Komatsu PC160LC-8 PC190LC-8 PC190NLC-8 Hydraulic Excavator Shop Manual UEN04566-00 PDF

Description

Komatsu PC160LC-8 PC190LC-8 PC190NLC-8 Hydraulic Excavator Shop Manual UEN04566-00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC160LC-8 PC190LC-8 PC190NLC-8 Hydraulic Excavator Shop Manual UEN04566-00 – PDF DOWNLOAD 

Language : English
Pages : 1072
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC160LC-8 PC190LC-8 PC190NLC-8 Hydraulic Excavator Shop Manual UEN04566-00 – PDF DOWNLOAD 

SERIAL NUMBERS K50001 and up

00 Index and foreword 3
100 Index 3
Composition of shop manual 4
Table of contents 6
00 Index and foreword 17
200 Foreword and general information 17
Safety notice 18
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling of electric equipment and hydraulic component 27
Handling of connectors newly used for engines 36
How to read electric wire code 39
Precautions when carrying out operation 42
Method of disassembling and connecting push-pull type coupler 45
Standard tightening torque table 48
Conversion table 52
01 Specification 59
100 Specification and technical data 59
Specification dimension drawings 60
Specifications 62
Weight table 65
Table of fuel, coolant and lubricants 67
Engine related parts 72
Radiator, oil cooler, aftercooler and fuel cooler 73
Diesel Particulate Filter 74
Diesel Particulate Filter – Component Parts 75
System Description 76
Regeneration 76
10 Structure, function and maintenance standard 71
100 Engine and cooling system 71
Power train 80
Swing circle 81
Swing machinery 82
Final drive 84
Sprocket 86
10 Structure, function and maintenance standard 79
200 Power train system 79
Track frame, recoil spring 90
Idler 92
Carrier roller 94
Track roller 95
Track shoe 96
10 Structure, function and maintenance standard 89
300 Undercarriage and frame 89
Hydraulic equipment layout drawing 102
Hydraulic tank 104
Hydraulic pump 106
10 Structure, function and maintenance standard 101
401 Hydraulic system, Part 1 101
Control valve 134
CLSS 148
Functions and operation by valve 152
10 Structure, function and maintenance standard 133
402 Hydraulic system, Part 2 133
Valve control 190
PPC valve 191
ATT EPC Valve Assembly 212
Solenoid valve 214
Accumulator 216
Return oil filter 217
Centre swivel joint 218
Travel motor 219
Swing motor 229
Attachment circuit selector valve 230
Quick coupler control valve 232
Hydraulic cylinder 234
10 Structure, function and maintenance standard 189
403 Hydraulic system, Part 3 189
Work equipment 238
Dimensions of components 240
10 Structure, function and maintenance standard 237
500 Work equipment 237
Air conditioner piping 246
10 Structure, function and maintenance standard 245
600 Cab and its attachments 245
Engine control system 250
Electronic control system 260
Monitor system 288
Sensor 316
PPC Levers 319
KOMTRAX system 321
10 Structure, function and maintenance standard 249
700 Electrical system 249
Outline of Auto Grease System 326
10 Structure, function and maintenance standard 325
700 Auto Grease system 325
Standard value table for engine 342
Standard value table for chassis related parts 343
20 Standard value table 341
100 Standard service value table 341
30 Testing and adjusting 355
101 Testing and adjusting, Part 1 355
Tools for testing, adjusting, and troubleshooting 357
Measuring engine speed 360
Measuring intake air pressure (boost pressure) 361
Checking exhaust gas colour 362
Adjusting valve clearance 363
Measuring compression pressure 365
Measurement of blow-by pressure 367
Measuring engine oil pressure 368
Handling fuel system parts 369
Releasing residual pressure from fuel system 369
Measuring fuel pressure 370
Measuring fuel discharge, return and leakage 372
Bleeding air from fuel circuit 376
Checking fuel circuit for leakage 378
Checking and adjusting air conditioner compressor belt tension 379
Replacing the fan belt 380
Testing of clearance in swing circle bearings 381
Checking and adjusting track shoe tension 382
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits 383
Inspection and adjustment of control circuit oil pressure 386
Inspection and adjustment of pump PC control circuit oil pressure 387
Inspection and adjustment of pump LS control circuit oil pressure 390
Measurement of solenoid valve output pressure 394
Testing of PPC valve output pressure 397
Adjustment of work equipment and swing PPC valve 398
Measuring and adjusting quick coupler control valve output pressure 399
Inspection of locations of hydraulic drift of work equipment 400
Testing and adjusting travel deviation 402
Release of residual pressure from hydraulic circuit 404
Measurement of oil leakage 405
Bleeding air from each part 407
Inspection procedures for diode 409
Checking cab tipping stopper 410
Installation and adjustment of mirrors and camera 411
Inspection of air conditioner Recirc/Fresh air filter 414
30 Testing and adjusting 417
102 Testing and adjusting, Part 2 417
Special functions of machine monitor 418
Handling voltage circuit of engine controller 470
Preparation work for troubleshooting of electrical system 471
Procedure for testing diodes 476
Pm-clinic service 477
30 Testing and adjusting 469
103 Testing and adjusting, Part 3 469
Failure code table 484
Fuse locations 488
40 Troubleshooting 483
100 Failure code table and fuse locations 483
40 Troubleshooting 491
200 General information on troubleshooting 491
Points to remember when troubleshooting 492
Sequence of events in troubleshooting 493
Checks before troubleshooting 494
Classification and troubleshooting steps 495
Information in troubleshooting table 496
Phenomena looking like troubles and troubleshooting Nos 498
Connection table for connector pin numbers 501
T-branch box and T-branch adapter table 537
40 Troubleshooting 541
301 Troubleshooting by failure code, Part 1 541
Failure code [989L00] Engine controller lock caution 1 543
Failure code [989M00] Engine controller lock caution 2 543
Failure code [989N00] Engine controller lock caution 3 544
Failure code [AA10NX] Air cleaner clogging 545
Failure code [AB00KE] Charge voltage low 546
Failure code [B@BAZG] Eng oil press low 548
Failure code [B@BAZK] Eng oil level low 549
Failure code [B@BCNS] Eng coolant overheat 550
Failure code [B@BCZK] Eng water level low 552
Failure code [B@HANS] Hydr oil overheat 554
Failure code [CA111] ECM critical internal failure 555
Failure code [CA115] Eng Ne and bkup speed sens error 556
Failure code [CA122] Chg air press sensor high error 558
Failure code [CA123] Chg air press sensor low error 560
Failure code [CA131] Throttle sensor high error 562
Failure code [CA132] Throttle sensor low error 564
Failure code [CA144] Coolant temp sens high error 566
Failure code [CA145] Coolant temp sens low error 568
Failure code [CA153] Chg air temp sensor high error 570
Failure code [CA154] Chg air temp sensor low error 572
Failure code [CA155] Chg air temp high speed derate 574
Failure code [CA187] Sens supply 2 volt low error 576
Failure code [CA221] Ambient press sens high error 578
Failure code [CA222] Ambient press sens low error 580
Failure code [CA227] Sens supply 2 volt high error 582
Failure code [CA234] Eng overspeed 583
Failure code [CA238] Ne speed sens supply volt error 584
Failure code [CA271] IMV/PCV1 short error 585
Failure code [CA272] IMV/PCV1 open error 586
Failure code [CA322] Inj #1 open/short error 588
Failure code [CA324] Inj #3 open/short error 590
Failure code [CA331] Inj #2 open/short error 592
Failure code [CA332] Inj #4 open/short error 594
40 Troubleshooting 597
302 Troubleshooting by failure code, Part 2 597
Failure code [CA342] Calibration code incompatibility 599
Failure code [CA351] Inj drive circuit error 600
Failure code [CA352] Sens supply 1 volt low error 602
Failure code [CA386] Sens supply 1 volt high error 604
Failure code [CA428] Water in fuel sensor high error 606
Failure code [CA429] Water in fuel sensor low error 608
Failure code [CA435] Eng oil press sw error 610
Failure code [CA441] Battery voltage low error 612
Failure code [CA442] Battery voltage high error 614
Failure code [CA449] Rail press very high error 616
Failure code [CA451] Rail press sensor high error 618
Failure code [CA452] Rail press sensor low error 620
Failure code [CA488] Chg air temp high torque derate 622
Failure code [CA553] Rail press high error 622
Failure code [CA559] Rail press low error 623
Failure code [CA689] Eng Ne speed sensor error 624
Failure code [CA731] Eng Bkup speed sens phase error 626
Failure code [CA757] All persistent data lost error 628
Failure code [CA778] Eng Bkup speed sensor error 630
Failure code [CA1633] KOMNET datalink timeout error 632
Failure code [CA2185] Throttle sens sup volt high error 634
Failure code [CA2186] Throttle sens sup volt low error 635
Failure code [CA2249] Rail press very low error 636
Failure code [CA2311] IMV solenoid error 638
Failure code [CA2555] Grid htr relay volt high error 640
Failure code [CA2556] Grid htr relay volt low error 642
Failure code [D110KB] Battery relay drive short 644
Failure code [D19JKZ] Personal code relay abnormality 646
Failure code [D862KA] GPS antenna discon 648
Failure code [DA22KK] Pump solenoid power low error 650
Failure code [DA25KP] 5V sensor 1 power abnormality 652
Failure code [DA26KP] 5V sensor 2 power abnormality 655
Failure code [DA29KQ] Model selection abnormality 656
40 Troubleshooting 659
303 Troubleshooting by failure code, Part 3 659
Failure code [DA2RMC] CAN discon (Pump controller detected) 662
Failure code [DAF8KB] Short circuit in camera power supply 664
Failure code [DAFGMC] GPS module error 666
Failure code [DAFRMC] CAN discon (Monitor detected) 668
Failure code [DGH2KB] Hydr oil sensor short 670
Failure code [DHPAMA] F Pump press sensor abnormality 672
Failure code [DHPBMA] R Pump press sensor abnormality 674
Failure code [DHS5KX] Travel PPC press sensor abnormality 676
Failure code [DHSAMA] Sw RH PPC press sen abnormality 678
Failure code [DHSBMA] Sw LH PPC press sen abnormality 680
Failure code [DHX1MA] Overload sensor abnormality (Analog) 682
Failure code [DW43KA] Travel speed sol discon 683
Failure code [DW43KB] Travel speed sol short 684
Failure code [DW45KA] Swing brake sol discon 686
Failure code [DW45KB] Swing brake sol short 688
Failure code [DW91KA] Travel junction sol discon 690
Failure code [DW91KB] Travel junction sol short 692
Failure code [DWA2KA] Service sol discon 694
Failure code [DWA2KB] Service sol short 695
Failure code [DWJ0KA] Merge-divider sol discon 696
Failure code [DWJ0KB] Merge-divider sol short 698
Failure code [DWK0KA] 2-stage relief sol discon 700
Failure code [DWK0KB] 2-stage relief sol short 702
40 Troubleshooting 705
304 Troubleshooting by failure code, Part 4 705
Failure code [DXA8KA] PC-EPC sol discon 706
Failure code [DXA8KB] PC-EPC sol short 708
Failure code [DXE4KA] Service current EPC discon 710
Failure code [DXE4KB] Service current EPC short 712
Failure code [DY20KA] Wiper working abnormality 714
Failure code [DY20MA] Wiper parking abnormality 716
Failure code [DY2CKA] Washer drive discon 718
Failure code [DY2CKB] Washer drive short 720
Failure code [DY2DKB] Wiper drive (for) short 722
Failure code [DY2EKB] Wiper drive (rev) short 724
40 Troubleshooting 727
400 Troubleshooting of electrical system (E-mode) 727
Before carrying out troubleshooting of electrical system 729
Information contained in troubleshooting table 731
E-1 When starting switch turned ON, machine monitor displays nothing 732
E-2 When starting switch turned ON (before starting engine), basic check item lights up 734
E-3 Engine does not start (Engine does not turn) 737
E-4 Preheater does not operate 740
E-5 Automatic warm-up system does not operate (in cold season) 742
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 744
E-7 Precaution lights up while engine is running 746
E-8 Emergency stop item lights up while engine is running 751
E-9 Engine coolant temperature gauge does not indicate normally 752
E-10 Hydraulic oil temperature gauge does not indicate normally 753
E-11 Fuel level gauge does not indicate normally 755
E-12 Contents of display by machine monitor are different from applicable machine 757
E-13 Machine monitor does not display some items 757
E-14 Function switch does not work 757
E-15 Auto-decelerator does not operate normally 758
E-16 Working mode does not change 759
E-17 Travel speed does not change 760
E-18 Alarm buzzer cannot be stopped 761
E-19 Windshield wiper and window washer do not operate 762
E-20 Power maximizing function does not operate normally 766
E-21 Swing holding brake does not operate normally 768
E-22 Travel alarm does not sound or does not stop sounding 770
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 772
E-24 While starting switch is in OFF position, service meter is not displayed 784
E-25 Machine monitor cannot be set in service mode 784
E-26 Monitoring function does not display lever control signal normally 786
E-27 KOMTRAX system does not operate normally 800
Information contained in troubleshooting table 805
System chart for hydraulic and mechanical systems 806
H-1 Speed or power of all work equipment, swing, and travel are low 808
H-2 Engine speed sharply drops or engine stalls 809
H-3 No work equipment, travel and swing move 810
H-4 Abnormal noise is heard from around hydraulic pump 810
H-5 Auto-decelerator does not work 811
H-6 Fine control mode does not function 811
H-7 Speed or power of boom is low 812
H-8 Speed or power of arm is low 813
H-9 Speed or power of bucket is low 814
H-10 Work equipment does not move in its single operation 815
H-11 Hydraulic drift of work equipment is large 816
H-12 Time lag of work equipment is large 817
H-13 One-touch power max system does not operate 817
H-14 Work equipment loaded more is slower during compound operation 818
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE 818
H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel 819
H-17 Machine deviates during travel 820
H-18 Travel speed is low 821
H-19 Machine cannot be steered easily or steering power is low 822
H-20 Travel speed does not change or it is kept low or high 823
H-21 Track does not move (Only either side) 823
H-22 Machine does not swing 824
H-23 Swing acceleration or swing speed is low 825
H-24 Excessive overrun when stopping swing 826
H-25 When upper structure stops swinging, it makes large shock 827
H-26 When upper structure stops swinging, it makes large sound 827
H-27 Hydraulic drift of swing is large 828
H-28 Attachment circuit does not change 829
H-29 Flow rate in attachment circuit cannot be adjusted 829
Quick coupler 830
40 Troubleshooting 803
500 Troubleshooting of hydraulic and mechanical system (H-mode) 803
S-17 Diesel Particulate Filter System 860
40 Troubleshooting 835
600 Troubleshooting of engine (S-mode) 835
Method of using troubleshooting chart 838
S-1 Starting performance is poor 842
S-2 Engine does not start 843
S-3 Engine does not pick up smoothly 846
S-4 Engine stops during operations 847
S-5 Engine does not rotate smoothly 848
S-6 Engine lack output (or lacks power) 849
S-7 Exhaust smoke is black (incomplete combustion) 850
S-8 Oil consumption is excessive (or exhaust smoke is blue) 851
S-9 Oil becomes contaminated quickly 852
S-10 Fuel consumption is excessive 853
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 854
S-12 Oil pressure drops 855
S-13 Oil level rises (Entry of coolant/fuel) 856
S-14 Coolant temperature becomes too high (overheating) 857
S-15 Abnormal noise is made 858
S-16 Vibration is excessive 859
40 Troubleshooting 863
600 Troubleshooting of Auto Grease system 863
50 Disassembly and assembly 871
100 General information on disassembly and assembly 871
How to read this manual 872
Coating materials list 874
Special tool list 877
Sketches of special tools 880
Removal and installation of fuel supply pump assembly 884
Removal and installation of fuel injector assembly 887
Removal and installation of engine front oil seal 906
Removal and installation of engine rear oil seal 908
Removal and installation of cylinder head assembly 893
Removal and installation of radiator assembly 911
Removal and installation of aftercooler assembly 913
Removal and installation of hydraulic oil cooler assembly 915
Removal and installation of engine and hydraulic pump assembly 917
50 Disassembly and assembly 883
200 Engine and cooling system 883
Removal and installation of engine hood assembly 924
Removal and installation of fuel tank assembly 926
Removal and installation of travel motor and final drive assembly 930
Disassembly and assembly of final drive assembly 932
Removal and installation of swing motor and swing machinery assembly 939
Disassembly and assembly of swing motor and swing machinery assembly 941
Removal and installation of swing circle assembly 949
50 Disassembly and assembly 929
300 Power train 929
Disassembly and assembly of carrier roller 952
Disassembly and assembly of track roller assembly 955
Disassembly and assembly of idler assembly 957
Disassembly and assembly of recoil spring 960
Expansion and installation of track shoe assembly 962
Removal and installation of sprocket 964
Removal and installation of revolving frame assembly 965
Removal and installation of counterweight 967
50 Disassembly and assembly 951
400 Undercarriage and frame 951
Removal and installation of centre swivel joint assembly 972
Disassembly and assembly of center swivel joint assembly 974
Removal and installation of hydraulic tank assembly 976
Removal and installation of hydraulic pump assembly 979
Removal and installation of hydraulic pump input shaft oil seal 982
Removal and installation of control valve assembly 983
Disassembly and assembly of control valve assembly 987
Disassembly and assembly of work equipment PPC valve assembly 989
Disassembly and assembly of travel PPC valve assembly 990
Disassembly and assembly of hydraulic cylinder assembly 993
Disassembly and Assembly of Quick Coupler Valve 999
50 Disassembly and assembly 971
500 Hydraulic system 971
Removal and installation of work equipment assembly 1002
50 Disassembly and assembly 1001
600 Work equipment Body 1001
Removal and installation of operator’s cab assembly 1008
Removal and installation of operator cab glass (stuck glass) 1012
Removal and installation of front window assembly 1023
Removal and installation of floor frame assembly 1030
Removal and installation of air conditioner unit assembly 1034
50 Disassembly and assembly 1007
700 Cab and its attachments 1007
Removal and installation of monitor assembly 1040
Removal and installation of pump controller assembly 1042
Removal and installation of engine controller assembly 1045
Removal and installation of KOMTRAX terminal 1047
50 Disassembly and assembly 1039
800 Electrical system 1039
90 Diagrams and drawings 1049
100 Hydraulic circuit diagram 1049
Hydraulic circuit diagram 1/2 1051
Hydraulic circuit diagram 2/2 1053
90 Diagrams and drawings 1057
200 Electrical diagrams and drawings 1057
Electrical circuit diagram (1/5) 1059
Electrical circuit diagram (2/5) 1061
Electrical circuit diagram (3/5) 1063
Electrical circuit diagram (4/5) 1065
Electrical circuit diagram (5/5) 1067
Connectors table and arrangement drawing PC160LC-8, PC190LC-8, PC190NLC-8 1069

DESCRIPTION:

Komatsu PC160LC-8 PC190LC-8 PC190NLC-8 Hydraulic Excavator Shop Manual UEN04566-00 – PDF DOWNLOAD 

SERIAL NUMBERS K50001 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 26/12/24