Komatsu PC195LC-8 Hydraulic Excavator Shop Manual PDF

Description

Komatsu PC195LC-8 Hydraulic Excavator Shop Manual LEBMP19802 – PDF DOWNLOAD

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Komatsu PC195LC-8 Hydraulic Excavator Shop Manual LEBMP19802 – PDF DOWNLOAD 

Language : English
Pages : 1031
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC195LC-8 Hydraulic Excavator Shop Manual LEBMP19802 – PDF DOWNLOAD 

SERIAL NUMBER J10001 and up

00 Index and foreword
100 Index LEBMP19800-01
Composition of shop manual 2
Table of contents 4
200 Foreword and general information LEBMP19800-02
Safety notice 2
How to read the shop manual 7
Explanation of terms for maintenance standard 9
Handling of electric equipment and hydraulic component 11
Handling of connectors newly used for engines 20
How to read electric wire code 23
Precautions when carrying out operation 26
Method of disassembling and connecting push-pull type coupler 29
Standard tightening torque table 32
Conversion table 36
01 Specification
100 Specification and technical data LEBMP19800-03
Specification dimension drawings 2
Specifications 4
Weight table 7
Table of fuel, coolant and lubricants 9
10 Structure, function and maintenance standard
100 Engine and cooling system LEBMP19800-04
Engine related parts 2
Radiator, oil cooler, aftercooler and fuel cooler 3
200 Power train system LEBMP19800-05
Power train 2
Swing circle 3
Swing machinery 4
Final drive 6
Sprocket 8
300 Undercarriage and frame LEBMP19800-06
Track frame, recoil spring 2
Idler 4
Carrier roller 6
Track roller 7
Track shoe 8
401 Hydraulic system, Part 1 LEBMP19800-07
Hydraulic equipment layout drawing 2
Hydraulic tank 4
Hydraulic pump 6
402 Hydraulic system, Part 2 LEBMP19800-08
Control valve 2
LEBMP19802-01
PC195LC-8 00-100 5
100 Index
Table of contents
CLSS 16
Functions and operation by valve 20
403 Hydraulic system, Part 3 LEBMP19800-09
Valve control 2
PPC valve 3
ATT EPC Valve Assembly 24
Solenoid valve 26
Accumulator 28
Return oil filter 29
Centre swivel joint 30
Travel motor 31
Swing motor 41
Attachment circuit selector valve 42
Quick coupler control valve 44
Hydraulic cylinder 46
500 Work equipment LEBMP19800-10
Work equipment 2
Dimensions of components 4
600 Cab and its attachments LEBMP19800-11
Air conditioner piping 2
700 Electrical system LEBMP19800-12
Engine control system 2
Electronic control system 12
Monitor system 40
Sensor 68
PPC Levers 71
KOMTRAX system 73
20 Standard value table
100 Standard service value table LEBMP19800-14
Standard value table for engine 2
Standard value table for chassis related parts 3
30 Testing and adjusting
101 Testing and adjusting, Part 1 LEBMP19800-15
Tools for testing, adjusting, and troubleshooting 3
Measuring engine speed 6
Measuring intake air pressure (boost pressure) 7
Checking exhaust gas colour 8
Adjusting valve clearance 9
Measuring compression pressure 11
Measurement of blow-by pressure 13
Measuring engine oil pressure 14
Handling fuel system parts 15
LEBMP19802-01
00-100 6 PC195LC-8
100 Index
Table of contents
Measuring fuel pressure 16
Measuring fuel discharge, return and leakage 18
Bleeding air from fuel circuit 22
Checking fuel circuit for leakage 24
Checking and adjusting air conditioner compressor belt tension 25
Replacing the fan belt 26
Testing of clearance in swing circle bearings 27
Checking and adjusting track shoe tension 28
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits 29
Inspection and adjustment of control circuit oil pressure 32
Inspection and adjustment of pump PC control circuit oil pressure 33
Inspection and adjustment of pump LS control circuit oil pressure 36
Measurement of solenoid valve output pressure 40
Testing of PPC valve output pressure 43
Adjustment of work equipment and swing PPC valve 44
Measuring and adjusting quick coupler control valve output pressure 45
Inspection of locations of hydraulic drift of work equipment 46
Testing and adjusting travel deviation 48
Release of residual pressure from hydraulic circuit 50
Measurement of oil leakage 51
Bleeding air from each part 53
Inspection procedures for diode 55
Checking cab tipping stopper 56
Installation and adjustment of mirrors and camera 57
Inspection of air conditioner Recirc/Fresh air filter 60
102 Testing and adjusting, Part 2 LEBMP19800-16
Special functions of machine monitor 2
103 Testing and adjusting, Part 3 LEBMP19800-17
Handling voltage circuit of engine controller 2
Preparation work for troubleshooting of electrical system 3
Procedure for testing diodes 8
Pm-clinic service 9
40 Troubleshooting
100 Failure code table and fuse locations LEBMP19800-18
Failure code table 2
Fuse locations 6
200 General information on troubleshooting LEBMP19800-19
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Checks before troubleshooting 4
Classification and troubleshooting steps 5
Information in troubleshooting table 6
Phenomena looking like troubles and troubleshooting Nos 8
Connection table for connector pin numbers 11
T-branch box and T-branch adapter table 47
301 Troubleshooting by failure code, Part 1 LEBMP19800-20
Failure code [989L00] Engine controller lock caution 1 3
Failure code [989M00] Engine controller lock caution 2 3
Failure code [989N00] Engine controller lock caution 3 4
LEBMP19802-01
PC195LC-8 00-100 7
100 Index
Table of contents
Failure code [AA10NX] Air cleaner clogging 5
Failure code [AB00KE] Charge voltage low 6
Failure code [B@BAZG] Eng oil press low 8
Failure code [B@BAZK] Eng oil level low 9
Failure code [B@BCNS] Eng coolant overheat 10
Failure code [B@BCZK] Eng water level low 12
Failure code [B@HANS] Hydr oil overheat 14
Failure code [CA111] ECM critical internal failure 15
Failure code [CA115] Eng Ne and bkup speed sens error 16
Failure code [CA122] Chg air press sensor high error 18
Failure code [CA123] Chg air press sensor low error 20
Failure code [CA131] Throttle sensor high error 22
Failure code [CA132] Throttle sensor low error 24
Failure code [CA144] Coolant temp sens high error 26
Failure code [CA145] Coolant temp sens low error 28
Failure code [CA153] Chg air temp sensor high error 30
Failure code [CA154] Chg air temp sensor low error 32
Failure code [CA155] Chg air temp high speed derate 34
Failure code [CA187] Sens supply 2 volt low error 36
Failure code [CA221] Ambient press sens high error 38
Failure code [CA222] Ambient press sens low error 40
Failure code [CA227] Sens supply 2 volt high error 42
Failure code [CA234] Eng overspeed 43
Failure code [CA238] Ne speed sens supply volt error 44
Failure code [CA271] IMV/PCV1 short error 45
Failure code [CA272] IMV/PCV1 open error 46
Failure code [CA322] Inj #1 open/short error 48
Failure code [CA324] Inj #3 open/short error 50
Failure code [CA331] Inj #2 open/short error 52
Failure code [CA332] Inj #4 open/short error 54
302 Troubleshooting by failure code, Part 2 LEBMP19800-21
Failure code [CA342] Calibration code incompatibility 3
Failure code [CA351] Inj drive circuit error 4
Failure code [CA352] Sens supply 1 volt low error 6
Failure code [CA386] Sens supply 1 volt high error 8
Failure code [CA428] Water in fuel sensor high error 10
Failure code [CA429] Water in fuel sensor low error 12
Failure code [CA435] Eng oil press sw error 14
Failure code [CA441] Battery voltage low error 16
Failure code [CA442] Battery voltage high error 18
Failure code [CA449] Rail press very high error 20
Failure code [CA451] Rail press sensor high error 22
Failure code [CA452] Rail press sensor low error 24
Failure code [CA488] Chg air temp high torque derate 26
Failure code [CA553] Rail press high error 26
Failure code [CA559] Rail press low error 27
Failure code [CA689] Eng Ne speed sensor error 28
Failure code [CA731] Eng Bkup speed sens phase error 30
Failure code [CA757] All persistent data lost error 32
Failure code [CA778] Eng Bkup speed sensor error 34
LEBMP19802-01
00-100 8 PC195LC-8
100 Index
Table of contents
Failure code [CA1633] KOMNET datalink timeout error 36
Failure code [CA2185] Throttle sens sup volt high error 38
Failure code [CA2186] Throttle sens sup volt low error 39
Failure code [CA2249] Rail press very low error 40
Failure code [CA2311] IMV solenoid error 42
Failure code [CA2555] Grid htr relay volt high error 44
Failure code [CA2556] Grid htr relay volt low error 46
Failure code [D110KB] Battery relay drive short 48
Failure code [D19JKZ] Personal code relay abnormality 50
Failure code [D862KA] GPS antenna discon 52
Failure code [DA22KK] Pump solenoid power low error 54
Failure code [DA25KP] 5V sensor 1 power abnormality 56
Failure code [DA26KP] 5V sensor 2 power abnormality 59
Failure code [DA29KQ] Model selection abnormality 60
303 Troubleshooting by failure code, Part 3 LEBMP19800-22
Failure code [DA2RMC] CAN discon (Pump controller detected) 4
Failure code [DAF8KB] Short circuit in camera power supply 6
Failure code [DAFGMC] GPS module error 8
Failure code [DAFRMC] CAN discon (Monitor detected) 10
Failure code [DGH2KB] Hydr oil sensor short 12
Failure code [DHPAMA] F Pump press sensor abnormality 14
Failure code [DHPBMA] R Pump press sensor abnormality 16
Failure code [DHS5KX] Travel PPC press sensor abnormality 18
Failure code [DHSAMA] Sw RH PPC press sen abnormality 20
Failure code [DHSBMA] Sw LH PPC press sen abnormality 22
Failure code [DHX1MA] Overload sensor abnormality (Analog) 24
Failure code [DW43KA] Travel speed sol discon 25
Failure code [DW43KB] Travel speed sol short 26
Failure code [DW45KA] Swing brake sol discon 28
Failure code [DW45KB] Swing brake sol short 30
Failure code [DW91KA] Travel junction sol discon 32
Failure code [DW91KB] Travel junction sol short 34
Failure code [DWA2KA] Service sol discon 36
Failure code [DWA2KB] Service sol short 37
Failure code [DWJ0KA] Merge-divider sol discon 38
Failure code [DWJ0KB] Merge-divider sol short 40
Failure code [DWK0KA] 2-stage relief sol discon 42
Failure code [DWK0KB] 2-stage relief sol short 44
304 Troubleshooting by failure code, Part 4 LEBMP19800-23
Failure code [DXA8KA] PC-EPC sol discon 2
Failure code [DXA8KB] PC-EPC sol short 4
Failure code [DXE4KA] Service current EPC discon 6
Failure code [DXE4KB] Service current EPC short 8
Failure code [DY20KA] Wiper working abnormality 10
Failure code [DY20MA] Wiper parking abnormality 12
Failure code [DY2CKA] Washer drive discon 14
Failure code [DY2CKB] Washer drive short 16
Failure code [DY2DKB] Wiper drive (for) short 18
Failure code [DY2EKB] Wiper drive (rev) short 20
400 Troubleshooting of electrical system (E-mode) LEBMP19800-24
LEBMP19802-01
PC195LC-8 00-100 9
100 Index
Table of contents
Before carrying out troubleshooting of electrical system 3
Information contained in troubleshooting table 5
E-1 When starting switch turned ON, machine monitor displays nothing 6
E-2 When starting switch turned ON (before starting engine), basic check item lights up 8
E-3 Engine does not start (Engine does not turn) 11
E-4 Preheater does not operate 14
E-5 Automatic warm-up system does not operate (in cold season) 16
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 18
E-7 Precaution lights up while engine is running 20
E-8 Emergency stop item lights up while engine is running 25
E-9 Engine coolant temperature gauge does not indicate normally 26
E-10 Hydraulic oil temperature gauge does not indicate normally 27
E-11 Fuel level gauge does not indicate normally 29
E-12 Contents of display by machine monitor are different from applicable machine 31
E-13 Machine monitor does not display some items 31
E-14 Function switch does not work 31
E-15 Auto-decelerator does not operate normally 32
E-16 Working mode does not change 33
E-17 Travel speed does not change 34
E-18 Alarm buzzer cannot be stopped 35
E-19 Windshield wiper and window washer do not operate 36
E-20 Power maximizing function does not operate normally 40
E-21 Swing holding brake does not operate normally 42
E-22 Travel alarm does not sound or does not stop sounding 44
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 46
E-24 While starting switch is in OFF position, service meter is not displayed 58
E-25 Machine monitor cannot be set in service mode 58
E-26 Monitoring function does not display lever control signal normally 60
E-27 KOMTRAX system does not operate normally 74
500 Troubleshooting of hydraulic and mechanical system (H-mode) LEBMP19800-25
Information contained in troubleshooting table 3
System chart for hydraulic and mechanical systems 4
H-1 Speed or power of all work equipment, swing, and travel are low 6
H-2 Engine speed sharply drops or engine stalls 7
H-3 No work equipment, travel and swing move 8
H-4 Abnormal noise is heard from around hydraulic pump 8
H-5 Auto-decelerator does not work 9
H-6 Fine control mode does not function 9
H-7 Speed or power of boom is low 10
H-8 Speed or power of arm is low 11
H-9 Speed or power of bucket is low 12
H-10 Work equipment does not move in its single operation 13
H-11 Hydraulic drift of work equipment is large 14
H-12 Time lag of work equipment is large 15
H-13 One-touch power max system does not operate 15
H-14 Work equipment loaded more is slower during compound operation 16
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE 16
H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel 17
H-17 Machine deviates during travel 18
H-18 Travel speed is low 19
LEBMP19802-01
00-100 10 PC195LC-8
100 Index
Table of contents
H-19 Machine cannot be steered easily or steering power is low 20
H-20 Travel speed does not change or it is kept low or high 21
H-21 Track does not move (Only either side) 21
H-22 Machine does not swing 22
H-23 Swing acceleration or swing speed is low 23
H-24 Excessive overrun when stopping swing 24
H-25 When upper structure stops swinging, it makes large shock 25
H-26 When upper structure stops swinging, it makes large sound 25
H-27 Hydraulic drift of swing is large 26
H-28 Attachment circuit does not change 27
H-29 Flow rate in attachment circuit cannot be adjusted 27
Quick coupler 28
600 Troubleshooting of engine (S-mode) LEBMP19800-26
Method of using troubleshooting chart 4
S-1 Starting performance is poor 8
S-2 Engine does not start 9
S-3 Engine does not pick up smoothly 12
S-4 Engine stops during operations 13
S-5 Engine does not rotate smoothly 14
S-6 Engine lack output (or lacks power) 15
S-7 Exhaust smoke is black (incomplete combustion) 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) 17
S-9 Oil becomes contaminated quickly 18
S-10 Fuel consumption is excessive 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 20
S-12 Oil pressure drops 21
S-13 Oil level rises (Entry of coolant/fuel) 22
S-14 Coolant temperature becomes too high (overheating) 23
S-15 Abnormal noise is made 24
S-16 Vibration is excessive 25
S-17 Diesel Particulate Filter System 26
50 Disassembly and assembly
100 General information on disassembly and assembly LEBMP19800-28
How to read this manual 2
Coating materials list 4
Special tool list 7
Sketches of special tools 10
200 Engine and cooling system LEBMP19800-29
Removal and installation of fuel supply pump assembly 2
Removal and installation of fuel injector assembly 5
Removal and installation of cylinder head assembly 11
Removal and installation of engine front oil seal 24
Removal and installation of engine rear oil seal 26
Removal and installation of radiator assembly 29
Removal and installation of aftercooler assembly 31
Removal and installation of hydraulic oil cooler assembly 33
LEBMP19802-01
PC195LC-8 00-100 11
100 Index
Table of contents
Removal and installation of engine and hydraulic pump assembly 35
Removal and installation of engine hood assembly 42
Removal and installation of fuel tank assembly 44
300 Power train LEBMP19800-30
Removal and installation of travel motor and final drive assembly 2
Disassembly and assembly of final drive assembly 4
Removal and installation of swing motor and swing machinery assembly 11
Disassembly and assembly of swing motor and swing machinery assembly 13
Removal and installation of swing circle assembly 21
400 Undercarriage and frame LEBMP19800-31
Disassembly and assembly of carrier roller 2
Disassembly and assembly of track roller assembly 5
Disassembly and assembly of idler assembly 7
Disassembly and assembly of recoil spring 10
Expansion and installation of track shoe assembly 12
Removal and installation of sprocket 14
Removal and installation of revolving frame assembly 15
Removal and installation of counterweight 17
500 Hydraulic system LEBMP19800-32
Removal and installation of centre swivel joint assembly 2
Disassembly and assembly of center swivel joint assembly 4
Removal and installation of hydraulic tank assembly 6
Removal and installation of hydraulic pump assembly 9
Removal and installation of hydraulic pump input shaft oil seal 12
Removal and installation of control valve assembly 13
Disassembly and assembly of control valve assembly 17
Disassembly and assembly of work equipment PPC valve assembly 19
Disassembly and assembly of travel PPC valve assembly 20
Disassembly and assembly of hydraulic cylinder assembly 23
Disassembly and Assembly of Quick Coupler Valve 29
600 Work equipment Body LEBMP19800-33
Removal and installation of work equipment assembly 2
700 Cab and its attachments LEBMP19800-34
Removal and installation of operator’s cab assembly 2
Removal and installation of operator cab glass (stuck glass) 6
Removal and installation of front window assembly 17
Removal and installation of floor frame assembly 24
Removal and installation of air conditioner unit assembly 28
800 Electrical system LEBMP19800-35
Removal and installation of monitor assembly 2
Removal and installation of pump controller assembly 4
Removal and installation of engine controller assembly 7
Removal and installation of KOMTRAX terminal 9
90 Diagrams and drawings
100 Hydraulic circuit diagram LEBMP19800-36
Hydraulic circuit diagram 3
200 Electrical diagrams and drawings LEBMP19801-37
Electrical circuit diagram (1/6) 3
LEBMP19802-01
00-100 12 PC195LC-8
100 Index
Table of contents
Electrical circuit diagram (2/6) 5
Electrical circuit diagram (3/6) 7
Electrical circuit diagram (4/6) 9
Electrical circuit diagram (5/6) 11
Connectors table and arrangement drawing PC195LC-8 15
LEBMP19802-01
Electrical circuit diagram (6/6) 13

DESCRIPTION:

Komatsu PC195LC-8 Hydraulic Excavator Shop Manual LEBMP19802 – PDF DOWNLOAD 

SERIAL NUMBER J10001 and up

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)
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