Komatsu ecot3 PC160LC-8 Shop Manual
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Komatsu ecot3 PC160LC-8 Shop Manual

Hydraulic excavator
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SEN04566-13
HYDRAULIC
PC160LC
-8
EXCAVATOR
25001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu ecot3 PC160LC-8

  • Page 1 SEN04566-13 HYDRAULIC PC160LC EXCAVATOR 25001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 SEN04568-13 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC160LC-8 Machine model Serial number PC160LC-8 25001 and up 00 Index and foreword 100 Index Composition of shop manual .......................... 2 Table of contents ............................. 4 PC160LC-8 00-100 Find manuals at https://best-manuals.com...
  • Page 4 100 Index SEN04568-13 Composition of shop manual 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 5 100 Index SEN04568-13 Composition of shop manual 500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04801-00 600 Troubleshooting of engine (S-mode) SEN04802-00 50 Disassembly and assembly SEN04585-06 100 General information on disassembly and assembly SEN04758-02 200 Engine and cooling system SEN04759-04 300 Power train SEN04760-01...
  • Page 6 100 Index SEN04568-13 Table of contents Table of contents 00 Index and foreword 100 Index SEN04568-13 Composition of shop manual....................... Table of contents ......................... 200 Foreword and general information SEN04569-01 Safety notice..........................How to read the shop manual ..................... Explanation of terms for maintenance standard................Handling of electric equipment and hydraulic component............
  • Page 7 100 Index SEN04568-13 Table of contents Anti-drop valve for boom ......................28 Anti-drop valve for arm........................ 34 Return oil filter ..........................41 Center swivel joint ........................42 Travel motor ..........................43 Swing motor ..........................53 Attachment circuit selector valve....................54 Hydraulic cylinder........................
  • Page 8 100 Index SEN04568-13 Table of contents Bleeding air from each part ......................52 Inspection procedures for diode ....................54 Checking cab tipping stopper ...................... 55 Installation and adjustment of mirrors and camera ..............56 Inspection of air conditioner Recirc/Fresh air filter ..............60 102 Testing and adjusting, Part 2 SEN04792-02 Special functions of machine monitor..................
  • Page 9 100 Index SEN04568-13 Table of contents 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 SEN04797-02 Failure code [CA342] Calibration code incompatibility ..............
  • Page 10 100 Index SEN04568-13 Table of contents 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 SEN04799-00 Failure code [DXA8KA] PC-EPC sol discon................
  • Page 11 100 Index SEN04568-13 Table of contents 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..............
  • Page 12 100 Index SEN04568-13 Table of contents Removal and installation of fuel tank assembly ................47 300 Power train SEN04760-01 Removal and installation of travel motor and final drive assembly..........Disassembly and assembly of final drive assembly ..............Removal and installation of swing motor and swing machinery assembly ........11 Disassembly and assembly of swing motor and swing machinery assembly ......
  • Page 13 100 Index SEN04568-13 Table of contents PC160LC-8 00-100...
  • Page 14 SEN04568-13 PC160LC-8 Hydraulic excavator Form No. SEN04568-13 © 2017 KOMATSU All Rights Reserved Printed in Japan 02-17 (01) 00-100 PC160LC-8...

  • Page 15: Table Of Contents

    SEN04569-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC160LC-8 Machine model Serial number PC160LC-8 25001 and up 00 Index and foreword 200 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 16: 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 17 200 Foreword and general information SEN04569-01 Safety notice Preparations for work When removing a cover which is under Before adding oil or making any repairs, internal pressure or under pressure from a park the machine on a hard and level spring, always leave 2 bolts in diagonal ground, and apply the parking brake and positions.
  • Page 18 200 Foreword and general information SEN04569-01 Safety notice 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 well seen from the operator's seat and where he can see the working condition easily.
  • Page 19 200 Foreword and general information SEN04569-01 Safety notice 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.
  • Page 20 200 Foreword and general information SEN04569-01 Safety notice a Example of O-ring (Fitted to every joint of Precautions for disconnecting and con- necting hoses and tubes in air conditioner hoses and tubes) circuit Disconnection For the environment, the air condi- tioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of...

  • Page 21: 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-8...
  • Page 22 200 Foreword and general information SEN04569-01 How to read the shop manual 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 23: Explanation Of Terms For Maintenance Standard

    200 Foreword and general information SEN04569-01 Explanation of terms for maintenance standard Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
  • Page 24 200 Foreword and general information SEN04569-01 Explanation of terms for maintenance standard 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 25: Handling Of Electric Equipment And Hydraulic Component

    200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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 26 200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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...
  • Page 27 200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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 28 200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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.
  • Page 29 200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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).
  • Page 30 200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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 31 200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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.
  • Page 32 200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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 33 200 Foreword and general information SEN04569-01 Handling of electric equipment and hydraulic component 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 34: Handling Of Connectors Newly Used For Engines

    200 Foreword and general information SEN04569-01 Handling of connectors newly used for engines Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 95 – 170, 12V140 engines 95E-5 Various temperature sensors 107E-1 Example)
  • Page 35 200 Foreword and general information SEN04569-01 Handling of connectors newly used for engines Push lock type 95, 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.
  • Page 36 200 Foreword and general information SEN04569-01 Handling of connectors newly used for engines 95, 125 – 170, 12V140 engines Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pull out connector (5) in the direction of Example) the arrow.

  • Page 37: How To Read Electric Wire Code

    200 Foreword and general information SEN04569-01 How to read electric wire code 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 38 200 Foreword and general information SEN04569-01 How to read electric wire code 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...
  • Page 39 200 Foreword and general information SEN04569-01 How to read electric wire code 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 &...

  • Page 40: Precautions When Carrying Out Operation

    200 Foreword and general information SEN04569-01 Precautions when carrying out operation 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 41 200 Foreword and general information SEN04569-01 Precautions when carrying out operation 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.
  • Page 42 200 Foreword and general information SEN04569-01 Precautions when carrying out operation Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.

  • Page 43: Method Of Disassembling And Connecting Push-Pull Type Coupler

    200 Foreword and general information SEN04569-01 Method of disassembling and connecting push-pull type coupler Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
  • Page 44 200 Foreword and general information SEN04569-01 Method of disassembling and connecting push-pull type coupler Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
  • Page 45 200 Foreword and general information SEN04569-01 Method of disassembling and connecting push-pull type coupler Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por-...

  • Page 46: Standard Tightening Torque Table

    200 Foreword and general information SEN04569-01 Standard tightening torque table Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque...
  • Page 47 200 Foreword and general information SEN04569-01 Standard tightening torque table Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 –...
  • Page 48 200 Foreword and general information SEN04569-01 Standard tightening torque table Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below.
  • Page 49 200 Foreword and general information SEN04569-01 Standard tightening torque table Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below.

  • Page 50: Conversion Table

    200 Foreword and general information SEN04569-01 Conversion table Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches Convert 55 mm into inches.
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