Komatsu PC160LC-7 PC160LC-8 Hydraulic Excavator Workshop Repair Service Manual PDF - MKTMSPC160LC.zip
A full-service repair guide, complete with electrical wiring schematics, for the Komatsu Hydraulic Excavators PC160LC-7 and PC160LC-8 — packed with every technical detail you need to service, troubleshoot, overhaul, and rebuild these machines the way expert technicians do.
Contained in the Komatsu Hydraulic Excavators PC160LC-7, PC160LC-8 workshop service repair manual:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 4,548 pages
File Format: PDF
Language: English
SEBM028606 - Hydraulic Excavator PC160LC-7 Shop Manual.pdf
SEN04566-00TH - Hydraulic Excavator PC160LC-8 Shop Manual.pdf
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TEN00096-01 - Hydraulic Excavator GALEO PC160LC-7 Operation & Maintenance Manual.pdf
TEN00308-00TH - Hydraulic Excavator PC160LC-8 Operation & Maintenance Manual.pdf
TEN00308-03 - Hydraulic Excavator PC160LC-8 Operation & Maintenance Manual.pdf
TEN00473-02 - Hydraulic Excavator PC160LC-8 Operation & Maintenance Manual.pdf
MAIN SECTIONS
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