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KOMATSU PC160-6K PC180LC, 180NLC-6K SHOP MANUAL UEBM000601 – PDF DOWNLOAD
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KOMATSU PC160-6K PC180LC, 180NLC-6K SHOP MANUAL UEBM000601 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC160-6K PC180LC, 180NLC-6K SHOP MANUAL UEBM000601 – PDF DOWNLOAD
Language : English
Pages : 692
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC160-6K PC180LC, 180NLC-6K SHOP MANUAL UEBM000601 – PDF DOWNLOAD
MAIN MENU........................................................................................................................................................................................... 0 COVER............................................................................................................................................................................................... 1 CONTENTS............................................................................................................................................................................................ 1 SAFETY.............................................................................................................................................................................................. 1 SAFETY NOTICE................................................................................................................................................................................... 6 FOREWARD............................................................................................................................................................................................ 8 GENERAL......................................................................................................................................................................................... 8 HOW TO READ THE SHOP MANUAL..................................................................................................................................................................... 9 HOISTING INSTRUCTIONS........................................................................................................................................................................... 10 COATING MATERIALS............................................................................................................................................................................... 11 STANDARD TIGHTENING TORQUE...................................................................................................................................................................... 12 ELECTRIC WIRE CODE.............................................................................................................................................................................. 14 CONVERSION TABLE................................................................................................................................................................................ 15 01 GENERAL.......................................................................................................................................................................................... 22 SPECIFICATIONS.................................................................................................................................................................................. 23 SPECIFICATION DRAWINGS.......................................................................................................................................................................... 25 WEIGHT TABLE.................................................................................................................................................................................... 29 FUEL, COOLANT AND LUBRICANTS.................................................................................................................................................................... 33 10 STRUCTURE AND FUNCTION........................................................................................................................................................................... 35 ENGINE RELATED PARTS............................................................................................................................................................................ 36 RADIATOR * OIL COOLER........................................................................................................................................................................... 37 POWER TRAIN..................................................................................................................................................................................... 38 FINAL DRIVE..................................................................................................................................................................................... 39 SWING CIRCLE.................................................................................................................................................................................... 40 SWING MACHINERY................................................................................................................................................................................. 41 TRACK FRAME, RECOIL SPRING...................................................................................................................................................................... 43 TRACK SHOE...................................................................................................................................................................................... 44 HYDRAULIC CIRCUIT DIAGRAM....................................................................................................................................................................... 47 FUEL & HYDRAULIC TANK........................................................................................................................................................................... 48 HYDRAULIC PUMP.................................................................................................................................................................................. 51 CONTROL VALVE................................................................................................................................................................................... 58 CLSS............................................................................................................................................................................................ 64 SWING MOTOR.....................................................................................................................................................................................101 CENTER SWIVEL JOINT.............................................................................................................................................................................103 TRAVEL MOTOR....................................................................................................................................................................................104 VALVE CONTROL...................................................................................................................................................................................112 WORK EQUIPMENT - SWING PPC VALVE................................................................................................................................................................113 TRAVEL PPC PEDAL................................................................................................................................................................................117 SAFETY LOCK VALVE...............................................................................................................................................................................124 PPC ACCUMULATOR.................................................................................................................................................................................124 PPC SHUTTLE * TRAVEL JUNCTION VALVE.............................................................................................................................................................125 EPC * SOLENOID VALVE............................................................................................................................................................................132 HYDRAULIC CYLINDER..............................................................................................................................................................................137 ADDITIONAL FILTER FOR BREAKING..................................................................................................................................................................139 OVERLOAD WARNING DEVICE.........................................................................................................................................................................140 HOSE BURST PROTECTION VALVE (BOOM)..............................................................................................................................................................144 WORK EQUIPMENT..................................................................................................................................................................................147 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE...........................................................................................................................................................150 ENGINE CONTROL SYSTEM...........................................................................................................................................................................151 ELECTRONIC CONTROL SYSTEM.......................................................................................................................................................................157 MACHINE MONITOR SYSTEM..........................................................................................................................................................................181 20 TESTING AND ADJUSTING............................................................................................................................................................................193 TABLE OF JUDGEMENT STANDARD VALUE...............................................................................................................................................................194 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.......................................................................................................................................................204 CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR..............................................................................................................................212 ADJUSTING ENGINE SPEED SENSOR...................................................................................................................................................................213 TESTING AND ADJUSTING GOVERNOR MOTOR LEVEL STROKE...............................................................................................................................................214 TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................................................................................................216 TESTING AND ADJUSTING TRACK SHOE TENSION........................................................................................................................................................217 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................................................................................................218 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...................................................................................................................226 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE.......................................................................................228 TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE................................................................................................................................................231 TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE................................................................................................................................................233 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...............................................................................................................................235 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.......................................................................................................................................................237 TESTING TRAVEL DEVIATION........................................................................................................................................................................238 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................................................................................................239 MEASURING OIL LEAKAGE...........................................................................................................................................................................241 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................................................243 BLEEDING AIR....................................................................................................................................................................................244 TROUBLESHOOTING.................................................................................................................................................................................247 POINTS TO REMEMBER WHEN TROUBLSHOOTING......................................................................................................................................................248 SEQUENCE OF EVENTS IN TROUBLSHOOTING........................................................................................................................................................249 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...................................................................................................................................................250 CHECKS BEFORE TROUBLESHOOTING...............................................................................................................................................................257 CONNECTOR TYPES AND MOUNTING LOCATIONS......................................................................................................................................................258 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................................................................................263 EXPLANATION OF CONTROL MACHANISM FOR ELECTRICAL SYSTEM......................................................................................................................................276 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.......................................................................................................................................277 METHOD OF USING JUDGEMENT TABLE.............................................................................................................................................................285 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................................................................................................287 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE....................................................................................................................................289 SERVICE CODE TABLE..........................................................................................................................................................................294 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)................................................................................................................................295 N-1 [E218] COMMUNICATION ABNORMALITY....................................................................................................................................................296 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE).............................................................................................................298 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM................................................................................................299 ACTION BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................................................................300 JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS..........................................................................................304 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE...................................................................................................................................................306 E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF).......................................................................................................308 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED....................................................................................................................309 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED...............................................................................................................310 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED...............................................................................................................311 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED....................................................................................................................312 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED......................................................................................................313 E-7 [E316] ABNORMALITY (STEP OUT) IN MOTOR IS DISPLAYED.................................................................................................................................314 E-8 ENGINE DOES NOT START...............................................................................................................................................................316 E-9 ENGINE SPEED IS IRREGULAR...........................................................................................................................................................318 a) IDLING SPEED IS IRREGULAR........................................................................................................................................................318 b) THERE IS HUNTING.................................................................................................................................................................320 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)...............................................................................................................................322 E-11 ENGINE DOES NOT STOP...............................................................................................................................................................324 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP).................................................................................................................326 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...................................................................................................................................................329 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................................................................................330 S-1 STARTING PERFORMARMANCE IS POOR (STARTING ALWAYS TAKES TIME)........................................................................................................................334 S-2 ENGINE DOES NOT START...............................................................................................................................................................335 1) ENGINE DOES NOT TURN.............................................................................................................................................................335 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEEN INJECTED)..........................................................................................................336 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FEUL IS BEING INJECTED).......................................................................................................337 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)................................................................................................................................338 S-4 ENGINE STOPS DURING OPERATIONS......................................................................................................................................................339 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................................................................................................340 S-6 ENGINE LACKS OUTPUT (NO POWER)......................................................................................................................................................341 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)......................................................................................................................................342 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................................................................................................343 S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................................................................................................344 S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................................................................................................345 S-11 OIL LEVEL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN......................................................................................................346 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).........................................................................................................................347 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...............................................................................................................................................348 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................................................................................349 S-15 ABNORMAL NOISE IS MADE.............................................................................................................................................................350 S-16 VIBRATION IS EXCESSIVE.............................................................................................................................................................351 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE).................................................................................................................352 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM..........................................................................................................................353 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..............................................................................................................354 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.........................................................................................360 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE ..................................................................................................................................................362 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...............................................................................................................364 C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................365 C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................367 C-6 [E201] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED....................................................................................................................369 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED....................................................................................................................371 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED....................................................................................................................373 C-10 [E205] SHORT CIRCUIT IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED................................................................................................................375 C-11 [E215] DISCONNECTION IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED................................................................................................................376 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED..................................................................................................................377 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED.........................................................................................................378 C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED....................................................................................................................................379 C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED........................................................................................................................381 C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS............................................................................................................................382 C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.....................................................................................................................383 C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED.............................................................................................................384 C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED......................................................................................................................385 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).................................................................................................................387 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...................................................................................................................................................388 F-1 BIT PATTERN 20- (1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................................................................390 F-2 BIT PATTERN 20- (2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP....................................................................................................................391 F-3 BIT PATTERN 20- (3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................................................................................392 F-4 BIT PATTERN 20- (4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................................................................................393 F-5 BIT PATTERN 20- (5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP....................................................................................................................394 F-6 BIT PATTERN 20- (6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...................................................................................................................395 F-7 BIT PATTERN 21- (1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................396 F-8 BIT PATTERN 21- (2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................397 F-9 BIT PATTERN 21- (3) SWING LOCK SWITCH DOES NOT LIGHT UP.............................................................................................................................398 F-10 BIT PATTERN 22- (5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP.....................................................................................................................399 F-11 BIT PATTERN 22- (6) L.H. KNOB SWITCH DOES NOT LIGHT UP.............................................................................................................................400 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)....................................................................................................................................401 TABLE OF FAILURE MODES AND CAUSES.......................................................................................................................................................402 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER..................................................................................................................406 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...........................................................................................................................408 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...............................................................................................................................................409 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)..............................................................................................................................................409 H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)...................................................................................................................410 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR....................................................................................................................................410 H-7 BOOM IS SLOW OR LACKS POWER.........................................................................................................................................................412 H-8 ARM IS SLOW OR LACKS POWER..........................................................................................................................................................414 H-9 BUCKET IS SLOW OR LACKS POWER.......................................................................................................................................................416 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).................................................................................................417 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)......................................................................................................................................417 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)..........................................................................................................................................418 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED..............................................................................................................................418 H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED..................................................................................................................419 H-15 LACK OF POWER WHEN PRESSURE RISES..................................................................................................................................................419 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW....................................................................................................................419 H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW..........................................................................................................................................420 H-20 TRAVEL DEVIATION...................................................................................................................................................................421 H-21 TRAVEL SPEED IS SLOW...............................................................................................................................................................422 H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER.......................................................................................................................................424 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED.....................................................................................................................426 H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...............................................................................................................................................426 H-25 DOES NOT SWING.....................................................................................................................................................................427 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW..................................................................................................................................428 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING..............................................................................................................................................430 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)...........................................................................................................................431 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING.......................................................................................................................................431 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING.................................................................................................................................................432 H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED...................................................................................................................................433 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)..........................................................................................................................................435 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................................................................436 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE...................................................................................................................................................438 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED; [E102] ERROR IN CLOCK DATA IS DISPLAYED..............................................................................................440 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED.......................................................................441 M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED...........................................................................................................................................442 M-4 [E106] DROP IN ENGINE OIL PRESSURE DETECTED IS DISPLAYED............................................................................................................................442 M-5 [E108] ENGINE WATER TEMPERATURE 105 c DETECTED IS DISPLAYED........................................................................................................................443 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL LIGHT UP FOR 3 SECONDS....................................................................................444 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT........................................................................................446 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)......................................................................446 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES.......................................................................................................447 M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP....................................................................................................................449 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH...................................................................................................450 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)......................................452 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)....454 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND..............................................457 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS...........................................................................................................................457 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)...............................................................................................458 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE............................................................................................................................................459 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)................................................................................459 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL..............................................................................................................................................460 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY.............................................................................................................................................460 M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP...................................................................................................461 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH.................................................................................................461 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING.............................................................................................................................462 M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED................................................................................462 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM.................................................................................................................................................463 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM........................................................................................................................................464 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM...........................................................................................................................................465 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM..............................................................................................................................................466 M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED..............................................................................................................467 30 DISASSEMBLY AND ASSEMBLY.........................................................................................................................................................................473 METHOD OF USING MANUAL..........................................................................................................................................................................475 PRECAUTIONS WHEN CARRYING OUT OPERATION.........................................................................................................................................................477 SPECIAL TOOL LIST...............................................................................................................................................................................479 GOVERNOR MOTOR ASSEMBLY.........................................................................................................................................................................482 REMOVAL AND INSTALLATION....................................................................................................................................................................482 HYDRAULIC OIL COOLER ASSEMBLY...................................................................................................................................................................483 REMOVAL AND INSTALLATION....................................................................................................................................................................483 RADIATOR * HYDRAULIC OIL COOLER ASSEMBLY........................................................................................................................................................484 REMOVAL.....................................................................................................................................................................................484 INSTALLATION................................................................................................................................................................................485 ENGINE * HYDRAULIC PUMP ASSEMBLY................................................................................................................................................................486 REMOVAL.....................................................................................................................................................................................486 INSTALLATION................................................................................................................................................................................489 DAMPER ASSEMBLY.................................................................................................................................................................................490 REMOVAL AND INSTALLATION....................................................................................................................................................................490 FUEL/HYDRAULIC TANK ASSEMBLY....................................................................................................................................................................491 REMOVAL.....................................................................................................................................................................................491 INSTALLATION................................................................................................................................................................................492 CENTER SWIVEL JOINT ASSEMBLY....................................................................................................................................................................493 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................493 TRAVEL MOTOR ASSEMBLY...........................................................................................................................................................................494 REMOVAL AND INSTALLATION....................................................................................................................................................................494 FINAL DRIVE ASSEMBLY............................................................................................................................................................................495 REMOVAL AND INSTALLATION....................................................................................................................................................................495 SPROCKET........................................................................................................................................................................................497 REMOVAL AND INSTALLATION....................................................................................................................................................................497 SWING MOTOR ASSEMBLY............................................................................................................................................................................498 REMOVAL AND INSTALLATION....................................................................................................................................................................498 SWING MACHINERY ASSEMBLY........................................................................................................................................................................499 REMOVAL AND INSTALLATION....................................................................................................................................................................499 SWING MOTOR.....................................................................................................................................................................................501 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................501 REVOLVIING FRAME ASSEMBLY.......................................................................................................................................................................508 REMOVAL.....................................................................................................................................................................................508 INSTALLATION................................................................................................................................................................................509 SWING CIRCLE ASSEMBLY...........................................................................................................................................................................510 REMOVAL.....................................................................................................................................................................................510 INSTALLATION................................................................................................................................................................................511 IDLER * RECOIL SPRING ASSEMBLY..................................................................................................................................................................512 REMOVAL AND INSTALLATION....................................................................................................................................................................512 RECOIL SPRING ASSEMBLY..........................................................................................................................................................................513 DISASSEMBLY.................................................................................................................................................................................513 ASSEMBLY....................................................................................................................................................................................514 IDLER ASSEMBLY..................................................................................................................................................................................515 DISASSEMBLY.................................................................................................................................................................................515 ASSEMBLY....................................................................................................................................................................................516 TRACK ROLLER....................................................................................................................................................................................518 REMOVAL AND INSTALLATION....................................................................................................................................................................518 DISASSEMBLY.................................................................................................................................................................................519 ASSEMBLY....................................................................................................................................................................................520 CARRIER ROLLER ASSEMBLY.........................................................................................................................................................................522 REMOVAL AND INSTALLATION....................................................................................................................................................................522 DISASSEMBLY.................................................................................................................................................................................523 ASSEMBLY....................................................................................................................................................................................524 TRACK SHOE ASSEMBLY.............................................................................................................................................................................526 REMOVAL AND INSTALLATION....................................................................................................................................................................526 MAIN PUMP ASSEMBLY..............................................................................................................................................................................529 REMOVAL.....................................................................................................................................................................................529 INSTALLATION................................................................................................................................................................................530 CONTROL VALVE ASSEMBLY..........................................................................................................................................................................531 REMOVAL.....................................................................................................................................................................................531 INSTALLATION ...............................................................................................................................................................................532 DISASSEMBLY.................................................................................................................................................................................533 ASSEMBLY....................................................................................................................................................................................535 LS SELECT VALVE ASSEMBLY........................................................................................................................................................................537 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................537 LS SHUTTLE VALVE................................................................................................................................................................................538 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................538 PRESSURE COMPENSATION VALVE ASSEMBLY............................................................................................................................................................539 DISASSEMBLY.................................................................................................................................................................................539 ASSEMBLY....................................................................................................................................................................................540 MAIN RELIEF VALVE ASSEMBLY......................................................................................................................................................................541 DISASSEMBLY.................................................................................................................................................................................541 ASSEMBLY....................................................................................................................................................................................542 LS CONTROL EPC VALVE ASSEMBLY...................................................................................................................................................................543 REMOVAL AND INSTALLATION....................................................................................................................................................................543 SOLENOID VALVE ASSEMBLY.........................................................................................................................................................................544 REMOVAL AND INSTALLATION....................................................................................................................................................................544 PPC SHUTTLE VALVE ASSEMBLY......................................................................................................................................................................545 REMOVAL.....................................................................................................................................................................................545 INSTALLATION................................................................................................................................................................................546 DISASSEMBLY.................................................................................................................................................................................547 ASSEMBLY....................................................................................................................................................................................548 WORK EQUIPMENT SWING PPC VALVE ASSEMBLY.........................................................................................................................................................549 REMOVAL AND INSTALLATION....................................................................................................................................................................549 TRAVEL PPC VALVE ASSEMBLY.......................................................................................................................................................................550 REMOVAL AND INSTALLATION....................................................................................................................................................................550 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................551 BOOM CYLINDER ASSEMBLY..........................................................................................................................................................................553 REMOVAL.....................................................................................................................................................................................553 INSTALLATION................................................................................................................................................................................554 ARM CYLINDER ASSEMBLY...........................................................................................................................................................................555 REMOVAL.....................................................................................................................................................................................555 INSTALLATION................................................................................................................................................................................556 BUCKET CYLINDER ASSEMBLY........................................................................................................................................................................557 REMOVAL.....................................................................................................................................................................................557 INSTALLATION................................................................................................................................................................................558 HYDRAULIC CYLINDER ASSEMBLY.....................................................................................................................................................................559 DISASSEMBLY.................................................................................................................................................................................559 ASSEMBLY....................................................................................................................................................................................561 WORK EQUIPMENT ASSEMBLY.........................................................................................................................................................................564 REMOVAL.....................................................................................................................................................................................564 INSTALLATION................................................................................................................................................................................565 BUCKET ASSEMBLY.................................................................................................................................................................................566 REMOVAL AND INSTALLATION....................................................................................................................................................................566 ARM ASSEMBLY....................................................................................................................................................................................566 REMOVAL AND INSTALLATION....................................................................................................................................................................566 ARM, BUCKET ASSEMBLY............................................................................................................................................................................568 REMOVAL AND INSTALLATION....................................................................................................................................................................568 BOOM ASSEMBLY...................................................................................................................................................................................570 REMOVAL.....................................................................................................................................................................................570 INSTALLATION ...............................................................................................................................................................................571 OPERATOR'S CAB ASSEMBLY.........................................................................................................................................................................572 REMOVAL.....................................................................................................................................................................................572 INSTALLATION................................................................................................................................................................................574 COUNTERWEIGHT ASSEMBLY..........................................................................................................................................................................575 REMOVAL AND INSTALLATION....................................................................................................................................................................575 GOVERNOR, PUMP CONTROLLER ASSEMBLY..............................................................................................................................................................576 REMOVAL AND INSTALLATION....................................................................................................................................................................576 MONITOR PANEL ASSEMBLY..........................................................................................................................................................................577 REMOVAL AND INSTALLATION....................................................................................................................................................................577 FINAL DRIVE ASSEMBLY............................................................................................................................................................................583 DISASSEMBLY.................................................................................................................................................................................583 ASSEMBLY....................................................................................................................................................................................594 (SPECIAL TOOLS).............................................................................................................................................................................606 SWING MACHINERY ASSEMBLY........................................................................................................................................................................613 DISASSEMBLY.................................................................................................................................................................................613 ASSEMBLY....................................................................................................................................................................................629 (SPECIAL TOOLS).............................................................................................................................................................................649 40 MAINTENANCE STANDARD.............................................................................................................................................................................653 ENGINE MOUNT....................................................................................................................................................................................654 SWING MACHINERY.................................................................................................................................................................................655 SWING CIRCLE....................................................................................................................................................................................657 FINAL DRIVE.....................................................................................................................................................................................658 TRACK FRAME, RECOIL SPRING......................................................................................................................................................................660 IDLER...........................................................................................................................................................................................661 CARRIER ROLLER..................................................................................................................................................................................663 TRACK ROLLER....................................................................................................................................................................................664 TRACK SHOE......................................................................................................................................................................................665 CONTROL VALVE...................................................................................................................................................................................667 SUCTION-SAFETY VALVE............................................................................................................................................................................675 SWING MOTOR.....................................................................................................................................................................................676 WORK EQUIPMENT, SWING PPC VALVE.................................................................................................................................................................677 TRAVEL PPC VALVE................................................................................................................................................................................678 SERVICE PPC VALVE...............................................................................................................................................................................679 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE........................................................................................................................................................680 EPC SOLENOID VALVE..............................................................................................................................................................................681 CENTER SWIVEL JOINT.............................................................................................................................................................................682 ARM, BOOM SAFETY VALVE..........................................................................................................................................................................683 HYDRAULIC CYLINDER..............................................................................................................................................................................684 WORK EQUIPMENT..................................................................................................................................................................................685
DESCRIPTION:
KOMATSU PC160-6K PC180LC, 180NLC-6K SHOP MANUAL UEBM000601 – PDF DOWNLOAD
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
S.S 19/12/24
