Komatsu PC160LC -7E0 Shop Manual

Hydraulic excavator

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SEN01892-05

HYDRAULIC

PC160LC

-7E0

EXCAVATOR

SERIAL NUMBERS

20001

and up

Table of Contents

Summary of Contents for Komatsu PC160LC -7E0

Page 1 SEN01892-05 HYDRAULIC PC160LC -7E0 EXCAVATOR SERIAL NUMBERS 20001 and up...
Page 2 SEN01894-05 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC160LC-7E0 Machine model Serial number PC160LC-7E0 20001 and up 00 Index and foreword Index Composition of shop manual .......................... 2 Table of contents ............................. 4 PC160LC-7E0 Find manuals at https://best-manuals.com...
Page 3 SEN01894-05 00 Index and foreword Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
Page 4 00 Index and foreword SEN01894-05 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02118-00 Troubleshooting of engine (S-mode) SEN02119-02 50 Disassembly and assembly SEN01910-03 General information on disassembly and assembly SEN02447-02 SEN02448-03 q Engine and cooling system Power train SEN02449-01 Undercarriage and frame SEN02450-01 Hydraulic system SEN02451-00...
Page 5 SEN01894-05 00 Index and foreword Table of contents 00 Index and foreword Index SEN01894-05 Composition of shop manual....................... Table of contents ......................... Foreword and general information SEN01895-02 Safety notice..........................How to read the shop manual ..................... Explanation of terms for maintenance standard................Handling of electric equipment and hydraulic component............
Page 6 00 Index and foreword SEN01894-05 Return oil filter ..........................23 Center swivel joint ........................24 Travel motor ..........................25 Swing motor ..........................35 Attachment circuit selector valve....................36 Hydraulic cylinder........................40 Work equipment SEN01904-00 Work equipment .......................... Dimensions of components ......................Cab and its attachments SEN01905-00 Air conditioner piping........................
Page 7 SEN01894-05 00 Index and foreword Bleeding air from each part ......................27 Inspection procedures for diode ....................29 Adjusting mirrors ......................... 30 Testing and adjusting, Part 3 SEN02110-02 Special functions of machine monitor..................Handling voltage circuit of engine controller................30 Procedure for turning on KOMTRAX terminal ................
Page 8 00 Index and foreword SEN01894-05 Failure code [CA342] Calibration code incompatibility ..............Failure code [CA351] Injectors drive circuit error ................ 10 Failure code [CA352] Sens supply 1 volt low error ..............12 Failure code [CA386] Sens supply 1 volt high error ..............14 Failure code [CA428] Water in fuel sensor high error ..............
Page 9 SEN01894-05 00 Index and foreword Failure code [DY2CKB] Washer drive S/C .................. 36 Failure code [DY2DKB] Wiper drive (for) S/C ................38 Failure code [DY2EKB] Wiper drive (rev) S/C................40 Troubleshooting of electrical system (E-mode) SEN02117-00 Before carrying out troubleshooting of electrical system............. Information contained in troubleshooting table................
Page 10 00 Index and foreword SEN01894-05 H-17 Machine deviates during travel................... 18 H-18 Travel speed is low......................19 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)................
Page 11 SEN01894-05 00 Index and foreword Undercarriage and frame SEN02450-01 Disassembly and assembly of carrier roller................. Disassembly and assembly of track roller assembly..............Disassembly and assembly of idler assembly................Disassembly and assembly of recoil spring ................10 Expansion and installation of track shoe assembly ..............12 Removal and installation of sprocket...................
Page 12 00 Index and foreword SEN01894-05 PC160LC-7E0...
Page 14: Table Of Contents
SEN01895-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC160LC-7E0 Machine model Serial number PC160LC-7E0 20001 and up 00 Index and foreword Foreword and general information 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 ...................
Page 15: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 16 00 Index and foreword SEN01895-02 When disassembling or assembling, sup- When removing piping, stop the fuel or oil port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips stands before starting work. onto the floor, wipe it up immediately. Fuel Remove all mud and oil from the steps or or oil on the floor can cause you to slip other places used to get on and off the...
Page 17 SEN01895-02 00 Index and foreword Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily.
Page 18 00 Index and foreword SEN01895-02 If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again. turning on a switch which was turned OFF Do not lift up the load slantingly.
Page 19 SEN01895-02 00 Index and foreword Precautions for disconnecting and con- necting hoses and tubes in air conditioner circuit Disconnection Collect the air conditioner refriger- ant (R134a) from the air condi- tioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a).
Page 20: How To Read The Shop Manual
Engine volume This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. PC160LC-7E0...
Page 21 SEN01895-02 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark q q q q When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.
Page 22: Explanation Of Terms For Maintenance Standard
00 Index and foreword SEN01895-02 Explanation of terms for maintenance standard The maintenance standard values necessary for judgment of products and parts are described by the follow- ing terms. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
Page 23 SEN01895-02 00 Index and foreword Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
Page 24: Handling Of Electric Equipment And Hydraulic Component
00 Index and foreword SEN01895-02 Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
Page 25 SEN01895-02 00 Index and foreword Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring may be broken.
Page 26 00 Index and foreword SEN01895-02 Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
Page 27 SEN01895-02 00 Index and foreword Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins. Check that there is no damage or breakage to the outside of the con- nector.
Page 28 00 Index and foreword SEN01895-02 Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) Push in female connector (2) horizon- tally until the lock clicks.
Page 29 SEN01895-02 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
Page 30 00 Index and foreword SEN01895-02 Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. Do not place objects on top of the control- ler.
Page 31 SEN01895-02 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
Page 32 00 Index and foreword SEN01895-02 Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
Page 33: Handling Of Connectors Newly Used For Engines
SEN01895-02 00 Index and foreword Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 107 – 170, 12V140 engine 107E-1 Various temperature sensors 114E-3 Example) 125E-5 Intake air temperature sensor in 140E-5 intake manifold: TIM 170E-5...
Page 34 00 Index and foreword SEN01895-02 Push lock type 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engine Example)
Page 35 SEN01895-02 00 Index and foreword 125 – 170, 12V140 engine Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pullout connector (5) in the direction of the Example) arrow. Intake air pressure sensor in intake mani- fold (CANNON-04): PIM etc.
Page 36: How To Read Electric Wire Code
00 Index and foreword SEN01895-02 How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols.
Page 37 SEN01895-02 00 Index and foreword Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
Page 38 00 Index and foreword SEN01895-02 Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...
Page 39: Precautions When Carrying Out Operation
SEN01895-02 00 Index and foreword Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly.
Page 40 00 Index and foreword SEN01895-02 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
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Komatsu PC160LC -7E0 Shop Manual

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