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Komatsu ecot3 PC160LC-8, Shop Manual

The Komatsu ecot3 PC160LC-8 is a top-of-the-line construction excavator, known for its exceptional performance and eco-friendly design. Get the most out of this powerful machine with our comprehensive Shop Manual, available for free download at manualshive.com. Access the manual now and unlock the full potential of your PC160LC-8.

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SEN04569-01

PC160LC-8

00-200

  7

200 Foreword and general information

How to read the shop manual

How to read the shop manual

1

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 dis-
assembly 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.

2.

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.

q

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.

q

Materials and specifications are subject to change without notice.

q

Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.

Summary of Contents for ecot3 PC160LC-8

Page 1: ...HYDRAULIC EXCAVATOR SEN04566 13 PC160LC 8 SERIAL NUMBERS 25001 and up ...

Page 2: ...Find manuals at https best manuals com ...

Page 3: ...04568 13 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC160LC 8 Machine model Serial number PC160LC 8 25001 and up 00 Index and foreword 1 100 Index Composition of shop manual 2 Table of contents 4 Find manuals at https best manuals com ...

Page 4: ...SEN04569 01 01 Specification SEN04570 00 100 Specification and technical data SEN04571 00 10 Structure function and maintenance standard SEN04572 03 100 Engine and cooling system SEN04573 00 200 Power train system SEN04574 00 300 Undercarriage and frame SEN04575 01 401 Hydraulic system Part 1 SEN04576 00 402 Hydraulic system Part 2 SEN04577 00 403 Hydraulic system Part 3 SEN04578 02 500 Work equip...

Page 5: ...disassembly and assembly SEN04758 02 200 Engine and cooling system SEN04759 04 300 Power train SEN04760 01 400 Undercarriage and frame SEN04761 03 500 Hydraulic system SEN04762 00 600 Work equipment SEN04763 01 700 Cab and its attachments SEN04764 00 800 Electrical system SEN04765 00 90 Diagrams and drawings SEN04586 03 100 Hydraulic diagrams and drawings SEN04587 01 q 200 Electrical diagrams and ...

Page 6: ...cal data SEN04571 00 Specification dimension drawings 2 Specifications 4 Weight table 6 Table of fuel coolant and lubricants 8 10 Structure function and maintenance standard 100 Engine and cooling system SEN04573 00 Engine related parts 2 Radiator oil cooler aftercooler and fuel cooler 3 200 Power train system SEN04574 00 Power train 2 Swing circle 3 Swing machinery 4 Final drive 6 Sprocket 8 300 ...

Page 7: ...esting compression pressure 11 Testing of blow by pressure 13 Testing engine oil pressure 14 Handling fuel system parts 15 Releasing residual pressure from fuel system 15 Testing 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 be...

Page 8: ...code 989M00 Engine controller lock caution 2 3 Failure code 989N00 Engine controller lock caution 3 4 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 Failur...

Page 9: ... 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...

Page 10: ...ant temperature gauge does not indicate normally 25 E 10 Hydraulic oil temperature gauge does not indicate normally 26 E 11 Fuel level gauge does not indicate normally 28 E 12 Contents of display by machine monitor are different from applicable machine 30 E 13 Machine monitor does not display some items 30 E 14 Function switch does not work 30 E 15 Auto decelerator does not operate normally 31 E 1...

Page 11: ...oting 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 co...

Page 12: ...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 23 600 Work equipment SEN04763 01 Removal and installation of work equipment assembly 2 Removal and installation of anti drop valve assembly for boom 5 Removal and inst...

Page 13: ...SEN04568 13 PC160LC 8 00 100 11 100 Index Table of contents ...

Page 14: ...00 100 12 PC160LC 8 SEN04568 13 PC160LC 8 Hydraulic excavator Form No SEN04568 13 2017 KOMATSU All Rights Reserved Printed in Japan 02 17 01 ...

Page 15: ...y 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 ...

Page 16: ...ny operation always wear safety shoes and helmet Do not wear loose work clothes or clothes with buttons missing q Always wear safety glasses when hit ting parts with a hammer q Always wear safety glasses when grinding parts with a grinder etc 4 When carrying out any operation with 2 or more workers always agree on the oper ating procedure before starting Always inform your fellow workers before st...

Page 17: ...damage Always use slings which have ample capacity and install them to proper places Operate the hoist or crane slowly to prevent the component from hitting any other part Do not work with any part still raised by the hoist or crane 6 When removing a cover which is under internal pressure or under pressure from a spring always leave 2 bolts in diagonal positions Loosen those bolts gradually and al...

Page 18: ...pes form ing a wide hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load in kN kg when hoisting is made with 2 ropes each of which is allowed to sling up to 9 8 kN 1 000 kg vertically at various hanging angles When the 2 ropes sling a load vertically up to 1...

Page 19: ...ot move the crane while the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the ground and check safety and then lift it up 9 Consider the travel route in advance and lift up a load to a safe height 10 Place the control switch on a position where it will not be an...

Page 20: ...frigerant gas gets in your eyes or contacts your skin you may lose your sight and your skin may be frozen Accordingly put on safety glasses safety gloves and safety clothes when recover ing or adding the refrigerant Refrigerant gas must be recovered and added by a qualified person 2 Connection 1 When installing the air conditioner cir cuit hoses and tubes take care that dirt dust water etc will no...

Page 21: ...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 ca...

Page 22: ...hop manual the units are indicated with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are necessary when performing work a Caution Special technical precautions or other precautions for preserving stan dards are necessary when performing work 4 Weight Weight of pa...

Page 23: ...ed q The above size set temporarily is called the standard size and the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The tolerance may be indicated in the text and a table as standard size upper limit of tolerance lower limit of tolerance Example 120 0 022 0 126 q Usually the size of...

Page 24: ... and check that the interference is in the standard range 4 Repair limit and allowable value or allow able dimension q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the repair limit q If a part is worn to the repair limit it must be replaced or repaired q The performance and function of a prod uct lowers while it is used A value whi...

Page 25: ...in boxes or cases wiring harnesses are more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely to suffer deformation or damage For this reason it is necessary to be extremely careful when handling wiring harnesses 2 Main failures occurring in wiring harnes...

Page 26: ...om entering but at the same time if water does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connector or take other appropriate action before passing electricity through it 5 Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil f...

Page 27: ...nd pull the connec tors apart a Never pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip pull the connector in a parallel direction to the clip for removing stop pers a If the connector is twisted up and down or to the left or right the housing may bre...

Page 28: ...be careful not to make it too hot as this will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For connectors with the lock stopper push in the connector until the stop per clicks into position 3 Correct any protrusion of the boot and any misalignment of the wirin...

Page 29: ... connector 2 Connection Right of figure 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are set normally Arrow 1 2 3 a Right of figure Lock a is pulled down not set completely and lock b is set completely 1 Male connector 2 Female connector a b Locks q Dis...

Page 30: ...ssed air there is the risk that oil in the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use a dryer to dry the connector a Hot air from the dryer can be used but regulate the time that the hot air is used in order not to make the connector or related par...

Page 31: ...rrying out arc welding on the body disconnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the power OFF before discon necting or connecting connectors 2 Before carrying out troubleshooting check that all the related connectors are properly inserted a Disconn...

Page 32: ...it is desirable to use unit exchange Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings After any piping or equipment is removed the openings should be sealed with caps tapes or vinyl bags to prevent any dirt or dust from entering If the opening is ...

Page 33: ... and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and old oil from the hydraulic circuit Normally flushing is carried out twice primary flushing is carried out with flushing oil and secondary flushing is carried out ...

Page 34: ...or of flywheel housing NE 95 170 12V140 engines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor 1 toward you a Even if lock L2 is pressed connec tor 1 cannot be pulled out toward you if part A does not float In this case float part A with a small screw driver w...

Page 35: ...ing lock C pull out connector 3 in the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor with flat head screwdriver 1 pull out connector 3 in the direction of the arrow q 107 114 engines Example Intake air pressure temperature sensor in intake manifold SUMI...

Page 36: ...MO 3 a Pull the connector straight up 4 Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn housing H1 in the direction of the arrow a When connector is unlocked housing H1 becomes heavy to turn 2 Pull out housing H1 in the direction of the arrow a Housing ...

Page 37: ...ing nomi nal No of 0 85 Indicates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material of wire are shown in Table 1 Since AV and AVS are classified by size nominal No they are not indi cated Table 1 Type Sym bol Material Using temperature range C Example of use...

Page 38: ... 29 1 96 2 09 3 08 3 30 5 23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Number of strands Diam eter of strand 50 0 45 84 0 45 41 0 80 70 0 80 85 0 80 108 0 80 127 0 80 169 0 80 217 0 80 Sectional area mm2 7 95 13 36 20 61 35 19 42 73 54 29 63 84 8...

Page 39: ...ue Red BrR Brown Red LW Blue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red White GR Green Red RY Red Yellow GW Green White Sb Sky Blue GY Green Yellow Y Yellow L Blue YB Yellow Black LB Blue Black YG Yellow Green Lg Light green YL Yellow Blue LgB Light g...

Page 40: ...n raising components be sure to use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal a Precautions when handling piping during disassembly Fit the following plugs into the piping after disc...

Page 41: ...c cylinder 4 5 times stopping the cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for the first time after repair or long storage follow the same procedure 3 Precautions when completing the operation 1 Refilling with coolant oil and grease q If the coolant ...

Page 42: ...g parts for a crack and damage If any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler If any abnormal sound is heard repair the muffler referring to Troubleshooti...

Page 43: ... 1 and push hose joint 2 into mating adapter 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fig 2 3 Hold hose adapter 1 or hose 5 and pull it out Fig 3 a Since some hydraulic oil flows out prepare an oil receiving container 2 Connection 1 Hold hose adap...

Page 44: ...n ring 6 contacts contact surface a of the hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to discon nect it Fig 8 2 Connection q Hold the tightening portion and push body 7 straight until sliding prevention ring 6 contacts contact surface a of the hexag o...

Page 45: ... of the hexag onal portion at the male end Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 and 2 pull out whole body 9 to discon nect it Fig 12 2 Connection q Hold the tightening portion and push body 9 straight until the sliding prevention ring contac...

Page 46: ...the ones indicated in the table for bolts shown in Fig B Values of tightening torques shown in the table for Fig A are applied Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 0 7 5 12 19 98 123 10 0 12 5 14 22 157 196 16 20 16 24 245 309 25 31 5 18 27 343 427 35 43 5 20 30 490 608 50 62 22 32 662 829 67 5 84 5 24 36 ...

Page 47: ...Nominal No Thread diameter Width across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 10 12 33 363 480 37 0 49 0 422 43 0 14 42 746 1 010 76 0 103 883 90 0 Nominal No Thread diameter Width across flats Tightening torque Nm kgm mm mm Range Target 08 8 14 5 88 8...

Page 48: ... the 102 107 and 114 engine series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thread Thread diameter mm Reference 02 19 34 54 3 5 5 5 44 4 5 9 16 18UN 14 3 34 63 3 5 6 5 14 03 22 54 93 5 5 9 5 74 7 5 11 16 16UN 17 5 24 59 98 6 0 10 0 78 8 0 18 04 27 84 132 8 5 13 5 103 10 5...

Page 49: ... Taper screws a Unless there are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque mm Nm kgm 6 8 2 0 81 0 20 8 10 2 1 02 0 20 10 12 2 1 22 0 20 12 24 4 2 45 0 41 14 36 5 3 67 0 51 Tightening torque Material In cast iron or steel In aluminum Thread size inch Nm kgm Nm kgm 1 16 15 2 1 53 0 20 5 1 0 51 0 10 1...

Page 50: ...ppear in the table so divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 inches Millimeters to inches B 1 mm 0 0393...

Page 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com ...

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