Komatsu PC160LC-7E0 Hydraulic Excavator Service Manual
922 pages · Publication SEN01892-05
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- Models
- PC160LC-7E0
- Serial coverage
- 20001 and up
- Manual type
- Service Manual
- Pages
- 922
- Publication
- SEN01892-05
- Condition
- Brand new
What's inside
From the manual's own table of contents: 178 sections, 328 entries. See sample pages (PDF, 803 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Track frame, recoil spring
Idler
Show all 178 sections
Carrier roller
Track roller
Track shoe
Hydraulic equipment layout drawing
Hydraulic tank
Hydraulic pump
Control valve
CLSS
Functions and operation by valve
Valve control
PPC valve
Solenoid valve
Accumulator45 topics
- Return oil filter
- Center swivel joint
- Travel motor
- Swing motor
- Attachment circuit selector valve
- Hydraulic cylinder
- Work equipment
- Dimensions of components
- Air conditioner piping
- Engine control
- Electronic control system
- Monitor system
- Sensor
- KOMTRAX terminal system
- Standard value table for engine
- Standard value table for chassis related parts
- Tools for testing, adjusting, and troubleshooting
- Measuring engine speed
- Measuring intake air pressure (boost pressure)
- Checking exhaust gas color
- Adjusting valve clearance
- Measuring compression pressure
- Measurement of blow-by pressure
- Measuring engine oil pressure
- Handling fuel system parts
- Releasing residual pressure from fuel system
- Measuring fuel pressure
- Measuring fuel discharge, return and leakage
- Bleeding air from fuel circuit
- Checking fuel circuit for leakage
- Checking and adjusting air conditioner compressor belt tension
- Replacing the fan belt
- Testing of clearance in swing circle bearings
- Checking and adjusting track shoe tension
- Inspection and adjustment oil pressure in work equipment, swing, and travel circuits
- Inspection and adjustment of control circuit oil pressure
- Inspection and adjustment of pump PC control circuit oil pressure
- Inspection and adjustment of pump LS control circuit oil pressure
- Measurement of solenoid valve output pressure
- Testing of PPC valve output pressure
- Adjustment of work equipment and swing PPC valve
- Inspection of locations of hydraulic drift of work equipment
- Testing and adjusting travel deviation
- Release of residual pressure from hydraulic circuit
- Measurement of oil leakage
Bleeding air from each part
Inspection procedures for diode
Adjusting mirrors
Special functions of machine monitor
Handling voltage circuit of engine controller
Procedure for turning on KOMTRAX terminal
Indication by KOMTRAX terminal lamps
Preparation work for troubleshooting of electrical system
Pm-clinic service
Failure code table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Possible problems and troubleshooting No
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Failure code [AA10NX] Air cleaner clogging
Failure code [AB00KE] Charge voltage low
Failure code [B@BAZG] Eng. oil press. low
Failure code [B@BAZK] Eng. oil level low
Failure code [B@BCNS] Eng. coolant overheat
Failure code [B@BCZK] Eng. coolant level low
Failure code [B@HANS] Hydr oil overheat
Failure code [CA111] EMC critical internal failure
Failure code [CA115] Eng Ne and bkup speed sens error
Failure code [CA122] Chg air press sensor high error
Failure code [CA123] Chg air press sensor low error
Failure code [CA131] Throttle sensor high error
Failure code [CA132] Throttle sensor low error
Failure code [CA144] Coolant temp sens high error
Failure code [CA145] Coolant temp sens low error
Failure code [CA153] Chg air temp sensor high error
Failure code [CA154] Chg air temp sensor low error
Failure code [CA155] Chg air temp high speed derate
Failure code [CA187] Sens supply 2 volt low error
Failure code [CA221] Ambient press sens high error
Failure code [CA222] Ambient press sens low error
Failure code [CA227] Sens supply 2 volt high error
Failure code [CA234] Eng. overspeed
Failure code [CA238] Ne speed sens supply volt error
Failure code [CA271] IMV/PCV1 short error
Failure code [CA272] IMV/PCV1 open error
Failure code [CA322] Inj #1 open/short error
Failure code [CA324] Inj #3 open/short error
Failure code [CA331] Inj #2 open/short error
Failure code [CA332] Inj #4 open/short error55 topics
- Failure code [CA342] Calibration code incompatibility
- Failure code [CA351] Injectors drive circuit error
- Failure code [CA352] Sens supply 1 volt low error
- Failure code [CA386] Sens supply 1 volt high error
- Failure code [CA428] Water in fuel sensor high error
- Failure code [CA429] Water in fuel sensor low error
- Failure code [CA435] Eng oil press sw error
- Failure code [CA441] Engine controller battery voltage low error
- Failure code [CA442] Engine controller battery voltage high error
- Failure code [CA449] Rail press very high error
- Failure code [CA451] Rail press sensor high error
- Failure code [CA452] Rail press sensor low error
- Failure code [CA488] Chg air temp high torque derate
- Failure code [CA553] Rail press high error
- Failure code [CA559] Rail press low error
- Failure code [CA689] Eng Ne speed sensor error
- Failure code [CA731] Eng Bkup speed sens phase error
- Failure code [CA757] All continuous data lost error
- Failure code [CA778] Eng Bkup speed sensor error
- Failure code [CA1633] KOMNET Datalink timeout error
- Failure code [CA2185] Throt sens sup volt high error
- Failure code [CA2186] Throt sens sup volt low error
- Failure code [CA2249] Rail press very low error
- Failure code [CA2311] IMV solenoid error
- Failure code [CA2555] Grid htr relay volt high error
- Failure code [CA2556] Grid htr relay volt low error
- Failure code [D110KB] Battery relay drive S/C
- Failure code [D196KA] Service return relay disc
- Failure code [D196KB] Service return relay S/C
- Failure code [DA22KK] Pump solenoid power low error
- Failure code [DA25KP] Press. sensor power abnormality
- Failure code [DA2RMC] Pump comm. abnormality
- Failure code [DA2SKQ] Model selection abnormality
- Failure code [DAFRMC] Monitor comm. abnormality
- Failure code [DGH2KB] Hydr oil sensor short
- Failure code [DHPAMA] F pump press sensor abnormality
- Failure code [DHPBMA] R pump press sensor abnormality
- Failure code [DHSAMA] Sw RH PPC press sen. abnormality
- Failure code [DHSBMA] Sw LH PPC press sen. abnormality
- Failure code [DW43KA] Travel speed sol. disc
- Failure code [DW43KB] Travel speed sol. S/C
- Failure code [DW45KA] Swing brake sol. disc
- Failure code [DW45KB] Swing brake sol. S/C
- Failure code [DW91KA] Travel junction sol. disc
- Failure code [DW91KB] Travel junction sol. S/C
- Failure code [DWJ0KA] Merge-divider sol. disc
- Failure code [DWJ0KB] Merge-divider sol. S/C
- Failure code [DWK0KA] 2-stage relief sol. disc
- Failure code [DWK0KB] 2-stage relief sol. S/C
- Failure code [DXA0KA] PC-EPC sol. disc
- Failure code [DXA0KB] PC-EPC sol. S/C
- Failure code [DXE4KA] Service current EPC disc
- Failure code [DXE4KB] Service current EPC S/C
- Failure code [DY20KA] Wiper working abnormality
- Failure code [DY20MA] Wiper parking abnormality
Failure code [DY2CKB] Washer drive S/C
Failure code [DY2DKB] Wiper drive (for) S/C
Failure code [DY2EKB] Wiper drive (rev) S/C
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
Engine does not start
Auto-decelerator does not operate
Automatic warming-up system does not operate
Preheater does not operate
All work equipment, swing, and travel mechanism do not move
Power maximizing function does not operate
Machine monitor does not display at all
Machine monitor does not display some items
Contents of display by machine monitor are different from applicable machine
Fuel level monitor was lighted in red while engine running
Engine coolant temperature gauge does not indicate normally
Hydraulic oil temperature gauge does not indicate normally
Fuel level gauge does not indicate normally
Swing lock monitor does not indicate normally
When monitor switch is operated, monitor displays nothing
Windshield wiper and window washer do not operate
Monitoring function fails to display “boom raise” normally
Monitoring function fails to display “boom lower” normally
Monitoring function fails to display “arm IN” normally
Monitoring function fails to display “arm OUT” normally
Monitoring function fails to display “bucket CURL” normally
Monitoring function fails to display “bucket DUMP” normally
Monitoring function fails to display “swing left” normally
Monitoring function fails to display "swing right" normally
Monitoring function fails to display “travel” normally
Monitoring function fails to display “travel differential pressure” normally
Monitoring function fails to display “service” normally
KOMTRAX system does not operate normally
Air conditioner does not operate
Travel alarm does not sound or does not stop sounding
Horn does not sound
Attachment circuit does not change
System chart for hydraulic and mechanical systems
Speed or power of all work equipment, swing, and travel are low
Engine speed sharply drops or engine stalls
No work equipment, travel and swing move
Abnormal noise is heard from around hydraulic pump
Auto-decelerator does not work
Fine control mode does not function
Speed or power of boom is low
Speed or power of arm is low
Speed or power of bucket is low
Work equipment does not move in its single operation
Hydraulic drift of work equipment is large
Time lag of work equipment is large
One-touch power max system does not operate
Work equipment loaded more is slower during compound operation
Boom RAISE speed is low in compound operation of swing + boom RAISE
Travel speed lowers largely during compound operation of work equipment/swing + travel50 topics
- Machine deviates during travel
- Travel speed is low
- Machine cannot be steered easily or steering power is low
- Travel speed does not change or it is kept low or high
- Track does not move (Only either side)
- Machine does not swing
- Swing acceleration or swing speed is low
- Excessive overrun when stopping swing
- When upper structure stops swinging, it makes large shock
- When upper structure stops swinging, it makes large sound
- Hydraulic drift of swing is large
- Attachment circuit does not change
- Flow rate in attachment circuit cannot be adjusted
- Method of using troubleshooting chart
- Starting performance is poor
- Engine does not start
- Engine does not pick up smoothly
- Engine stops during operations
- Engine does not rotate smoothly
- Engine lack output (or lacks power)
- Exhaust smoke is black (incomplete combustion)
- Oil consumption is excessive (or exhaust smoke is blue)
- Oil becomes contaminated quickly
- Fuel consumption is excessive
- Oil is in coolant (or coolant spurts back or coolant level goes down)
- Oil pressure drops
- Oil level rises (Entry of coolant/fuel)
- Coolant temperature becomes too high (overheating)
- Abnormal noise is made
- Vibration is excessive
- How to read this manual
- Coating materials list
- Special tool list
- Sketches of special tools
- Removal and installation of fuel supply pump assembly
- Removal and installation of fuel injector assembly
- Removal and installation of front oil seal
- Removal and installation of rear oil seal
- Removal and installation of cylinder head assembly
- Removal and installation of radiator assembly
- Removal and installation of aftercooler assembly
- Removal and installation of work equipment oil cooler assembly
- Removal and installation of engine and hydraulic pump assembly
- Removal and installation of engine hood assembly
- Removal and installation of fuel tank assembly
- 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
- Disassembly and assembly of swing motor and swing machinery assembly
- Removal and installation of swing circle assembly
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
Expansion and installation of track shoe assembly
Removal and installation of sprocket
Removal and installation of revolving frame assembly
Removal and installation of counterweight
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Removal and installation of hydraulic pump input shaft oil seal
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of work equipment assembly
Removal and installation of operator’s cab
Removal and installation of operator's cab glass (Stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser
Removal and installation of air conditioner unit assembly
Removal and installation of machine monitor assembly
Removal and installation of governor, pump controller assembly
Removal and installation of engine controller assembly
Removal and installation of KOMTRAX assembly
Hydraulic circuit diagram
Electrical circuit diagram (1/6)
Electrical circuit diagram (2/6)
Electrical circuit diagram (3/6)
Electrical circuit diagram (4/6)
Electrical circuit diagram (5/6)
Electrical circuit diagram (6/6)
Connectors table and arrangement drawing
Inside this manual
Real pages from this service manual (922 pages). Open the sample pages (PDF, 802 KB)
- Troubleshooting, page 543: Failure code [CA778] Eng Bkup speed sensor error
- Diagram, page 613: Failure code [DXE4KB] Service current EPC S/C
- Specifications, page 837: 50 Disassembly and assembly
- Foldout diagram, page 914: PC160LC-7E0
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the PC160LC-7E0 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual SEN01892-05$99.95
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 922 pages
Quantity one is the manual described above.
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Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).