Komatsu Excavator PC160LC-8 PC190LC-8 PC190NLC-8 service & repair manual

Description Komatsu Excavator PC160LC-8 PC190LC-8 PC190NLC-8 service & repair manual

Komatsu Hydraulic Excavator PC160LC-8, PC190LC-8, PC190NLC-8 pdf workshop service manual

Serial numbers:
K50001 and up

Technical documentation, specifications, troubleshooting, testing, adjusting, electrical wiring diagrams, hydraulic schematics, maintenance, disassembly, assembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Composition of shop manual
Foreword and general information
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
Specification and technical data
Specification dimension drawings
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
Diesel Particulate Filter
Diesel Particulate Filter - Component Parts
System Description
Regeneration
Power train system
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Undercarriage and frame
Track frame, recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system
Hydraulic equipment layout drawing
Hydraulic tank
Hydraulic pump
Control valve
CLSS
Functions and operation by valve
Valve control
PPC valve
ATT EPC Valve Assembly
Solenoid valve
Accumulator
Return oil filter
Centre swivel joint
Travel motor
Swing motor
Attachment circuit selector valve
Quick coupler control valve
Hydraulic cylinder
Work equipment
Dimensions of components
Cab and its attachments
Air conditioner piping
Electrical system
Engine control system
Electronic control system
Monitor system
Sensor
PPC Levers
KOMTRAX system
Auto Grease system
Outline of Auto Grease System
Assembly
Components
The Greasing Cycle
Introduction

Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis related parts

Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas colour
Adjusting valve clearance
Measuring compression pressure
Measurement of blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
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
Measuring and adjusting quick coupler control valve output pressure
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

Troubleshooting
Failure code table and fuse locations
Failure code table
Fuse locations
General information on troubleshooting
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
Troubleshooting by failure code
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
Troubleshooting of Auto Grease system
Finding malfunctions
Malfunction finding procedures

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
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 engine front oil seal
Removal and installation of engine 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
Power train
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
Undercarriage and frame
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
Hydraulic system
Removal and installation of centre 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
Disassembly and Assembly of Quick Coupler Valve
Work equipment Body
Removal and installation of work equipment assembly
Cab and its attachments
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
Electrical system
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

Diagrams and drawings
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram
Connectors table and arrangement drawing

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