Komatsu Hydraulic Excavator PC160LC-8 SHOP MANUAL SEN04566-16 PDF
$36.95
Komatsu Hydraulic Excavator PC160LC-8 SHOP MANUAL SEN04566-16 – PDF DOWNLOAD
SERIAL NUMBERS 25001 and up
Description
Komatsu Hydraulic Excavator PC160LC-8 SHOP MANUAL SEN04566-16 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Hydraulic Excavator PC160LC-8 SHOP MANUAL SEN04566-16 – PDF DOWNLOAD
Language : English
Pages :1068
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu Hydraulic Excavator PC160LC-8 SHOP MANUAL SEN04566-16 – PDF DOWNLOAD
SERIAL NUMBERS 25001 and up
1. General precautions
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.
TABLE OF CONTENTS:
Komatsu Hydraulic Excavator PC160LC-8 SHOP MANUAL SEN04566-16 – PDF DOWNLOAD
SERIAL NUMBERS 25001 and up
Cover 1
00 Index and foreword 3
100 Index 3
Composition of shop manual 4
Table of contents 6
200 Foreword and general information 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
How to read electric wire code 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table 46
Conversion table 50
01 Specification 57
100 Specification and technical data 57
Specification dimension drawings 58
Specifications 60
Weight table 62
Table of fuel, coolant and lubricants 64
10 Structure, function and maintenance standard 67
100 Engine and cooling system 67
Engine related parts 68
Radiator, oil cooler, aftercooler and fuel cooler 69
200 Power train system 71
Power train 72
Swing circle 73
Swing machinery 74
Final drive 76
Sprocket 78
300 Undercarriage and frame 81
Track frame, recoil spring 82
Idler 84
Carrier roller 86
Track roller 87
Track shoe 88
401 Hydraulic system, Part 1 93
Hydraulic equipment layout drawing 94
Hydraulic tank 96
Hydraulic pump 98
402 Hydraulic system, Part 2 125
Control valve 126
CLSS 140
Functions and operation by valve 144
403 Hydraulic system, Part 3 181
Valve control 182
PPC valve 183
Solenoid valve 204
Accumulator 206
Anti-drop valve for boom 208
Anti-drop valve for arm 214
Return oil filter 221
Center swivel joint 222
Travel motor 223
Swing motor 233
Attachment circuit selector valve 234
Hydraulic cylinder 238
500 Work equipment 241
Work equipment 242
Dimensions of components 244
600 Cab and its attachments 249
Air conditioner piping 250
700 Electrical system 253
Engine control system 254
Electronic control system 264
Monitor system 292
Sensor 318
KOMTRAX system 322
20 Standard value table 325
100 Standard service value table 325
Standard value table for engine 326
Standard value table for chassis related parts 327
30 Testing and adjusting 339
101 Testing and adjusting, Part 1 339
Tools for testing, adjusting and troubleshooting 341
Testing engine speed 344
Testing intake air pressure (boost pressure) 345
Testing exhaust gas color 346
Adjusting valve clearance 347
Testing compression pressure 349
Testing blow-by pressure 351
Testing engine oil pressure 352
Handling fuel system parts 353
Releasing residual pressure from fuel system 353
Testing fuel pressure 354
Measuring fuel discharge, return and leakage 356
Bleeding air from fuel circuit 360
Checking fuel circuit for leakage 362
Checking and adjusting air conditioner compressor belt tension 363
Replacing fan belt 364
Testing clearance in swing circle bearings 365
Testing and adjusting track shoe tension 366
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits 367
Testing control circuit basic pressure 370
Testing and adjusting pump PC control circuit oil pressure 371
Testing and adjusting pump LS control circuit oil pressure 374
Testing solenoid valve output pressure 378
Testing PPC valve output pressure 381
Adjusting play of work equipment and swing PPC valves 382
Inspecting locations of hydraulic drift of work equipment 383
Testing and adjusting travel deviation 385
Releasing remaining pressure in hydraulic circuit 387
Measurement of oil leakage 388
Bleeding air from various parts 390
Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side) 392
Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side) 394
Replacing accumulator bladder on high pressure side for accumulator piping 396
Inspection procedures for diode 401
Checking cab tipping stopper 402
Installation and adjustment of mirrors and camera 403
Inspection of air conditioner Recirc/Fresh air filter 407
102 Testing and adjusting, Part 2 409
Special functions of machine monitor 410
103 Testing and adjusting, Part 3 463
Handling voltage circuit of engine controller 464
Preparation work for troubleshooting of electrical system 465
Procedure for testing diodes 470
Pm-clinic service 471
40 Troubleshooting 477
100 Failure code table and fuse locations 477
Failure code table 478
Fuse locations 481
200 General information on troubleshooting 485
Points to remember when troubleshooting 486
Sequence of events in troubleshooting 487
Checks before troubleshooting 488
Classification and troubleshooting steps 489
Information in troubleshooting table 490
Phenomena looking like troubles and troubleshooting Nos 492
Connection table for connector pin numbers 495
T- branch box and T- branch adapter table 531
301 Troubleshooting by failure code, Part 1 535
Failure code [989L00] Engine controller lock caution 1 537
Failure code [989M00] Engine controller lock caution 2 537
Failure code [989N00] Engine controller lock caution 3 538
Failure code [AA10NX] Air cleaner clogging 539
Failure code [AB00KE] Charge voltage low 540
Failure code [B@BAZG] Eng oil press low 542
Failure code [B@BAZK] Eng oil level low 543
Failure code [B@BCNS] Eng coolant overheat 544
Failure code [B@BCZK] Eng water level low 546
Failure code [B@HANS] Hydr oil overheat 548
Failure code [CA111] ECM critical internal failure 550
Failure code [CA115] Eng Ne and bkup speed sens error 551
Failure code [CA122] Chg air press sensor high error 552
Failure code [CA123] Chg air press sensor low error 554
Failure code [CA131] Throttle sensor high error 556
Failure code [CA132] Throttle sensor low error 558
Failure code [CA144] Coolant temp sens high error 560
Failure code [CA145] Coolant temp sens low error 562
Failure code [CA153] Chg air temp sensor high error 564
Failure code [CA154] Chg air temp sensor low error 566
Failure code [CA155] Chg air temp high speed derate 568
Failure code [CA187] Sens supply 2 volt low error 570
Failure code [CA221] Ambient press sens high error 572
Failure code [CA222] Ambient press sens low error 574
Failure code [CA227] Sens supply 2 volt high error 576
Failure code [CA234] Eng overspeed 577
Failure code [CA238] Ne speed sens supply volt error 578
Failure code [CA271] IMV/PCV1 short error 579
Failure code [CA272] IMV/PCV1 open error 580
Failure code [CA322] Inj #1 open/short error 582
Failure code [CA324] Inj #3 open/short error 584
Failure code [CA331] Inj #2 open/short error 586
Failure code [CA332] Inj #4 open/short error 588
302 Troubleshooting by failure code, Part 2 591
Failure code [CA342] Calibration code incompatibility 593
Failure code [CA351] Injectors Drive Circuit Error 594
Failure code [CA352] Sens supply 1 volt low error 596
Failure code [CA386] Sens supply 1 volt high error 598
Failure code [CA428] Water in fuel sensor high error 600
Failure code [CA429] Water in fuel sensor low error 602
Failure code [CA435] Eng oil press sw error 604
Failure code [CA441] Battery voltage low error 606
Failure code [CA442] Battery voltage high error 608
Failure code [CA449] Rail press very high error 610
Failure code [CA451] Rail press sensor high error 612
Failure code [CA452] Rail press sensor low error 614
Failure code [CA488] Chg air temp high torque derate 616
Failure code [CA553] Rail press high error 616
Failure code [CA559] Rail press low error 617
Failure code [CA689] Eng Ne speed sensor error 618
Failure code [CA731] Eng Bkup speed sens phase error 620
Failure code [CA757] All persistent data lost error 622
Failure code [CA778] Eng Bkup speed sensor error 624
Failure code [CA1633] KOMNET datalink timeout error 626
Failure code [CA2185] Throttle sens sup volt high error 628
Failure code [CA2186] Throttle sens sup volt low error 629
Failure code [CA2249] Rail press very low error 630
Failure code [CA2311] IMV solenoid error 632
Failure code [CA2555] Grid htr relay volt high error 634
Failure code [CA2556] Grid htr relay volt low error 636
Failure code [D110KB] Battery relay drive short 638
Failure code [D19JKZ] Personal code relay abnormality 640
Failure code [D862KA] GPS antenna discon 642
Failure code [DA22KK] Pump solenoid power low error 644
Failure code [DA25KP] 5V sensor 1 power abnormality 646
Failure code [DA26KP] 5V sensor 2 power abnormality 649
Failure code [DA29KQ] Model selection abnormality 650
303 Troubleshooting by failure code, Part 3 653
Failure code [DA2RMC] CAN discon (Pump controller detected) 656
Failure code [DAF8KB] Short circuit in camera power supply 658
Failure code [DAFGMC] GPS module error 660
Failure code [DAFRMC] CAN discon (Monitor detected) 662
Failure code [DGH2KB] Hydr oil sensor short 664
Failure code [DHPAMA] F Pump press sensor abnormality 666
Failure code [DHPBMA] R Pump press sensor abnormality 668
Failure code [DHS5KX] Travel PPC press sensor abnormality 670
Failure code [DHSAMA] Sw RH PPC press sen abnormality 672
Failure code [DHSBMA] Sw LH PPC press sen abnormality 674
Failure code [DHX1MA] Overload sensor abnormality (Analog) 676
Failure code [DW43KA] Travel speed sol discon 677
Failure code [DW43KB] Travel speed sol short 678
Failure code [DW45KA] Swing brake sol discon 680
Failure code [DW45KB] Swing brake sol short 682
Failure code [DW91KA] Travel junction sol discon 684
Failure code [DW91KB] Travel junction sol short 686
Failure code [DWA2KA] Service sol discon 688
Failure code [DWA2KB] Service sol short 689
Failure code [DWJ0KA] Merge-divider sol discon 690
Failure code [DWJ0KB] Merge-divider sol short 692
Failure code [DWK0KA] 2-stage relief sol discon 694
Failure code [DWK0KB] 2-stage relief sol short 696
304 Troubleshooting by failure code, Part 4 699
Failure code [DXA8KA] PC-EPC sol discon 700
Failure code [DXA8KB] PC-EPC sol short 702
Failure code [DXE4KA] Service current EPC discon 704
Failure code [DXE4KB] Service current EPC short 706
Failure code [DY20KA] Wiper working abnormality 708
Failure code [DY20MA] Wiper parking abnormality 710
Failure code [DY2CKA] Washer drive discon 712
Failure code [DY2CKB] Washer drive short 714
Failure code [DY2DKB] Wiper drive (for) short 716
Failure code [DY2EKB] Wiper drive (rev) short 718
400 Troubleshooting of electrical system (E-mode) 721
Before carrying out troubleshooting of electrical system 723
Information in troubleshooting table 725
E-1 When starting switch turned ON, machine monitor displays nothing 726
E-2 When starting switch is turned to ON position (before starting engine), basic check item lights up 728
E-3 Engine does not start (Engine does not crank) 731
E-4 Preheater does not operate 734
E-5 Automatic warm-up system does not operate (in cold season) 736
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 738
E-7 Precaution lights up while engine is running 740
E-8 Emergency stop item lights up while engine is running 744
E-9 Engine coolant temperature gauge does not indicate normally 745
E-10 Hydraulic oil temperature gauge does not indicate normally 746
E-11 Fuel level gauge does not indicate normally 748
E-12 Contents of display by machine monitor are different from applicable machine 750
E-13 Machine monitor does not display some items 750
E-14 Function switch does not work 750
E-15 Auto-decelerator does not operate normally 751
E-16 Working mode does not change 752
E-17 Travel speed does not change 753
E-18 Alarm buzzer cannot be stopped 754
E-19 Windshield wiper and window washer do not operate 755
E-20 Power maximizing function does not operate normally 757
E-21 Swing holding brake does not operate normally 759
E-22 Travel alarm does not sound or does not stop sounding 761
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 763
E-24 While starting switch is in OFF position, service meter is not displayed 774
E-25 Machine monitor cannot be set in service mode 774
E-26 Monitoring function does not display lever control signal normally 776
E-27 KOMTRAX system does not operate normally 786
500 Troubleshooting of hydraulic and mechanical system (H-mode) 789
Information contained in troubleshooting table 791
System chart for hydraulic and mechanical systems 792
H-1 Speed or power of all work equipment, swing, and travel are low 794
H-2 Engine speed sharply drops or engine stalls 795
H-3 No work equipment, travel and swing move 796
H-4 Abnormal noise is heard from around hydraulic pump 796
H-5 Auto-decelerator does not work 797
H-6 Fine control mode does not function 797
H-7 Speed or power of boom is low 798
H-8 Speed or power of arm is low 799
H-9 Speed or power of bucket is low 800
H-10 Work equipment does not move in its single operation 801
H-11 Hydraulic drift of work equipment is large 802
H-12 Time lag of work equipment is large 803
H-13 One-touch power max system does not operate 803
H-14 Work equipment loaded more is slower during compound operation 804
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE 804
H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel 805
H-17 Machine deviates during travel 806
H-18 Travel speed is low 807
H-19 Machine cannot be steered easily or steering power is low 808
H-20 Travel speed does not change or it is kept low or high 809
H-21 Track does not move (Only either side) 809
H-22 Machine does not swing 810
H-23 Swing acceleration or swing speed is low 811
H-24 Excessive overrun when stopping swing 812
H-25 When upper structure stops swinging, it makes large shock 813
H-26 When upper structure stops swinging, it makes large sound 813
H-27 Hydraulic drift of swing is large 814
H-28 Attachment circuit does not change 815
H-29 Flow rate in attachment circuit cannot be adjusted 815
600 Troubleshooting of engine (S-mode) 817
Method of using troubleshooting chart 820
S-1 Starting performance is poor 824
S-2 Engine does not start 825
S-3 Engine does not pick up smoothly 828
S-4 Engine stops during operations 829
S-5 Engine does not rotate smoothly 830
S-6 Engine lack output (or lacks power) 831
S-7 Exhaust smoke is black (incomplete combustion) 832
S-8 Oil consumption is excessive (or exhaust smoke is blue) 833
S-9 Oil becomes contaminated quickly 834
S-10 Fuel consumption is excessive 835
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 836
S-12 Oil pressure drops 837
S-13 Oil level rises (Entry of coolant/fuel) 838
S-14 Coolant temperature becomes too high (overheating) 839
S-15 Abnormal noise is made 840
S-16 Vibration is excessive 841
50 Disassembly and assembly 843
100 General information on disassembly and assembly 843
How to read this manual 844
Coating materials list 846
Special tool list 849
Sketches of special tools 852
200 Engine and cooling system 855
Removal and installation of fuel supply pump assembly 856
Removal and installation of fuel injector assembly 860
Removal and installation of cylinder head assembly 867
Removal and installation of front oil seal 880
Removal and installation of rear oil seal 882
Removal and installation of radiator assembly 885
Removal and installation of aftercooler assembly 887
Removal and installation of hydraulic oil cooler assembly 889
Removal and installation of engine and hydraulic pump assembly 891
Removal and installation of engine hood assembly 899
Removal and installation of fuel tank assembly 901
300 Power train 905
Removal and installation of travel motor and final drive assembly 906
Disassembly and assembly of final drive assembly 908
Removal and installation of swing motor and swing machinery assembly 915
Disassembly and assembly of swing motor and swing machinery assembly 917
Removal and installation of swing circle assembly 924
400 Undercarriage and frame 927
Disassembly and assembly of carrier roller 928
Disassembly and assembly of track roller assembly 931
Disassembly and assembly of idler assembly 933
Disassembly and assembly of recoil spring 936
Expansion and installation of track shoe assembly 938
Removal and installation of sprocket 940
Removal and installation of revolving frame assembly 941
Removal and installation of counterweight assembly 943
500 Hydraulic system 947
Removal and installation of center swivel joint assembly 948
Disassembly and assembly of center swivel joint assembly 950
Removal and installation of hydraulic tank assembly 952
Removal and installation of hydraulic pump assembly 955
Removal and installation of hydraulic pump input shaft oil seal 958
Removal and installation of control valve assembly 959
Disassembly and assembly of control valve assembly 963
Disassembly and assembly of work equipment PPC valve assembly 965
Disassembly and assembly of travel PPC valve assembly 966
Disassembly and assembly of hydraulic cylinder assembly 969
600 Work equipment 977
Removal and installation of work equipment assembly 978
Remove and installation anti-drop valve assembly for boom 981
Removal and installation of anti- drop valve assembly for arm 984
Disassembly and assembly anti- drop valve assembly 986
700 Cab and its attachments 989
Removal and installation of operator’s cab assembly 990
Removal and installation of operator cab glass (stuck glass) 994
Removal and installation of front window assembly1004
Removal and installation of floor frame assembly1011
Removal and installation of air conditioner unit assembly1015
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLEVER ASSEMBLY1018
800 Electrical system1033
Removal and installation of monitor assembly1034
Removal and installation of pump controller assembly1036
Removal and installation of engine controller assembly1039
Removal and installation of KOMTRAX terminal1041
90 Diagrams and drawings1043
100 Hydraulic circuit diagram1043
Hydraulic circuit diagram1045
200 Electrical diagrams and drawings1051
Electrical circuit diagram (1/6)1053
Electrical circuit diagram (2/6)1055
Electrical circuit diagram (3/6)1057
Electrical circuit diagram (4/6)1059
Electrical circuit diagram (5/6)1061
Electrical circuit diagram (6/6)1063
Connectors table and arrangement drawing1065
IMAGES PREVIEW OF THE MANUAL:
S.M 26/12/24
