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Komatsu PC160LC-8 Hydraulic Excavator Shop Manual 25001 and up – PDF DOWNLOAD
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Komatsu PC160LC-8 Hydraulic Excavator Shop Manual
Book Code: SEN04566-10
SERIAL NUMBERS : 25001 and up
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Description
Komatsu PC160LC-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC160LC-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC160LC-8
Serial Number: 25001 and up
Book Code: SEN04566-10
Language: English
Pages: 1016
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC160LC-8 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-8 Hydraulic Excavator Shop Manual
COVER ............................................................................................................ 1 00 Index and foreword............................................................................................. 0 100 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.................................................................................................. 0 100 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................................................................... 0 100 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 Return oil filter......................................................................................... 207 Center swivel joint....................................................................................... 208 Travel motor.............................................................................................. 209 Swing motor............................................................................................... 219 Attachment circuit selector valve......................................................................... 220 Hydraulic cylinder........................................................................................ 224 500 Work equipment............................................................................................ 227 Work equipment............................................................................................ 228 Dimensions of components.................................................................................. 230 600 Cab and its attachments................................................................................... 235 Air conditioner piping.................................................................................... 236 700 Electrical system......................................................................................... 239 Engine control system..................................................................................... 240 Electronic control system................................................................................. 250 Monitor system............................................................................................ 278 Sensor.................................................................................................... 304 KOMTRAX system............................................................................................ 308 20 Standard value table........................................................................................... 0 100 Standard service value table.............................................................................. 311 Standard value table for engine........................................................................... 312 Standard value table for chassis related parts............................................................ 313 30 Testing and adjusting.......................................................................................... 0 101 Testing and adjusting, Part 1............................................................................. 325 Tools for testing, adjusting and troubleshooting.......................................................... 327 Testing engine speed...................................................................................... 330 Testing intake air pressure (boost pressure).............................................................. 331 Testing exhaust gas color................................................................................. 332 Adjusting valve clearance................................................................................. 333 Testing compression pressure.............................................................................. 335 Testing blow-by pressure.................................................................................. 337 Testing engine oil pressure............................................................................... 338 Handling fuel system parts................................................................................ 339 Releasing residual pressure from fuel system.............................................................. 339 Testing fuel pressure..................................................................................... 340 Measuring fuel discharge, return and leakage.............................................................. 342 Bleeding air from fuel circuit............................................................................ 346 Checking fuel circuit for leakage......................................................................... 348 Checking and adjusting air conditioner compressor belt tension............................................ 349 Replacing fan belt........................................................................................ 350 Testing clearance in swing circle bearings................................................................ 351 Testing and adjusting track shoe tension.................................................................. 352 Inspection and adjustment oil pressure in work equipment, swing, and travel circuits...................... 353 Testing control circuit basic pressure.................................................................... 356 Testing and adjusting pump PC control circuit oil pressure................................................ 357 Testing and adjusting pump LS control circuit oil pressure................................................ 360 Testing solenoid valve output pressure.................................................................... 364 Testing PPC valve output pressure......................................................................... 367 Adjusting play of work equipment and swing PPC valves..................................................... 368 Inspecting locations of hydraulic drift of work equipment................................................. 369 Testing and adjusting travel deviation.................................................................... 371 Releasing remaining pressure in hydraulic circuit......................................................... 373 Measurement of oil leakage................................................................................ 374 Bleeding air from various parts........................................................................... 376 Inspection procedures for diode........................................................................... 378 Checking cab tipping stopper.............................................................................. 379 Installation and adjustment of mirrors and camera......................................................... 380 Inspection of air conditioner Recirc/Fresh air filter..................................................... 384 102 Testing and adjusting, Part 2............................................................................. 387 Special functions of machine monitor...................................................................... 388 103 Testing and adjusting, Part 3............................................................................. 441 Handling voltage circuit of engine controller............................................................. 442 Preparation work for troubleshooting of electrical system................................................. 443 Procedure for testing diodes.............................................................................. 448 Pm-clinic service......................................................................................... 449 40 Troubleshooting................................................................................................ 0 100 Failure code table and fuse locations..................................................................... 455 Failure code table........................................................................................ 456 Fuse locations............................................................................................ 459 200 General information on troubleshooting.................................................................... 463 Points to remember when troubleshooting................................................................... 464 Sequence of events in troubleshooting..................................................................... 465 Checks before troubleshooting............................................................................. 466 Classification and troubleshooting steps.................................................................. 467 Information in troubleshooting table...................................................................... 468 Phenomena looking like troubles and troubleshooting Nos................................................... 470 Connection table for connector pin numbers................................................................ 473 T- branch box and T- branch adapter table................................................................. 509 301 Troubleshooting by failure code, Part 1................................................................... 513 Failure code [989L00] Engine controller lock caution 1.................................................... 515 Failure code [989M00] Engine controller lock caution 2.................................................... 515 Failure code [989N00] Engine controller lock caution 3.................................................... 516 Failure code [AA10NX] Air cleaner clogging................................................................ 517 Failure code [AB00KE] Charge voltage low.................................................................. 518 Failure code [B@BAZG] Eng oil press. low.................................................................. 520 Failure code [B@BAZK] Eng oil level low................................................................... 521 Failure code [B@BCNS] Eng coolant overheat................................................................ 522 Failure code [B@BCZK] Eng water level low................................................................. 524 Failure code [B@HANS] Hydr oil overheat................................................................... 526 Failure code [CA111] ECM critical internal failure........................................................ 528 Failure code [CA115] Eng Ne and bkup speed sens error..................................................... 529 Failure code [CA122] Chg air press sensor high error...................................................... 530 Failure code [CA123] Chg air press sensor low error....................................................... 532 Failure code [CA131] Throttle sensor high error........................................................... 534 Failure code [CA132] Throttle sensor low error............................................................ 536 Failure code [CA144] Coolant temp sens high error......................................................... 538 Failure code [CA145] Coolant temp sens low error.......................................................... 540 Failure code [CA153] Chg air temp sensor high error....................................................... 542 Failure code [CA154] Chg air temp sensor low error........................................................ 544 Failure code [CA155] Chg air temp high speed derate....................................................... 546 Failure code [CA187] Sens supply 2 volt low error......................................................... 548 Failure code [CA221] Ambient press sens high error........................................................ 550 Failure code [CA222] Ambient press sens low error......................................................... 552 Failure code [CA227] Sens supply 2 volt high error........................................................ 554 Failure code [CA234] Eng. overspeed....................................................................... 555 Failure code [CA238] Ne speed sens supply volt error...................................................... 556 Failure code [CA271] IMV/PCV1 short error................................................................. 557 Failure code [CA272] IMV/PCV1 open error.................................................................. 558 Failure code [CA322] Inj #1 open/short error.............................................................. 560 Failure code [CA324] Inj #3 open/short error.............................................................. 562 Failure code [CA331] Inj #2 open/short error.............................................................. 564 Failure code [CA332] Inj #4 open/short error.............................................................. 566 302 Troubleshooting by failure code, Part 2................................................................... 569 Failure code [CA342] Calibration code incompatibility..................................................... 571 Failure code [CA351] Injectors Drive Circuit Error........................................................ 572 Failure code [CA352] Sens supply 1 volt low error......................................................... 574 Failure code [CA386] Sens supply 1 volt high error........................................................ 576 Failure code [CA428] Water in fuel sensor high error...................................................... 578 Failure code [CA429] Water in fuel sensor low error....................................................... 580 Failure code [CA435] Eng oil press sw error............................................................... 582 Failure code [CA441] Battery voltage low error............................................................ 584 Failure code [CA442] Battery voltage high error........................................................... 586 Failure code [CA449] Rail press very high error........................................................... 588 Failure code [CA451] Rail press sensor high error......................................................... 590 Failure code [CA452] Rail press sensor low error.......................................................... 592 Failure code [CA488] Chg air temp high torque derate...................................................... 594 Failure code [CA553] Rail press high error................................................................ 594 Failure code [CA559] Rail press low error................................................................. 595 Failure code [CA689] Eng Ne speed sensor error............................................................ 596 Failure code [CA731] Eng Bkup speed sens phase error...................................................... 598 Failure code [CA757] All persistent data lost error...................................................... 600 Failure code [CA778] Eng Bkup speed sensor error.......................................................... 602 Failure code [CA1633] KOMNET datalink timeout error....................................................... 604 Failure code [CA2185] Throttle sens. sup. volt. high error................................................ 606 Failure code [CA2186] Throttle sens. sup. volt. low error................................................. 607 Failure code [CA2249] Rail press very low error........................................................... 608 Failure code [CA2311] IMV solenoid error.................................................................. 610 Failure code [CA2555] Grid htr relay volt high error...................................................... 612 Failure code [CA2556] Grid htr relay volt low error....................................................... 614 Failure code [D110KB] Battery relay drive short........................................................... 616 Failure code [D19JKZ] Personal code relay abnormality..................................................... 618 Failure code [D862KA] GPS antenna discon.................................................................. 620 Failure code [DA22KK] Pump solenoid power low error....................................................... 622 Failure code [DA25KP] 5V sensor 1 power abnormality....................................................... 624 Failure code [DA26KP] 5V sensor 2 power abnormality....................................................... 627 Failure code [DA29KQ] Model selection abnormality......................................................... 628 303 Troubleshooting by failure code, Part 3................................................................... 631 Failure code [DA2RMC] CAN discon (Pump controller detected)............................................... 634 Failure code [DAF8KB] Short circuit in camera power supply................................................ 636 Failure code [DAFGMC] GPS module error.................................................................... 638 Failure code [DAFRMC] CAN discon (Monitor detected)....................................................... 640 Failure code [DGH2KB] Hydr oil sensor short............................................................... 642 Failure code [DHPAMA] F Pump press sensor abnormality..................................................... 644 Failure code [DHPBMA] R Pump press sensor abnormality..................................................... 646 Failure code [DHS5KX] Travel PPC press sensor abnormality................................................. 648 Failure code [DHSAMA] Sw RH PPC press sen. abnormality.................................................... 650 Failure code [DHSBMA] Sw LH PPC press sen. abnormality.................................................... 652 Failure code [DHX1MA] Overload sensor abnormality (Analog)................................................ 654 Failure code [DW43KA] Travel speed sol discon............................................................. 655 Failure code [DW43KB] Travel speed sol short.............................................................. 656 Failure code [DW45KA] Swing brake sol discon.............................................................. 658 Failure code [DW45KB] Swing brake sol short............................................................... 660 Failure code [DW91KA] Travel junction sol discon.......................................................... 662 Failure code [DW91KB] Travel junction sol short........................................................... 664 Failure code [DWA2KA] Service sol discon.................................................................. 666 Failure code [DWA2KB] Service sol short................................................................... 667 Failure code [DWJ0KA] Merge-divider sol discon............................................................ 668 Failure code [DWJ0KB] Merge-divider sol short............................................................. 670 Failure code [DWK0KA] 2-stage relief sol discon........................................................... 672 Failure code [DWK0KB] 2-stage relief sol short............................................................ 674 304 Troubleshooting by failure code, Part 4................................................................... 677 Failure code [DXA8KA] PC-EPC sol discon................................................................... 678 Failure code [DXA8KB] PC-EPC sol short.................................................................... 680 Failure code [DXE4KA] Service current EPC discon.......................................................... 682 Failure code [DXE4KB] Service current EPC short........................................................... 684 Failure code [DY20KA] Wiper working abnormality........................................................... 686 Failure code [DY20MA] Wiper parking abnormality........................................................... 688 Failure code [DY2CKA] Washer drive discon................................................................. 690 Failure code [DY2CKB] Washer drive short.................................................................. 692 Failure code [DY2DKB] Wiper drive (for) short............................................................. 694 Failure code [DY2EKB] Wiper drive (rev) short............................................................. 696 400 Troubleshooting of electrical system (E-mode)............................................................. 699 Before carrying out troubleshooting of electrical system.................................................. 701 Information in troubleshooting table...................................................................... 703 E-1 When starting switch turned ON, machine monitor displays nothing...................................... 704 E-2 When starting switch is turned to ON position (before starting engine), basic check item lights up.... 706 E-3 Engine does not start (Engine does not crank)......................................................... 709 E-4 Preheater does not operate............................................................................ 712 E-5 Automatic warm-up system does not operate (in cold season)............................................ 714 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked....................... 716 E-7 Precaution lights up while engine is running.......................................................... 718 E-8 Emergency stop item lights up while engine is running................................................. 722 E-9 Engine coolant temperature gauge does not indicate normally........................................... 723 E-10 Hydraulic oil temperature gauge does not indicate normally........................................... 724 E-11 Fuel level gauge does not indicate normally.......................................................... 726 E-12 Contents of display by machine monitor are different from applicable machine......................... 728 E-13 Machine monitor does not display some items.......................................................... 728 E-14 Function switch does not work........................................................................ 728 E-15 Auto-decelerator does not operate normally........................................................... 729 E-16 Working mode does not change......................................................................... 730 E-17 Travel speed does not change......................................................................... 731 E-18 Alarm buzzer cannot be stopped....................................................................... 732 E-19 Windshield wiper and window washer do not operate.................................................... 733 E-20 Power maximizing function does not operate normally.................................................. 735 E-21 Swing holding brake does not operate normally........................................................ 737 E-22 Travel alarm does not sound or does not stop sounding................................................ 739 E-23 Air conditioner does not operate normally (including air conditioner abnormality record)............. 741 E-24 While starting switch is in OFF position, service meter is not displayed............................. 752 E-25 Machine monitor cannot be set in service mode........................................................ 752 E-26 Monitoring function does not display lever control signal normally................................... 754 E-27 KOMTRAX system does not operate normally............................................................. 764 500 Troubleshooting of hydraulic and mechanical system (H-mode)............................................... 767 Information contained in troubleshooting table............................................................ 769 System chart for hydraulic and mechanical systems......................................................... 770 H-1 Speed or power of all work equipment, swing, and travel are low....................................... 772 H-2 Engine speed sharply drops or engine stalls........................................................... 773 H-3 No work equipment, travel and swing move.............................................................. 774 H-4 Abnormal noise is heard from around hydraulic pump.................................................... 774 H-5 Auto-decelerator does not work........................................................................ 775 H-6 Fine control mode does not function................................................................... 775 H-7 Speed or power of boom is low......................................................................... 776 H-8 Speed or power of arm is low.......................................................................... 777 H-9 Speed or power of bucket is low....................................................................... 778 H-10 Work equipment does not move in its single operation................................................. 779 H-11 Hydraulic drift of work equipment is large........................................................... 780 H-12 Time lag of work equipment is large.................................................................. 781 H-13 One-touch power max system does not operate.......................................................... 781 H-14 Work equipment loaded more is slower during compound operation....................................... 782 H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE.................................. 782 H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel............... 783 H-17 Machine deviates during travel....................................................................... 784 H-18 Travel speed is low.................................................................................. 785 H-19 Machine cannot be steered easily or steering power is low............................................ 786 H-20 Travel speed does not change or it is kept low or high............................................... 787 H-21 Track does not move (Only either side)............................................................... 787 H-22 Machine does not swing............................................................................... 788 H-23 Swing acceleration or swing speed is low............................................................. 789 H-24 Excessive overrun when stopping swing................................................................ 790 H-25 When upper structure stops swinging, it makes large shock............................................ 791 H-26 When upper structure stops swinging, it makes large sound............................................ 791 H-27 Hydraulic drift of swing is large.................................................................... 792 H-28 Attachment circuit does not change................................................................... 793 H-29 Flow rate in attachment circuit cannot be adjusted................................................... 793 600 Troubleshooting of engine (S-mode)........................................................................ 795 Method of using troubleshooting chart..................................................................... 798 S-1 Starting performance is poor......................................................................... 802 S-2 Engine does not start................................................................................ 803 S-3 Engine does not pick up smoothly..................................................................... 806 S-4 Engine stops during operations....................................................................... 807 S-5 Engine does not rotate smoothly...................................................................... 808 S-6 Engine lack output (or lacks power).................................................................. 809 S-7 Exhaust smoke is black (incomplete combustion)....................................................... 810 S-8 Oil consumption is excessive (or exhaust smoke is blue).............................................. 811 S-9 Oil becomes contaminated quickly..................................................................... 812 S-10 Fuel consumption is excessive....................................................................... 813 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)............................... 814 S-12 Oil pressure drops.................................................................................. 815 S-13 Oil level rises (Entry of coolant/fuel)............................................................. 816 S-14 Coolant temperature becomes too high (overheating).................................................. 817 S-15 Abnormal noise is made.............................................................................. 818 S-16 Vibration is excessive.............................................................................. 819 50 Disassembly and assembly....................................................................................... 0 100 General information on disassembly and assembly........................................................... 821 How to read this manual................................................................................... 822 Coating materials list.................................................................................... 824 Special tool list......................................................................................... 827 Sketches of special tools................................................................................. 830 200 Engine and cooling system................................................................................. 833 Removal and installation of fuel supply pump assembly..................................................... 834 Removal and installation of fuel injector assembly........................................................ 838 Removal and installation of cylinder head assembly........................................................ 845 Removal and installation of front oil seal................................................................ 858 Removal and installation of rear oil seal................................................................. 860 Removal and installation of radiator assembly............................................................. 863 Removal and installation of aftercooler assembly.......................................................... 865 Removal and installation of hydraulic oil cooler assembly................................................. 867 Removal and installation of engine and hydraulic pump assembly............................................ 869 Removal and installation of engine hood assembly.......................................................... 877 Removal and installation of fuel tank assembly............................................................ 879 300 Power train............................................................................................... 883 Removal and installation of travel motor and final drive assembly......................................... 884 Disassembly and assembly of final drive assembly.......................................................... 886 Removal and installation of swing motor and swing machinery assembly...................................... 893 Disassembly and assembly of swing motor and swing machinery assembly...................................... 895 Removal and installation of swing circle assembly......................................................... 902 400 Undercarriage and frame................................................................................... 905 Disassembly and assembly of carrier roller................................................................ 906 Disassembly and assembly of track roller assembly......................................................... 909 Disassembly and assembly of idler assembly................................................................ 911 Disassembly and assembly of recoil spring................................................................. 914 Expansion and installation of track shoe assembly......................................................... 916 Removal and installation of sprocket...................................................................... 918 Removal and installation of revolving frame assembly...................................................... 919 Removal and installation of counterweight assembly........................................................ 921 500 Hydraulic system.......................................................................................... 925 Removal and installation of center swivel joint assembly.................................................. 926 Disassembly and assembly of center swivel joint assembly.................................................. 928 Removal and installation of hydraulic tank assembly....................................................... 930 Removal and installation of hydraulic pump assembly....................................................... 933 Removal and installation of hydraulic pump input shaft oil seal........................................... 936 Removal and installation of control valve assembly........................................................ 937 Disassembly and assembly of control valve assembly........................................................ 941 Disassembly and assembly of work equipment PPC valve assembly............................................. 943 Disassembly and assembly of travel PPC valve assembly..................................................... 944 Disassembly and assembly of hydraulic cylinder assembly................................................... 947 600 Work equipment Body....................................................................................... 955 Removal and installation of work equipment assembly....................................................... 956 700 Cab and its attachments................................................................................... 961 Removal and installation of operator’s cab assembly....................................................... 962 Removal and installation of operator cab glass (stuck glass).............................................. 966 Removal and installation of front window assembly......................................................... 976 Removal and installation of floor frame assembly.......................................................... 983 Removal and installation of air conditioner unit assembly................................................. 987 800 Electrical system......................................................................................... 991 Removal and installation of monitor assembly.............................................................. 992 Removal and installation of pump controller assembly...................................................... 994 Removal and installation of engine controller assembly.................................................... 997 Removal and installation of KOMTRAX terminal.............................................................. 999 90 Diagrams and drawings.......................................................................................... 0 100 Hydraulic circuit diagram.................................................................................1001 Hydraulic circuit diagram.................................................................................1003 200 Electrical diagrams and drawings..........................................................................1006 Electrical circuit diagram (1/6)..........................................................................1008 Electrical circuit diagram (2/6)..........................................................................1009 Electrical circuit diagram (3/6)..........................................................................1010 Electrical circuit diagram (4/6)..........................................................................1011 Electrical circuit diagram (5/6)..........................................................................1012 Electrical circuit diagram (6/6)..........................................................................1013 Connectors table and arrangement drawing..................................................................1014
KOMATSU PC160LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL 25001 AND UP – PDF DOWNLOAD:
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