Komatsu PC160LC-7 Excavator Shop Manual SEBM028603 – PDF DOWNLOAD 

Description

Komatsu PC160LC-7 Excavator Shop Manual SEBM028603 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC160LC-7 Excavator Shop Manual SEBM028603 – PDF DOWNLOAD 

Language : English
Pages : 679
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC160LC-7 Excavator Shop Manual SEBM028603 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
PC160LC-7                  10001 and up

COVER 1
CONTENTS 2
01 GENERAL 26
SPECIFICATION DIMENSION DRAWINGS 27
SPECIFICATIONS 29
WEIGHT TABLE 31
FUEL,COOLANT,AND LUBRICANTS 33
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD 34
ENGINE RELATED PARTS 35
RADIATOR・OIL COOLER・AFTERCOOLER 36
POWER TRAIN 37
SWING MACHINERY 38
SWING CIRCLE 39
FINAL DRIVE 40
TRACK FRAME・RECOIL SPRING 42
IDLER 44
CARRIER ROLLER 46
TRACK ROLLER 47
TRACK SHOE 48
HYDRAULIC EQUIPMENT LAYOUT DRAWING 52
VALVE CONTROL 54
HYDRAULIC TANK 55
HYDRAULIC PUMP 56
PC-EPC VALVE 74
CONTROL VALVE 79
CLSS 92
TRAVEL JUNCTION VALVE 122
SELF-REDUCING PRESSURE VALVE 123
CENTER SWIVEL JOINT 124
SWING MOTOR 125
TRAVEL MOTOR 126
WORK EQUIPMENT・SWING PPC VALVE 135
TRAVEL PPC VALVE 139
SERVICE PPC VALVE 148
SOLENOID VALVE 151
ACCUMULATOR 153
RETURN OIL FILTER 154
ATTACHMENT CIRCUIT SELECTOR VALVE 155
HYDRAULIC CYLINDER 157
WORK EQUIPMENT 159
AIR CONDITIONER 165
ENGINE CONTROL 166
ELECTRONIC CONTROL SYSTEM 172
MULTI MONITOR SYSTEM 197
7-SEGMENT MONITOR SYSTEM 217
SENSOR 224
20 TESTING AND ADJUSTING 227
STANDARD VALVE TABLE FOR ENGINE RELATED PARTS 228
STANDARD VALVE TABLE FOR CHASSIS RELATED PARTS 229
TESTING AND ADJUSTING 238
TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING 239
INSPECTION AND ADJUSTING OF ENGINE RPM 241
MEASUREMENT OF EXHAUST GAS COLOR 243
ADJUSTMENT OF VALVE CLEARANCE 244
MEASUREMENT OF COMPRESSION PRESSURE 246
MEASUREMENT OF BLOW-BY PRESSURE 247
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING 248
MEASUREMENT OF ENGINE OIL PRESSURE 250
ADJUSTMENT OF ENGINE SPEED SENSOR 251
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION 252
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS 253
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION 254
INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT,SWING, AND TRAVEL CIRCUITS 255
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE 258
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE 259
INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT OIL PRESSURE 262
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE 265
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE 268
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE 269
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT 270
TESTING AND ADJUSTING TRAVEL DEVIATION 272
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 274
MEASUREMENT OF OIL LEAKAGE 275
BLEEDING AIR FROM EACH PART 277
INSPECTION PROCEDURES FOR DIODE 279
SPECIAL FUNCTION OF MONITOR PANEL 280
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL 305
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM 321
PM-TUNE UP SERVICE 322
TROUBLESHOOTING 327
POINTS TO REMEMBER WHEN TROUBLESHOOTING 328
SEQUENCE OF EVENTS IN TROUBLESHOOTING 329
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 330
CHECKS BEFORE TROUBLESHOOTING 338
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING 339
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM 343
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 360
T-ADAPTER-BOXES AND T-ADAPTER TABLE 382
TROUBLESHOOTING ERROR CODE “ELECTRICAL SYSTEM” AND FAILURE CODE “MECHANICAL SYSTEM” ARE INDICATED 385
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE 387
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 392
ERROR CODE IN ELECTRICAL SYSTEM[E101](ABNORMAL DATA IN ERROR HISTORY) 394
ERROR CODE IN ELECTRICAL SYSTEM[E112](SHORT-CIRCUITING IN NORMAL ROTATOIN SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE) 396
ERROR CODE IN ELECTRICAL SYSTEM[E113](SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE) 398
ERROR CODE IN ELECTRICAL SYSTEM[E114](SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM) 400
ERROR CODE IN ELECTRICAL SYSTEM[E115](ABNORMAL OPERATION OF WINDSHIELD WIPER) 402
ERROR CODE IN ELECTRICAL SYSTEM[E116](ABNORMALITY OPERATION IN RETRACTING WINDSHIELD WIPER) 404
ERROR CODE IN ELECTRICAL SYSTEM[E201](SHORT-CIRCUITING IN TRAVEL JUNCTION SOLENOID) 406
ERROR CODE IN ELECTRICAL SYSTEM[E203](SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID) 408
ERROR CODE IN ELECTRICAL SYSTEM[E204](SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID) 410
ERROR CODE IN ELECTRICAL SYSTEM[E205](SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID) 412
ERROR CODE IN ELECTRICAL SYSTEM[E206](SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID) 414
ERROR CODE IN ELECTRICAL SYSTEM[E211](DISCONNECTION IN TRAVEL JUNCTION SOLENOID) 416
ERROR CODE IN ELECTRICAL SYSTEM[E213](DISCONNECTION IN SWING HOLDING BRAKE SOLENOID) 418
ERROR CODE IN ELECTRICAL SYSTEM[E214](DISCONNECTION OF MERGE/DIVIDE SOLENOID) 420
ERROR CODE IN ELECTRICAL SYSTEM[E215](DISCONNECTION IN 2-STAGE RELIEF SOLENOID) 422
ERROR CODE IN ELECTRICAL SYSTEM[E216](DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID) 424
ERROR CODE IN ELECTRICAL SYSTEM[E217](ABNORMALITY IN INPUTTING MODEL CODE) 426
ERROR CODE IN ELECTRICAL SYSTEM[E218](DISCONNECTION OF S-NET SIGNAL) 428
ERROR CODE IN ELECTRICAL SYSTEM[E224](ABNORMALITY IN F PUMP PRESSURE SENSOR) 430
ERROR CODE IN ELECTRICAL SYSTEM[E225](ABNORMALITY IN R PUMP PRESSURE SENSOR) 432
ERROR CODE IN ELECTRICAL SYSTEM[E226](ABNORMALITY IN PRESSURE SENSOR POWER SOURCE) 434
ERROR CODE IN ELECTRICAL SYSTEM[E227](ABNORMALITY IN ENGINE ROTATION SENSOR) 436
ERROR CODE IN ELECTRICAL SYSTEM[E228](SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY) 438
ERROR CODE IN ELECTRICAL SYSTEM[E232](SHORT-CIRCUITING IN PC-EPC SOLENOID) 440
ERROR CODE IN ELECTRICAL SYSTEM[E233](DISCONNECTION IN PC-EPC SOLENOID) 442
ERROR CODE IN ELECTRICAL SYSTEM[E238](DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY) 444
ERROR CODE IN ELECTRICAL SYSTEM[E245](SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SOLENOID) 446
ERROR CODE IN ELECTRICAL SYSTEM[E246](DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SOLENOID) 447
ERROR CODE IN ELECTRICAL SYSTEM[E306](ABNORMALITY IN GOVERNOR POTENTIOMETER) 448
ERROR CODE IN ELECTRICAL SYSTEM[E308](ABNORMALITY IN FUEL DIAL) 450
ERROR CODE IN ELECTRICAL SYSTEM[E311](SHORT-CIRCUITING IN COLD STARTING SOLENOID RELAY) 452
ERROR CODE IN ELECTRICAL SYSTEM[E312](DISCONNECTION IN COLD STARTING SOLENOID RELAY) 454
ERROR CODE IN ELECTRICAL SYSTEM[E315](SHORT-CIRCUITING IN BATTERY RELAY) 456
ERROR CODE IN ELECTRICAL SYSTEM[E316](STEP-OUT IN GOVERNOR MOTOR) 458
ERROR CODE IN ELECTRICAL SYSTEM[E317](DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B) 459
ERROR CODE IN ELECTRICAL SYSTEM[E318](SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PRASE B) 461
FAILURE CODE IN MECHANICAL SYSTEM[A000N1](OUT-OF-RATE ENGINE ROTATION AT HIGH IDLING) 463
FAILURE CODE IN MECHANICAL SYSTEM[A000N2](OUT-OF-RATE ENGINE ROTATION AT LOW IDLING) 463
FAILURE CODE IN MECHANICAL SYSTEM[AA10NX](AIR CLEANER CLOGGING) 464
FAILURE CODE IN MECHANICAL SYSTEM[ABOOKE](ABNORMALLY LOWERED CHARGING VOLTAGE) 465
FAILURE CODE IN MECHANICAL SYSTEM[B@BAZG](ABNORMALLY LOWERED ENGINE OIL PRESSURE) 467
FAILURE CODE IN MECHANICAL SYSTEM[B@BAZK](ABNORMALLY LOWERED ENGINE OIL LEVEL) 468
FAILURE CODE IN MECHANICAL SYSTEM[B@BCNS](ENGINE COOLING WATER OVERHEATING) 469
FAILURE CODE IN MECHANICAL SYSTEM[B@BAZK](ABNORMALLY LOWERED RADIATOR WATER LEVEL) 470
FAILURE CODE IN MECHANICAL SYSTEM[B@HANS](HYDRAULIC OIL OVERHEATING) 471
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E-MODE) 472
BEFORE CONDUCTING E-MODE TROUBLESHOOTING 473
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 474
E-1 ENGINE DOES NOT START 475
E-2 ENGINE STOPS WHILE IN OPERATION 480
E-3 ENGINE ROTATES UNSTABLY OR HUNTING 481
E-4 ENGINE DOES NOT STOP 483
E-5 AUTO-DECELERATOR DOES NOT WORK 485
E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK 486
E-7 PREHEATER DOES NOT OPERATE 487
E-8 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE 489
E-9 ONE-TOUCH POWER MAX SWITCH DOES NOT WORK 491
E-10 ATTACHMENT CIRCUIT DOES NOT CHANGE 492
E-11 NO DISPLAY IN MONITOR PANEL AT ALL 493
E-12 MONITOR PANEL DOES NOT DISPLAY PARTIALLY 494
E-13 CONTENTS OF MONITOR PANEL ARE DIFFERENT FROM MOUNTED MODEL 494
E-14 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 495
E-15 ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 496
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 497
E-17 FUEL GAUGE DOES NOT DISPLAY CORRECTLY 498
E-18 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY 499
E-19 WHEN MONITOR SWITCH IS OPERATED,NOTHING IS DISPLAYED 501
E-20 WINDSHIELD WIPER AND WINDOW WASHER DOES NOT WORK 503
E-21 ALARMING BUZZER CANNOT BE CANCELLED 507
E-22 “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 508
E-23 “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 509
E-24 “ARM IN” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 510
E-25 “ARM OUT” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 511
E-26 “BUCKET CURL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 512
E-27 “BUCKET DUMP” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 513
E-28 “SWING” IS NOT CORRECTLY DISPLAYED IS MONITOR FUNCTION 514
E-29 “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 516
E-30 “TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 518
E-31 “SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 520
E-32 AIR CONDITIONER DOES NOT WORK 522
E-33 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING 524
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 526
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 527
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 528
H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, SWING, AND TRAVEL ARE LOW 530
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS 531
H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE 532
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 532
H-5 AUTO-DECELERATOR DOES NOT WORK 533
H-6 FINE CONTROL MODE DOES NOT FUNCTION 533
H-7 SPEED OR POWER OF BOOM IS LOW 534
H-8 SPEED OR POWER OF ARM IS LOW 535
H-9 SPEED OR POWER OF BUCKET IS LOW 536
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION 537
H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE 538
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE 539
H-13 ONE-TOUCH POWER MAX SYSTEM DOES NOT OPERATE 539
H-14 WORK EQUIPMENT LOADED MORE IS LOWER DURING COMPOUND OPERATION 540
H-15 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING+BOOM RAISE 540
H-16 TRAVEL SPEED LOWERS LARGELY DURING COMPOUND OPERATION OF WORK EQUIPMENT/SWING+TRAVEL 541
H-17 MACHINE DEVIATES DURING TRAVEL 542
H-18 TRAVEL SPEED IS LOW 543
H-19 MACHINE CANNOT BE STEERED EASILY OR STEERING POWER IS LOW 544
H-20 TRAVEL SPEED DOES NOT CHANGE, OR IT IS KEPT LOW OR HIGH 545
H-21 TRACK DOES NOT MOVE (ONLY EITHER SIDE) 545
H-22 MACHINE DOES NOT SWING 546
H-23 SWING ACCELERATION OR SWING SPEED IS LOW 547
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING 548
H-25 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SHOCK 549
H-26 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND 549
H-27 HYDRAULIC DRIFT OF SWING IS LARGE 550
H-28 ATTACHMENT CIRCUIT DOES NOT CHANGE 551
H-29 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED 551
30 DISASSEMBLY AND ASSEMBLY 552
HOW TO READ THIS MANUAL 554
PRECAUTIONS WHEN PERFORMING OPERATION 556
SPECIAL TOOL LIST 558
SKETCHES OF SPECIAL TOOLS 561
STARTING MOTOR 562
REMOVAL AND INSTALLATION 562
FUEL INJECTION PUMP 563
SPECIAL TOOLS 563
REMOVAL 563
INSTALLATION 565
ENGINE FRONT SEAL 567
REMOVAL 567
INSTALLATION 568
ENGINE REAR SEAL 569
REMOVAL 569
INSTALLATION 570
CYLINDER HEAD 571
SPECIAL TOOLS 571
REMOVAL 571
INSTALLATION 574
RADIATOR 577
REMOVAL AND INSTALLATION 577
AFTERCOOLER 578
REMOVAL AND INSTALLATION 578
HYDRAULIC OIL COOLER 579
REMOVAL AND INSTALLATION 579
ENGINE AND HYDRAULIC PUMP 580
SPECIAL TOOLS 580
REMOVAL 580
INSTALLATION 583
TRACK SHOE 585
SPECIAL TOOLS 585
EXPANSION 585
INSTALLATION 586
SPROCKET 587
REMOVAL AND INSTALLATION 587
FINAL DRIVE 588
REMOVAL AND INSTALLATION 588
SPECIAL TOOLS 589
DISASSEMBLY 589
ASSEMBLY 591
IDLER 596
SPECIAL TOOLS 596
DISASSEMBLY 596
ASSEMBLY 597
RECOIL SPRING 599
SPECIAL TOOLS 599
DISASSEMBLY 599
ASSEMBLY 600
TRACK ROLLER 601
SPECIAL TOOLS 601
DISASSEMBLY AND ASSEMBLY 601
CARRIER ROLLER 602
SPECIAL TOOLS 602
DISASSEMBLY AND ASSEMBLY 602
SWING MOTOR AND SWING MACHINERY 603
REMOVAL AND INSTALLATION 603
SPECIAL TOOLS 604
DISASSEMBLY 604
ASSEMBLY 607
SWING MOTOR 612
SPECIAL TOOLS 612
DISASSEMBLY 612
ASSEMBLY 615
CENTER SWIVEL JOINT 620
REMOVAL 620
INSTALLATION 621
SPECIAL TOOLS 622
DISASSEMBLY AND ASSEMBLY 622
WORK EQUIPMENT 623
SPECIAL TOOLS 623
REMOVAL 623
INSTALLATION 625
REVOLVING FRAME 626
REMOVAL 626
INSTALLATION 627
SWING CIRCLE 628
REMOVAL AND INSTALLATION 628
HYDRAULIC TANK 629
REMOVAL 629
INSTALLATION 631
CONTROL VALVE 632
REMOVAL 632
INSTALLATION 635
DISASSEMBLY AND ASSEMBLY 636
HYDRAULIC PUMP 638
SPECIAL TOOLS 638
REMOVAL 638
INSTALLATION 639
HYDRAULIC PUMP INPUT SHAFT OIL SEAL 640
SPECIAL TOOLS 640
REMOVAL AND INSTALLATION 640
WORK EQUIPMENT PPC VALVE 641
DISASSEMBLY AND ASSEMBLY 641
TRAVEL PPC VALVE 642
DISASSEMBLY AND ASSEMBLY 642
HYDRAULIC CYLINDER 643
SPECIAL TOOLS 643
DISASSEMBLY 643
ASSEMBLY 645
COUNTERWEIGHT 649
REMOVAL AND INSTALLATION 649
AIR CONDITIONER UNIT 650
SPECIAL TOOLS 650
REMOVAL 650
INSTALLATION 652
OPERATOR’S CAB 653
REMOVAL 653
INSTALLATION 655
OPERATOR’S CAB GLASS (STUCK GLASS) 656
SPECIAL TOOLS 657
REMOVAL 657
INSTALLATION 658
FRONT WINDOW 667
REMOVAL 667
INSTALLATION 669
90 OTHERS 674
HYDRAULIC CIRCUIT DIAGRAM 675
ELECTRICAL CIRCUIT DIAGRAM (1/4) 676
ELECTRICAL CIRCUIT DIAGRAM (2/4) 677
ELECTRICAL CIRCUIT DIAGRAM (3/4) 678
ELECTRICAL CIRCUIT DIAGRAM (4/4) 679

DESCRIPTION:

Komatsu PC160LC-7 Excavator Shop Manual SEBM028603 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
PC160LC-7                  10001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

IMAGES PREVIEW OF THE MANUAL:

S.V  25/12/24