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Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual 20001 and up – PDF DOWNLOAD
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Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual
SERIAL NUMBERS 20001 and up
Book Code: SEN01892-05
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Description
Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC160LC-7E0
Serial Number: 20001 and up
Book Code: SEN01892-05
Language: English
Pages: 921
File Format: Portable Document Format (PDF)
KOMATSU PC160LC-7E0 HYDRAULIC EXCAVATOR SHOP MANUAL 20001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual
COVER.................................................................................................. 1 00 Index and foreword.................................................................................. 0 Index.............................................................................................. 2 Composition of shop manual..................................................................... 3 Table of contents.............................................................................. 5 Foreword and general information................................................................... 14 Safety notice.................................................................................. 15 How to read the shop manual.................................................................... 20 Explanation of terms for maintenance standard.................................................. 22 Handling of electric equipment and hydraulic component......................................... 24 Handling of connectors newly used for engines.................................................. 33 How to read electric wire code................................................................. 36 Precautions when carrying out operation........................................................ 39 Method of disassembling and connecting push-pull type coupler.................................. 42 Standard tightening torque table............................................................... 45 Conversion table............................................................................... 49 01 Specification....................................................................................... 0 Specification and technical data................................................................... 56 Specification dimension drawings............................................................... 57 Specifications................................................................................. 59 Weight table................................................................................... 61 Table of fuel, coolant and lubricants.......................................................... 63 10 Structure, function and maintenance standard........................................................ 0 Engine and cooling system.......................................................................... 66 Engine related parts........................................................................... 67 Radiator, oil cooler, aftercooler and fuel cooler.............................................. 68 Power train system................................................................................. 70 Power train.................................................................................... 71 Swing circle................................................................................... 72 Swing machinery................................................................................ 73 Final drive.................................................................................... 74 Sprocket....................................................................................... 76 Undercarriage and frame............................................................................ 79 Track frame, recoil spring..................................................................... 80 Idler.......................................................................................... 82 Carrier roller................................................................................. 84 Track roller................................................................................... 85 Track shoe..................................................................................... 86 Hydraulic system, Part 1........................................................................... 91 Hydraulic equipment layout drawing............................................................. 92 Hydraulic tank................................................................................. 94 Hydraulic pump................................................................................. 95 Hydraulic system, Part 2...........................................................................121 Control valve..................................................................................122 CLSS...........................................................................................135 Functions and operation by valve...............................................................138 Hydraulic system, Part 3...........................................................................173 Valve control..................................................................................174 PPC valve......................................................................................175 Solenoid valve.................................................................................191 Accumulator....................................................................................193 Return oil filter..............................................................................194 Center swivel joint............................................................................195 Travel motor...................................................................................196 Swing motor....................................................................................206 Attachment circuit selector valve..............................................................207 Hydraulic cylinder.............................................................................210 Work equipment.....................................................................................213 Work equipment.................................................................................214 Dimensions of components.......................................................................216 Cab and its attachments............................................................................221 Air conditioner piping.........................................................................222 Electrical system..................................................................................224 Engine control.................................................................................225 Electronic control system......................................................................234 Monitor system.................................................................................260 Sensor.........................................................................................278 KOMTRAX terminal system........................................................................281 20 Standard value table................................................................................ 0 Standard service value table.......................................................................286 Standard value table for engine................................................................287 Standard value table for chassis related parts.................................................288 30 Testing and adjusting............................................................................... 0 Testing and adjusting, Part 1......................................................................299 Tools for testing, adjusting, and troubleshooting..............................................300 Measuring engine speed.........................................................................303 Measuring intake air pressure (boost pressure).................................................304 Checking exhaust gas color.....................................................................305 Adjusting valve clearance......................................................................306 Measuring compression pressure.................................................................308 Measurement of blow-by pressure................................................................310 Measuring engine oil pressure..................................................................311 Handling fuel system parts.....................................................................312 Releasing residual pressure from fuel system...................................................312 Measuring fuel pressure........................................................................313 Measuring fuel discharge, return and leakage...................................................315 Bleeding air from fuel circuit.................................................................319 Checking fuel circuit for leakage..............................................................321 Checking and adjusting air conditioner compressor belt tension.................................322 Replacing the fan belt.........................................................................323 Testing and adjusting, Part 2......................................................................325 Testing of clearance in swing circle bearings..................................................326 Checking and adjusting track shoe tension......................................................327 Inspection and adjustment oil pressure in work equipment, swing, and travel circuits...........328 Inspection and adjustment of control circuit oil pressure......................................331 Inspection and adjustment of pump PC control circuit oil pressure..............................332 Inspection and adjustment of pump LS control circuit oil pressure..............................335 Measurement of solenoid valve output pressure..................................................339 Testing of PPC valve output pressure...........................................................342 Adjustment of work equipment and swing PPC valve...............................................343 Inspection of locations of hydraulic drift of work equipment...................................344 Testing and adjusting travel deviation.........................................................346 Release of residual pressure from hydraulic circuit............................................348 Measurement of oil leakage.....................................................................349 Bleeding air from each part....................................................................351 Inspection procedures for diode................................................................353 Adjusting mirrors..............................................................................354 Testing and adjusting, Part 3......................................................................357 Special functions of machine monitor...........................................................358 Handling voltage circuit of engine controller..................................................386 Procedure for turning on KOMTRAX terminal......................................................387 Indication by KOMTRAX terminal lamps...........................................................390 Preparation work for troubleshooting of electrical system......................................393 Pm-clinic service..............................................................................395 40 Troubleshooting..................................................................................... 0 Failure code table and fuse locations..............................................................401 Failure code table.............................................................................402 Fuse locations.................................................................................405 General information on troubleshooting.............................................................408 Points to remember when troubleshooting........................................................409 Sequence of events in troubleshooting..........................................................410 Checks before troubleshooting..................................................................411 Classification and troubleshooting steps.......................................................412 Information in troubleshooting table...........................................................413 Possible problems and troubleshooting No.......................................................415 Connection table for connector pin numbers.....................................................418 T- branch box and T- branch adapter table......................................................454 Troubleshooting by failure code, Part 1............................................................458 Failure code [AA10NX] Air cleaner clogging.....................................................460 Failure code [AB00KE] Charge voltage low.......................................................461 Failure code [B@BAZG] Eng. oil press. low......................................................463 Failure code [B@BAZK] Eng. oil level low.......................................................464 Failure code [B@BCNS] Eng. coolant overheat....................................................465 Failure code [B@BCZK] Eng. coolant level low...................................................467 Failure code [B@HANS] Hydr oil overheat........................................................468 Failure code [CA111] EMC critical internal failure.............................................468 Failure code [CA115] Eng Ne and bkup speed sens error..........................................469 Failure code [CA122] Chg air press sensor high error...........................................470 Failure code [CA123] Chg air press sensor low error............................................472 Failure code [CA131] Throttle sensor high error................................................474 Failure code [CA132] Throttle sensor low error.................................................476 Failure code [CA144] Coolant temp sens high error..............................................478 Failure code [CA145] Coolant temp sens low error...............................................480 Failure code [CA153] Chg air temp sensor high error............................................482 Failure code [CA154] Chg air temp sensor low error.............................................484 Failure code [CA155] Chg air temp high speed derate............................................486 Failure code [CA187] Sens supply 2 volt low error..............................................487 Failure code [CA221] Ambient press sens high error.............................................489 Failure code [CA222] Ambient press sens low error..............................................491 Failure code [CA227] Sens supply 2 volt high error.............................................493 Failure code [CA234] Eng. overspeed............................................................494 Failure code [CA238] Ne speed sens supply volt error...........................................495 Failure code [CA271] IMV/PCV1 short error......................................................496 Failure code [CA272] IMV/PCV1 open error.......................................................497 Failure code [CA322] Inj #1 open/short error...................................................498 Failure code [CA324] Inj #3 open/short error...................................................500 Troubleshooting by failure code, Part 2............................................................503 Failure code [CA331] Inj #2 open/short error...................................................506 Failure code [CA332] Inj #4 open/short error...................................................508 Failure code [CA342] Calibration code incompatibility..........................................510 Failure code [CA351] Injectors drive circuit error.............................................512 Failure code [CA352] Sens supply 1 volt low error..............................................514 Failure code [CA386] Sens supply 1 volt high error.............................................516 Failure code [CA428] Water in fuel sensor high error...........................................518 Failure code [CA429] Water in fuel sensor low error............................................520 Failure code [CA435] Eng oil press sw error....................................................522 Failure code [CA441] Engine controller battery voltage low error...............................524 Failure code [CA442] Engine controller battery voltage high error..............................526 Failure code [CA449] Rail press very high error................................................528 Failure code [CA451] Rail press sensor high error..............................................530 Failure code [CA452] Rail press sensor low error...............................................532 Failure code [CA488] Chg air temp high torque derate...........................................534 Failure code [CA553] Rail press high error.....................................................534 Failure code [CA559] Rail press low error......................................................535 Failure code [CA689] Eng Ne speed sensor error.................................................536 Failure code [CA731] Eng Bkup speed sens phase error...........................................538 Failure code [CA757] All continuous data lost error............................................540 Failure code [CA778] Eng Bkup speed sensor error...............................................542 Failure code [CA1633] KOMNET Datalink timeout error............................................544 Failure code [CA2185] Throt sens sup volt high error...........................................546 Failure code [CA2186] Throt sens sup volt low error............................................547 Failure code [CA2249] Rail press very low error................................................548 Failure code [CA2311] IMV solenoid error.......................................................550 Failure code [CA2555] Grid htr relay volt high error...........................................552 Failure code [CA2556] Grid htr relay volt low error............................................554 Troubleshooting by failure code, Part 3............................................................557 Failure code [D110KB] Battery relay drive S/C..................................................558 Failure code [D196KA] Service return relay disc................................................560 Failure code [D196KB] Service return relay S/C.................................................562 Failure code [DA22KK] Pump solenoid power low error............................................564 Failure code [DA25KP] Press. sensor power abnormality..........................................566 Failure code [DA2RMC] Pump comm. abnormality...................................................568 Failure code [DA2SKQ] Model selection abnormality..............................................570 Failure code [DAFRMC] Monitor comm. abnormality................................................572 Failure code [DGH2KB] Hydr oil sensor short....................................................574 Failure code [DHPAMA] F pump press sensor abnormality..........................................575 Failure code [DHPBMA] R pump press sensor abnormality..........................................577 Failure code [DHSAMA] Sw RH PPC press sen. abnormality.........................................579 Failure code [DHSBMA] Sw LH PPC press sen. abnormality.........................................581 Troubleshooting by failure code, Part 4............................................................584 Failure code [DW43KA] Travel speed sol. disc...................................................586 Failure code [DW43KB] Travel speed sol. S/C....................................................588 Failure code [DW45KA] Swing brake sol. disc....................................................590 Failure code [DW45KB] Swing brake sol. S/C.....................................................593 Failure code [DW91KA] Travel junction sol. disc................................................595 Failure code [DW91KB] Travel junction sol. S/C.................................................597 Failure code [DWJ0KA] Merge-divider sol. disc..................................................599 Failure code [DWJ0KB] Merge-divider sol. S/C...................................................601 Failure code [DWK0KA] 2-stage relief sol. disc.................................................603 Failure code [DWK0KB] 2-stage relief sol. S/C..................................................605 Failure code [DXA0KA] PC-EPC sol. disc.........................................................607 Failure code [DXA0KB] PC-EPC sol. S/C..........................................................609 Failure code [DXE4KA] Service current EPC disc.................................................611 Failure code [DXE4KB] Service current EPC S/C..................................................612 Failure code [DY20KA] Wiper working abnormality................................................613 Failure code [DY20MA] Wiper parking abnormality................................................615 Failure code [DY2CKB] Washer drive S/C.........................................................617 Failure code [DY2DKB] Wiper drive (for) S/C....................................................619 Failure code [DY2EKB] Wiper drive (rev) S/C....................................................621 Troubleshooting of electrical system (E-mode)......................................................624 Before carrying out troubleshooting of electrical system.......................................626 Information contained in troubleshooting table.................................................628 E-1 Engine does not start......................................................................629 E-2 Auto-decelerator does not operate..........................................................632 E-3 Automatic warming-up system does not operate...............................................634 E-4 Preheater does not operate.................................................................635 E-5 All work equipment, swing, and travel mechanism do not move................................637 E-6 Power maximizing function does not operate.................................................639 E-7 Machine monitor does not display at all....................................................641 E-8 Machine monitor does not display some items................................................643 E-9 Contents of display by machine monitor are different from applicable machine...............643 E-10 Fuel level monitor was lighted in red while engine running................................644 E-11 Engine coolant temperature gauge does not indicate normally...............................645 E-12 Hydraulic oil temperature gauge does not indicate normally................................647 E-13 Fuel level gauge does not indicate normally...............................................649 E-14 Swing lock monitor does not indicate normally.............................................650 E-15 When monitor switch is operated, monitor displays nothing.................................652 E-16 Windshield wiper and window washer do not operate.........................................653 E-17 Monitoring function fails to display "boom raise" normally................................657 E-18 Monitoring function fails to display "boom lower" normally................................659 E-19 Monitoring function fails to display "arm IN" normally....................................661 E-20 Monitoring function fails to display "arm OUT" normally...................................663 E-21 Monitoring function fails to display "bucket CURL" normally...............................665 E-22 Monitoring function fails to display "bucket DUMP" normally...............................667 E-23 Monitoring function fails to display "swing left" normally................................669 E-24 Monitoring function fails to display "swing right" normally...............................671 E-25 Monitoring function fails to display "travel" normally....................................673 E-26 Monitoring function fails to display "travel differential pressure" normally..............675 E-27 Monitoring function fails to display "service" normally...................................677 E-28 KOMTRAX system does not operate normally..................................................679 E-29 Air conditioner does not operate..........................................................681 E-30 Travel alarm does not sound or does not stop sounding.....................................683 E-31 Horn does not sound.......................................................................685 E-32 Attachment circuit does not change........................................................687 Troubleshooting of hydraulic and mechanical system (H-mode)........................................690 Information contained in troubleshooting table.................................................692 System chart for hydraulic and mechanical systems..............................................693 H-1 Speed or power of all work equipment, swing, and travel are low............................695 H-2 Engine speed sharply drops or engine stalls................................................696 H-3 No work equipment, travel and swing move...................................................697 H-4 Abnormal noise is heard from around hydraulic pump.........................................697 H-5 Auto-decelerator does not work.............................................................698 H-6 Fine control mode does not function........................................................698 H-7 Speed or power of boom is low..............................................................699 H-8 Speed or power of arm is low...............................................................700 H-9 Speed or power of bucket is low............................................................701 H-10 Work equipment does not move in its single operation......................................702 H-11 Hydraulic drift of work equipment is large................................................703 H-12 Time lag of work equipment is large.......................................................704 H-13 One-touch power max system does not operate...............................................704 H-14 Work equipment loaded more is slower during compound operation............................705 H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE.......................705 H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel....706 H-17 Machine deviates during travel............................................................707 H-18 Travel speed is low.......................................................................708 H-19 Machine cannot be steered easily or steering power is low.................................709 H-20 Travel speed does not change or it is kept low or high....................................710 H-21 Track does not move (Only either side)....................................................710 H-22 Machine does not swing....................................................................711 H-23 Swing acceleration or swing speed is low..................................................712 H-24 Excessive overrun when stopping swing.....................................................713 H-25 When upper structure stops swinging, it makes large shock.................................714 H-26 When upper structure stops swinging, it makes large sound.................................714 H-27 Hydraulic drift of swing is large.........................................................715 H-28 Attachment circuit does not change........................................................716 H-29 Flow rate in attachment circuit cannot be adjusted........................................716 Troubleshooting of engine (S-mode).................................................................718 Method of using troubleshooting chart..........................................................721 S-1 Starting performance is poor...............................................................725 S-2 Engine does not start......................................................................726 S-3 Engine does not pick up smoothly...........................................................729 S-4 Engine stops during operations.............................................................730 S-5 Engine does not rotate smoothly............................................................731 S-6 Engine lack output (or lacks power)........................................................732 S-7 Exhaust smoke is black (incomplete combustion).............................................733 S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................734 S-9 Oil becomes contaminated quickly...........................................................735 S-10 Fuel consumption is excessive.............................................................736 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).....................737 S-12 Oil pressure drops........................................................................738 S-13 Oil level rises (Entry of coolant/fuel)...................................................739 S-14 Coolant temperature becomes too high (overheating)........................................740 S-15 Abnormal noise is made....................................................................741 S-16 Vibration is excessive....................................................................742 50 Disassembly and assembly............................................................................ 0 General information on disassembly and assembly....................................................744 How to read this manual........................................................................745 Coating materials list.........................................................................747 Special tool list..............................................................................750 Sketches of special tools......................................................................753 Engine and cooling system..........................................................................756 Removal and installation of fuel supply pump assembly..........................................757 Removal and installation of fuel injector assembly.............................................760 Removal and installation of front oil seal.....................................................766 Removal and installation of rear oil seal......................................................768 Removal and installation of cylinder head assembly.............................................771 Removal and installation of radiator assembly..................................................782 Removal and installation of aftercooler assembly...............................................784 Removal and installation of work equipment oil cooler assembly.................................786 Removal and installation of engine and hydraulic pump assembly.................................788 Removal and installation of engine hood assembly...............................................795 Removal and installation of fuel tank assembly.................................................797 Power train........................................................................................800 Removal and installation of travel motor and final drive assembly..............................801 Disassembly and assembly of final drive assembly...............................................802 Removal and installation of swing motor and swing machinery assembly...........................809 Disassembly and assembly of swing motor and swing machinery assembly...........................811 Removal and installation of swing circle assembly..............................................818 Undercarriage and frame............................................................................820 Disassembly and assembly of carrier roller.....................................................821 Disassembly and assembly of track roller assembly..............................................824 Disassembly and assembly of idler assembly.....................................................826 Disassembly and assembly of recoil spring......................................................829 Expansion and installation of track shoe assembly..............................................831 Removal and installation of sprocket...........................................................833 Removal and installation of revolving frame assembly...........................................834 Removal and installation of counterweight......................................................836 Hydraulic system...................................................................................838 Removal and installation of center swivel joint assembly.......................................839 Disassembly and assembly of center swivel joint assembly.......................................841 Removal and installation of hydraulic tank assembly............................................842 Removal and installation of hydraulic pump assembly............................................845 Removal and installation of control valve assembly.............................................848 Disassembly and assembly of control valve assembly.............................................852 Removal and installation of hydraulic pump input shaft oil seal................................854 Disassembly and assembly of work equipment PPC valve assembly..................................855 Disassembly and assembly of travel PPC valve assembly..........................................856 Disassembly and assembly of hydraulic cylinder assembly........................................857 Work equipment Body................................................................................864 Removal and installation of work equipment assembly............................................865 Cab and its attachments............................................................................870 Removal and installation of operator's cab.....................................................871 Removal and installation of operator's cab glass (Stuck glass).................................874 Removal and installation of front window assembly..............................................885 Removal and installation of floor frame assembly...............................................892 Electrical system..................................................................................896 Removal and installation of air conditioner compressor assembly................................897 Removal and installation of air conditioner condenser..........................................898 Removal and installation of air conditioner unit assembly......................................899 Removal and installation of machine monitor assembly...........................................901 Removal and installation of governor, pump controller assembly.................................902 Removal and installation of engine controller assembly.........................................903 Removal and installation of KOMTRAX assembly...................................................905 90 Diagrams and drawings............................................................................... 0 Hydraulic circuit diagram..........................................................................908 Hydraulic circuit diagram......................................................................909 Electrical diagrams and drawings...................................................................911 Electrical circuit diagram (1/6)...............................................................913 Electrical circuit diagram (2/6)...............................................................914 Electrical circuit diagram (3/6)...............................................................915 Electrical circuit diagram (4/6)...............................................................916 Electrical circuit diagram (5/6)...............................................................917 Electrical circuit diagram (6/6)...............................................................918 Connectors table and arrangement drawing.......................................................919
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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