Komatsu Galeo Pc160lc-7e0 Hydraulic Excavator Operation Maintenance & Updated Service Manual
Komatsu Galeo Pc160lc-7e0 Hydraulic Excavator (2 Manual Set) Operation Maintenance & Updated Service Repair Workshop Manual Download
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Galeo Pc160lc-7e0 Hydraulic Excavator Operation & Service 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: 2,563 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN01892-05 – Hydraulic Excavator PC160LC-7E0 Shop Manual.pdf
UEN01892-04 – Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Shop Manual.pdf
TEN00175-06 – Hydraulic Excavator GALEO PC160LC-7E0 Operation & Maintenance Manual.pdf
UEAM006800 – Hydraulic Excavator PC160LC-7E0 Operation & Maintenance Manual.pdf
Komatsu Galeo Pc160lc-7e0 Hydraulic Excavator Operation Maintenance & Updated Service Manual
MAIN SECTIONS
COVER…1
00 Index and foreword…0
Index…2
Composition of shop manual…3
Table of contents…5
Foreword and general information…14
Safety notice…15
How to read the shop manual…20
Explanation of terms for maintenance standard…22
Handling of electric equipment and hydraulic component…24
Handling of connectors newly used for engines…33
How to read electric wire code…36
Precautions when carrying out operation…39
Method of disassembling and connecting push-pull type coupler…42
Standard tightening torque table…45
Conversion table…49
01 Specification…0
Specification and technical data…56
Specification dimension drawings…57
Specifications…59
Weight table…61
Table of fuel, coolant and lubricants…63
10 Structure, function and maintenance standard…0
Engine and cooling system…66
Engine related parts…67
Radiator, oil cooler, aftercooler and fuel cooler…68
Power train system…70
Power train…71
Swing circle…72
Swing machinery…73
Final drive…74
Sprocket…76
Undercarriage and frame…79
Track frame, recoil spring…80
Idler…82
Carrier roller…84
Track roller…85
Track shoe…86
Hydraulic system, Part 1…91
Hydraulic equipment layout drawing…92
Hydraulic tank…94
Hydraulic pump…95
Hydraulic system, Part 2…121
Control valve…122
CLSS…135
Functions and operation by valve…138
Hydraulic system, Part 3…173
Valve control…174
PPC valve…175
Solenoid valve…191
Accumulator…193
Return oil filter…194
Center swivel joint…195
Travel motor…196
Swing motor…206
Attachment circuit selector valve…207
Hydraulic cylinder…210
Work equipment…213
Work equipment…214
Dimensions of components…216
Cab and its attachments…221
Air conditioner piping…222
Electrical system…224
Engine control…225
Electronic control system…234
Monitor system…260
Sensor…278
KOMTRAX terminal system…281
20 Standard value table…0
Standard service value table…286
Standard value table for engine…287
Standard value table for chassis related parts…288
30 Testing and adjusting…0
Testing and adjusting, Part 1…299
Tools for testing, adjusting, and troubleshooting…300
Measuring engine speed…303
Measuring intake air pressure (boost pressure)…304
Checking exhaust gas color…305
Adjusting valve clearance…306
Measuring compression pressure…308
Measurement of blow-by pressure…310
Measuring engine oil pressure…311
Handling fuel system parts…312
Releasing residual pressure from fuel system…312
Measuring fuel pressure…313
Measuring fuel discharge, return and leakage…315
Bleeding air from fuel circuit…319
Checking fuel circuit for leakage…321
Checking and adjusting air conditioner compressor belt tension…322
Replacing the fan belt…323
Testing and adjusting, Part 2…325
Testing of clearance in swing circle bearings…326
Checking and adjusting track shoe tension…327
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits…328
Inspection and adjustment of control circuit oil pressure…331
Inspection and adjustment of pump PC control circuit oil pressure…332
Inspection and adjustment of pump LS control circuit oil pressure…335
Measurement of solenoid valve output pressure…339
Testing of PPC valve output pressure…342
Adjustment of work equipment and swing PPC valve…343
Inspection of locations of hydraulic drift of work equipment…344
Testing and adjusting travel deviation…346
Release of residual pressure from hydraulic circuit…348
Measurement of oil leakage…349
Bleeding air from each part…351
Inspection procedures for diode…353
Adjusting mirrors…354
Testing and adjusting, Part 3…357
Special functions of machine monitor…358
Handling voltage circuit of engine controller…386
Procedure for turning on KOMTRAX terminal…387
Indication by KOMTRAX terminal lamps…390
Preparation work for troubleshooting of electrical system…393
Pm-clinic service…395
40 Troubleshooting…0
Failure code table and fuse locations…401
table…402
Fuse locations…405
General information on troubleshooting…408
Points to remember when troubleshooting…409
Sequence of events in troubleshooting…410
Checks before troubleshooting…411
Classification and troubleshooting steps…412
Information in troubleshooting table…413
Possible problems and troubleshooting No…415
Connection table for connector pin numbers…418
T- branch box and T- branch adapter table…454
Troubleshooting by failure code, Part 1…458
[AA10NX] Air cleaner clogging…460
[AB00KE] Charge voltage low…461
[B@BAZG] Eng. oil press. low…463
[B@BAZK] Eng. oil level low…464
[B@BCNS] Eng. coolant overheat…465
[B@BCZK] Eng. coolant level low…467
[B@HANS] Hydr oil overheat…468
[CA111] EMC critical internal failure…468
[CA115] Eng Ne and bkup speed sens error…469
[CA122] Chg air press sensor high error…470
[CA123] Chg air press sensor low error…472
[CA131] Throttle sensor high error…474
[CA132] Throttle sensor low error…476
[CA144] Coolant temp sens high error…478
[CA145] Coolant temp sens low error…480
[CA153] Chg air temp sensor high error…482
[CA154] Chg air temp sensor low error…484
[CA155] Chg air temp high speed derate…486
[CA187] Sens supply 2 volt low error…487
[CA221] Ambient press sens high error…489
[CA222] Ambient press sens low error…491
[CA227] Sens supply 2 volt high error…493
[CA234] Eng. overspeed…494
[CA238] Ne speed sens supply volt error…495
[CA271] IMV/PCV1 short error…496
[CA272] IMV/PCV1 open error…497
[CA322] Inj #1 open/short error…498
[CA324] Inj #3 open/short error…500
Troubleshooting by failure code, Part 2…503
[CA331] Inj #2 open/short error…506
[CA332] Inj #4 open/short error…508
[CA342] Calibration code incompatibility…510
[CA351] Injectors drive circuit error…512
[CA352] Sens supply 1 volt low error…514
[CA386] Sens supply 1 volt high error…516
[CA428] Water in fuel sensor high error…518
[CA429] Water in fuel sensor low error…520
[CA435] Eng oil press sw error…522
[CA441] Engine controller battery voltage low error…524
[CA442] Engine controller battery voltage high error…526
[CA449] Rail press very high error…528
[CA451] Rail press sensor high error…530
[CA452] Rail press sensor low error…532
[CA488] Chg air temp high torque derate…534
[CA553] Rail press high error…534
[CA559] Rail press low error…535
[CA689] Eng Ne speed sensor error…536
[CA731] Eng Bkup speed sens phase error…538
[CA757] All continuous data lost error…540
[CA778] Eng Bkup speed sensor error…542
[CA1633] KOMNET Datalink timeout error…544
[CA2185] Throt sens sup volt high error…546
[CA2186] Throt sens sup volt low error…547
[CA2249] Rail press very low error…548
[CA2311] IMV solenoid error…550
[CA2555] Grid htr relay volt high error…552
[CA2556] Grid htr relay volt low error…554
Troubleshooting by failure code, Part 3…557
[D110KB] Battery relay drive S/C…558
[D196KA] Service return relay disc…560
[D196KB] Service return relay S/C…562
[DA22KK] Pump solenoid power low error…564
[DA25KP] Press. sensor power abnormality…566
[DA2RMC] Pump comm. abnormality…568
[DA2SKQ] Model selection abnormality…570
[DAFRMC] Monitor comm. abnormality…572
[DGH2KB] Hydr oil sensor short…574
[DHPAMA] F pump press sensor abnormality…575
[DHPBMA] R pump press sensor abnormality…577
[DHSAMA] Sw RH PPC press sen. abnormality…579
[DHSBMA] Sw LH PPC press sen. abnormality…581
Troubleshooting by failure code, Part 4…584
[DW43KA] Travel speed sol. disc…586
[DW43KB] Travel speed sol. S/C…588
[DW45KA] Swing brake sol. disc…590
[DW45KB] Swing brake sol. S/C…593
[DW91KA] Travel junction sol. disc…595
[DW91KB] Travel junction sol. S/C…597
[DWJ0KA] Merge-divider sol. disc…599
[DWJ0KB] Merge-divider sol. S/C…601
[DWK0KA] 2-stage relief sol. disc…603
[DWK0KB] 2-stage relief sol. S/C…605
[DXA0KA] PC-EPC sol. disc…607
[DXA0KB] PC-EPC sol. S/C…609
[DXE4KA] Service current EPC disc…611
[DXE4KB] Service current EPC S/C…612
[DY20KA] Wiper working abnormality…613