Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual SEN01892-05 PDF

Description

Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual SEN01892-05 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual SEN01892-05 – PDF DOWNLOAD 

Language : English
Pages : 921
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual SEN01892-05 – PDF DOWNLOAD 

SERIAL NUMBERS 20001 and up

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

DESCRIPTION:

Komatsu PC160LC-7E0 Hydraulic Excavator Shop Manual SEN01892-05 – PDF DOWNLOAD 

SERIAL NUMBERS 20001 and up

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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 24/12/24