Komatsu PC160LC-8 Hydraulic Excavator Service Manual
1,038 pages · Publication SEN0456-13
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- Models
- PC160LC-8
- Serial coverage
- 25001 and up
- Manual type
- Service Manual
- Pages
- 1,038
- Publication
- SEN0456-13
- Condition
- Brand new
What's inside
From the manual's own table of contents: 184 sections, 338 entries. See sample pages (PDF, 785 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 184 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
Accumulator47 topics
- Anti-drop valve for boom
- Anti-drop valve for arm
- 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 system
- Electronic control system
- Monitor system
- Sensor
- KOMTRAX system
- Standard value table for engine
- Standard value table for chassis related parts
- Tools for testing, adjusting, and troubleshooting
- Testing engine speed
- Testing intake air pressure (boost pressure)
- Testing exhaust gas color
- Adjusting valve clearance
- Testing compression pressure
- Testing of blow-by pressure
- Testing engine oil pressure
- Handling fuel system parts
- Releasing residual pressure from fuel system
- Testing 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
- Testing and adjusting track shoe tension
- Inspection and adjustment oil pressure in work equipment, swing, and travel circuits
- Testing control circuit oil pressure
- Testing and adjustment of pump PC control circuit oil pressure
- Testing and adjustment of pump LS control circuit oil pressure
- Testing 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
Checking cab tipping stopper
Installation and adjustment of mirrors and camera
Inspection of air conditioner Recirc/Fresh air filter
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
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
Phenomena looking like troubles and troubleshooting Nos
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Failure code [989L00] Engine controller lock caution 1
Failure code [989M00] Engine controller lock caution 2
Failure code [989N00] Engine controller lock caution 3
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 water level low
Failure code [B@HANS] Hydr oil overheat
Failure code [CA111] ECM 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 error55 topics
- 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 error
- Failure code [CA342] Calibration code incompatibility
- Failure code [CA351] Inj. 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] Battery voltage low error
- Failure code [CA442] 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 persistent data lost error
- Failure code [CA778] Eng Bkup speed sensor error
- Failure code [CA1633] KOMNET datalink timeout error
- Failure code [CA2185] Throttle sens. sup. volt. high error
- Failure code [CA2186] Throttle 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 short
- Failure code [D19JKZ] Personal code relay abnormality
- Failure code [D862KA] GPS antenna discon
- Failure code [DA22KK] Pump solenoid power low error
- Failure code [DA25KP] 5V sensor 1 power abnormality
- Failure code [DA26KP] 5V sensor 2 power abnormality
- Failure code [DA29KQ] Model selection abnormality
- Failure code [DA2RMC] CAN discon (Pump controller detected)
- Failure code [DAF8KB] Short circuit in camera power supply
- Failure code [DAFGMC] GPS module error
- Failure code [DAFRMC] CAN discon (Monitor detected)
- 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 [DHS5KX] Travel PPC press sensor abnormality
- Failure code [DHSAMA] Sw RH PPC press sen. abnormality
- Failure code [DHSBMA] Sw LH PPC press sen. abnormality
- Failure code [DHX1MA] Overload sensor abnormality (Analog)
- Failure code [DW43KA] Travel speed sol discon
- Failure code [DW43KB] Travel speed sol short
- Failure code [DW45KA] Swing brake sol discon
- Failure code [DW45KB] Swing brake sol short
- Failure code [DW91KA] Travel junction sol discon
- Failure code [DW91KB] Travel junction sol short
- Failure code [DWA2KA] Service sol discon
Failure code [DWA2KB] Service sol short
Failure code [DWJ0KA] Merge-divider sol discon
Failure code [DWJ0KB] Merge-divider sol short
Failure code [DWK0KA] 2-stage relief sol discon
Failure code [DWK0KB] 2-stage relief sol short
Failure code [DXA8KA] PC-EPC sol discon
Failure code [DXA8KB] PC-EPC sol short
Failure code [DXE4KA] Service current EPC discon
Failure code [DXE4KB] Service current EPC short
Failure code [DY20KA] Wiper working abnormality
Failure code [DY20MA] Wiper parking abnormality
Failure code [DY2CKA] Washer drive discon
Failure code [DY2CKB] Washer drive short
Failure code [DY2DKB] Wiper drive (for) short
Failure code [DY2EKB] Wiper drive (rev) short
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
When starting switch turned ON, machine monitor displays nothing
When starting switch turned ON (before starting engine), basic check item lights up
Engine does not start (Engine does not turn)
Preheater does not operate
Automatic warm-up system does not operate (in cold season)
All work equipment, swing, and travel mechanism do not move or cannot be locked
Precaution lights up while engine is running
Emergency stop item lights up while engine is running
Engine coolant temperature gauge does not indicate normally
Hydraulic oil temperature gauge does not indicate normally
Fuel level gauge does not indicate normally
Contents of display by machine monitor are different from applicable machine
Machine monitor does not display some items
Function switch does not work
Auto-decelerator does not operate normally
Working mode does not change
Travel speed does not change
Alarm buzzer cannot be stopped
Windshield wiper and window washer do not operate
Power maximizing function does not operate normally
Swing holding brake does not operate normally
Travel alarm does not sound or does not stop sounding
Air conditioner does not operate normally (including air conditioner abnormality record)
While starting switch is in OFF position, service meter is not displayed
Machine monitor cannot be set in service mode
Monitoring function does not display lever control signal normally
KOMTRAX system does not operate normally
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 low52 topics
- 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 + travel
- 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 cylinder head assembly
- Removal and installation of front oil seal
- Removal and installation of rear oil seal
- Removal and installation of radiator assembly
- Removal and installation of aftercooler assembly
- Removal and installation of hydraulic 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 hydraulic pump input shaft oil seal
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
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 anti-drop valve assembly for boom
Removal and installation of anti-drop valve assembly for arm
Disassembly and assembly of anti-drop valve assembly
Removal and installation of operator's cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly
Removal and installation of KOMTRAX terminal
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 (1,038 pages). Open the sample pages (PDF, 785 KB)
- Specifications, page 60: 100 Specification and technical data
- Troubleshooting, page 572: 301 Troubleshooting by failure code, Part 1
- Diagram, page 732: 400 Troubleshooting of electrical system (E-mode)
- Foldout diagram: Electrical circuit diagram (1/6)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the PC160LC-8 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 SEN0456-13$109.55
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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, 1,038 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Binder not included
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.
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).