 30-19
12
Removal
1. Remove the hydraulic pump assembly. For
details, see Removal and installation of hydraulic
pump assembly.
2. Remove damper assembly (1).
3. Set guide bolts [1] and lift off flywheel assembly
(2). [*1]
a Flywheel assembly: 25 kg
4. Remove engine rear seal (3). [*2]
a Break the seal carrier with a screwdriver, etc.
to remove the seal.
a Take care not to damage the other parts.
a The engine rear seal may be removed
according to the following procedure.
1) Make a hole about 3 mm in diameter on the
seal with a drill.
2) Attach a dent puller to a slide hammer and
insert the hammer into the drilled hole. Then
pull out seal (3) by sliding the hammer.
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

14. DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
30-20 PW160-7K
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Tighten the mounting bolts in the following
numerical order.
[*2]
a Install the engine rear seal according to the
following procedure.
1. Install pilot [2] to new engine rear seal (3).
a Before installing the engine rear seal,
degrease and dry the seal contact surface of
the crankshaft and the lip surface of the seal
to prevent oil leakage.
2. Install pilot [2] fitted with engine rear seal (3) in
the crankshaft.
3. Pull out pilot [2].
4. Using the push tool, set the engine rear seal so
that dimension "a" will be the following value.
q Dimension a: 25.8 mm
a Lightly hit the top, bottom, right, and left of
the push tool with a hammer to push in the
seal, taking care that the seal carrier will not
be bent.
Mounting bolt:
137 ± 7 Nm {13.97 ± 0.71 kgm}

15. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
PW160-7K 30-21
SPECIAL TOOLS
REMOVAL
a Disconnect the cable from the negative (–)
terminal of the battery.
1. Drain the coolant.
2. Close the fuel stop valve.
3. Open the engine hood.
4. Disconnect hose (1) from the engine. [*1]
5. Remove fan guard (2).
6. Remove the air conditioner compressor belt.[*2]
7. Disconnect connector E06 (35), and then
remove air conditioner compressor (3) and
bracket and move them toward the counter-
weight.
a Do not separate the air conditioner piping.
8. Disconnect terminal E01 (4) - Grid heater.
9. Remove the bracket mounting bolts of engine oil
level gauge guide (5) and move the level gauge
guide.
10. Remove 4 delivery tubes (6).
11. Remove tubes (7) and (8) between fuel filter and
fuel injection pump.
12. Remove bracket (9) and fuel filter as a unit. [*3]
13. Remove air intake connector (10) and ribbon
heater (11). [*4]
a Cover the openings with adhesive tapes, etc.
to prevent foreign matter from entering the
engine.
14. Remove heat insulation covers (12) and (13).
15. Remove muffler (14). [*5]
REMOVAL AND INSTALLATION OF
ASSEMBLY
CYLINDER HEAD ASSEM-
BLY
Symbol
Part No. Part name
Necessity
Q'ty
New/Remodel
Sketch
A
2 795-799-1171 Puller t 1
3 790-331-1110 Wrench t 1
Engine cooling water: Approx. 16.2 l
2
1
3
35
14
13
12

16. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
30-22 PW160-7K
16. Disconnect hoses (15) and (16). [*6]
17. Disconnect tubes (17) and (18). [*7]
18. Remove turbocharger assembly (19). [*8]
19. Remove exhaust manifold (20). [*9]
20. Referring to REMOVAL AND INSTALLATION OF
ENGINE FRONT SEAL, Removal procedure
steps 2 – 9, remove the cooling fan pulley.
21. Remove the tensioner.
22. Disconnect hoses (21) and (22). [*10]
23. Disconnect terminal B (23) and connector E12
(24).
24. Remove alternator (25) and bracket.
25. Disconnect connector E05 (26) in the rear of the
left of the engine.
26. Disconnect spill tube (28).
27. Remove 4 nozzle holder assemblies (27).
a If it is difficult to pull the nozzle holder
assemblies out of the cylinder head, use tool
A2.

17. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
PW160-7K 30-23
a Cover the nozzle holder assembly mounting
parts to prevent foreign matter from entering
the engine.
28. Remove head cover (29). [*11]
29. Remove rocker arm assemblies (30). [*12]
a Loosen the locknut and loosen the adjust-
ment screw of each rocker arm 2 – 3 turns.
30. Remove push rods (31). [*13]
31. Lift off cylinder head assembly (32). [*14]
Cylinder head assembly: 40 kg
32. Remove cylinder head gasket (33).

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19. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
30-24 PW160-7K
INSTALLATION
q Carry out installation in the reverse order to
removal.
[*1]
[*2]
a Install the air conditioner compressor belt.
For details, see TESTING AND ADJUSTING,
Inspection and adjustment of air compressor
belt tension.
[*3]
a Apply gasket sealant to the threads of the
bolt (only 1 piece) on the head cover side
among the 3 fuel filter bracket mounting
bolts.
[*4]
a Apply gasket sealant to the threads of only
the 2 of the air intake connector mounting
bolts indicated by the arrows in the following
figure
[*5]
a When connecting the exhaust pipe to under
the muffler, apply thermosetting sealant
(Firegum manufactured by Nihon Holts Co.,
Ltd. or equivalent) all round the pipe end.
[*6]
[*8]
[*9]
a Tighten the mounting bolts in the following
numerical order.
[*10]
[*11]
Hose clamp:
1st time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
Clamp nut of muffler U-bolt:
9.8 – 14.7 Nm {1.0 – 1.5 kgm}
Clamp of hose (15):
10.0 – 11.0 Nm {1.02 – 1.12 kgm}
Clamp of hose (16):
1st time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
Tube (17):
Turbocharger side:
10.3 ± 1.2 Nm {1.1 ± 0.1 kgm}
Cylinder block side:
35 ± 5 Nm {3.6 ± 0.5 kgm}
Tube (18):10 ± 2 Nm {1.0 ± 0.2 kgm}
Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm}
Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm}
Mounting bolt:
1st time: Tighten all the bolts to:
43 ± 6 Nm {4.38 ± 0.61 kgm}.
2nd time: Tighten only bolts 1 – 4 to:
43 ± 6 Nm {4.38 ± 0.61 kgm}
Clamp of hose (22):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}

20. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
PW160-7K 30-25
12[*12] [*13] [*14]
a Install the rocker arm assembly and cylinder
head assembly according to the following
procedure.
a Check that there is not foreign matter on the
cylinder head mounting face and in the cylin-
der.
1) Set cylinder head gasket (33) to the cylinder
block.
qCheck that the gasket is matched to
the holes of the block.
2) Sling cylinder head assembly (32) and set it
to the cylinder block.
3) Install push rods (31).
4) Install rocker arm assemblies (30) and
tighten mounting bolts (34) with the fingers.
a Check that the balls of adjustment
screws (35) are fitted to the sockets of
push rods (31).
5) Tighten the cylinder head bolts in the follow-
ing numerical order in 3 times.
Threads and seat of mounting bolt:
Engine oil (SAE15W-40)
a When not using tool A3, make marks on
the bolts and cylinder head, and then
tighten each bolt by the above angle.
6) Tighten rocker arm assembly mounting bolts
(34) permanently.
Cylinder head bolt:
1st time: Tighten all the bolts to:
90 ± 5 Nm {9.18 ± 0.51 kgm} in the
numerical order shown in the figure.
2nd time: Tighten bolts 3, 6, 11, and 14
to:
120 ± 5 Nm {12.24 ± 0.51 kgm} in order.
3rd time: Using tool A3, tighten all the
bolts by 90° ± 5° in the numerical order
shown in the figure. (Angle tightening)
Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}

21. DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
30-26 PW160-7K
7) Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjustment of
valve clearance.
q Refilling with water
Add water to the specified level. Run the engine
to circulate the water through the system. Then,
check the water level again.
q Bleeding air
Bleed air from the fuel piping. For details, see
REMOVAL AND INSTALLATION OF FUEL INJEC-
TION PUMP ASSEMBLY.
Cooling water: Approx. 16.2 l