Komatsu PC160LC-7E0,PC180LC-7E0,PC180NLC-7E0 Hydraulic Excavator Shop Manual PDF

Description

Komatsu PC160LC-7E0,PC180LC-7E0,PC180NLC-7E0 Hydraulic Excavator Shop Manual UEN01892-04 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC160LC-7E0,PC180LC-7E0,PC180NLC-7E0 Hydraulic Excavator Shop Manual UEN01892-04 – PDF DOWNLOAD

Language : English
Pages : 958
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC160LC-7E0,PC180LC-7E0,PC180NLC-7E0 Hydraulic Excavator Shop Manual UEN01892-04 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC160LC-7E0 K45001    and up
  PC180LC-7E0 K45001    and up
  PC180NLC-7E0 K45001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual . 4
Table of contents 6
00 Index and foreword 15
Foreword and general information . 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling electric equipment and hydraulic component 25
How to read electric wire code . 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table . 46
Conversion table . 50
01 Specification . 57
Specification and technical data . 57
Specification dimension drawings . 58
Specifications . 60
Weight table . 62
Table of fuel, coolant and lubricants 64
Engine related parts . 68
Radiator, oil cooler, aftercooler and fuel cooler 69
10 Structure, function and maintenance standard 67
Engine and cooling system 67
Power train 72
Swing circle . 73
Swing machinery 74
Final drive 76
Sprocket . 78
10 Structure, function and maintenance standard 71
Power train system . 71
Track frame, recoil spring . 82
Idler 84
Carrier roller . 86
Track roller . 87
Track shoe . 88
10 Structure, function and maintenance standard 81
Undercarriage and frame 81
Hydraulic equipment layout drawing . 94
Hydraulic tank . 96
Hydraulic pump . 98
10 Structure, function and maintenance standard 93
Hydraulic system, Part 1 . 93
Control valve 126
CLSS .140
Functions and operation by valve .144
Hydraulic drift prevention valve .168
10 Structure, function and maintenance standard 125
Hydraulic system, Part 2 .125
Valve control 186
PPC valve 187
Solenoid valve .204
Accumulator 206
Return oil filter 207
Centre swivel joint 208
Travel motor .209
Swing motor 219
Attachment circuit selector valve 220
Quick coupler control valve 224
Hydraulic cylinder .226
10 Structure, function and maintenance standard 185
Hydraulic system, Part 3 .185
Work equipment .230
Work equipment (2 Piece Boom) 231
Dimensions of components .234
10 Structure, function and maintenance standard 229
Work equipment .229
Air conditioner piping .240
10 Structure, function and maintenance standard 239
Cab and its attachments 239
Engine control .244
Electronic control system 253
Monitor system .279
Sensor .297
KOMTRAX terminal system 300
10 Structure, function and maintenance standard 243
Electrical system 243
Standard value table for engine 304
Standard value table for chassis related parts .305
20 Standard value table 303
Standard service value table .303
30 Testing and adjusting .319
Testing and adjusting, Part 1 319
Tools for testing, adjusting, and troubleshooting 320
Measuring engine speed .323
Measuring intake air pressure (boost pressure) .324
Checking exhaust gas colour 325
Adjusting valve clearance 326
Measuring compression pressure .328
Measurement of blow-by pressure 330
Measuring engine oil pressure 331
Handling fuel system parts .332
Releasing residual pressure from fuel system .332
Measuring fuel pressure 333
Measuring fuel discharge, return and leakage .335
Bleeding air from fuel circuit .339
Checking fuel circuit for leakage 341
Checking and adjusting air conditioner compressor belt tension .342
Replacing the fan belt .343
30 Testing and adjusting .345
Testing and adjusting, Part 2 345
Measurement of clearance in swing circle bearings 346
Checking and adjusting track shoe tension 347
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits .348
Inspection and adjustment of control circuit oil pressure 351
Inspection and adjustment of pump PC control circuit oil pressure 352
Inspection and adjustment of pump LS control circuit oil pressure 355
Measurement of solenoid valve output pressure 359
Measurement of PPC valve output pressure .362
Adjustment of work equipment and swing PPC valve .363
Measuring and adjusting quick coupler control valve output pressure 364
Inspection of locations of hydraulic drift of work equipment .365
Testing and adjusting travel deviation .367
Release of residual pressure from hydraulic circuit 369
Measurement of oil leakage .370
Bleeding air from each part 372
Inspection procedures for diode 374
Adjusting mirrors 375
Special functions of machine monitor .380
Handling voltage circuit of engine controller 408
Procedure for turning on KOMTRAX terminal 409
Indication by KOMTRAX terminal lamps .412
Preparation work for troubleshooting of electrical system 415
30 Testing and adjusting .379
Testing and adjusting, Part 3 379
Failure code table .424
Fuse locations .427
40 Troubleshooting .423
Failure code table and fuse locations 423
40 Troubleshooting .431
General information on troubleshooting .431
Points to remember when troubleshooting 432
Sequence of events in troubleshooting 433
Checks before troubleshooting 434
Classification and troubleshooting steps .435
Information in troubleshooting table .436
Possible problems and troubleshooting No .438
Wiring table for connector pin numbers .441
T-adapter box and T-adapter table 470
40 Troubleshooting .475
Troubleshooting by failure code, Part 1 475
Failure code [AA10NX] Air cleaner clogging .477
Failure code [AB00KE] Charge voltage low .478
Failure code [B@BAZG] Eng. oil press. low 480
Failure code [B@BAZK] Eng. oil level low .481
Failure code [B@BCNS] Eng. coolant overheat 482
Failure code [B@BCZK] Eng. coolant level low .484
Failure code [B@HANS] Hydr oil overheat 486
Failure code [CA111] EMC critical internal failure .486
Failure code [CA115] Eng Ne and bkup speed sens error 487
Failure code [CA122] Chg air press sensor high error .489
Failure code [CA123] Chg air press sensor low error 491
Failure code [CA131] Throttle sensor high error 493
Failure code [CA132] Throttle sensor low error .495
Failure code [CA144] Coolant temp sens high error 497
Failure code [CA145] Coolant temp sens low error .499
Failure code [CA153] Chg air temp sensor high error 501
Failure code [CA154] Chg air temp sensor low error .503
Failure code [CA155] Chg air temp high speed derate 505
Failure code [CA187] Sens supply 2 volt low error 507
Failure code [CA221] Ambient press sens high error .509
Failure code [CA222] Ambient press sens low error 511
Failure code [CA227] Sens supply 2 volt high error .513
Failure code [CA234] Eng. overspeed 514
Failure code [CA238] Ne speed sens supply volt error .515
Failure code [CA271] IMV/PCV1 short error 516
Failure code [CA272] IMV/PCV1 open error .517
Failure code [CA322] Inj #1 open/short error .519
Failure code [CA324] Inj #3 open/short error .521
40 Troubleshooting .525
Troubleshooting by failure code, Part 2 525
Failure code [CA331] Inj #2 open/short error .528
Failure code [CA332] Inj #4 open/short error .530
Failure code [CA342] Calibration code incompatibility 532
Failure code [CA351] Injectors drive circuit error .534
Failure code [CA352] Sens supply 1 volt low error 536
Failure code [CA386] Sens supply 1 volt high error .538
Failure code [CA428] Water in fuel sensor high error .540
Failure code [CA429] Water in fuel sensor low error 542
Failure code [CA435] Eng oil press sw error 544
Failure code [CA441] Engine controller battery voltage low error .546
Failure code [CA442] Engine controller battery voltage high error 548
Failure code [CA449] Rail press very high error 550
Failure code [CA451] Rail press sensor high error 552
Failure code [CA452] Rail press sensor low error .554
Failure code [CA488] Chg air temp high torque derate .556
Failure code [CA553] Rail press high error .556
Failure code [CA559] Rail press low error 557
Failure code [CA689] Eng Ne speed sensor error .558
Failure code [CA731] Eng Bkup speed sens phase error .560
Failure code [CA757] All continuous data lost error 562
Failure code [CA778] Eng Bkup speed sensor error .564
Failure code [CA1633] KOMNET Datalink timeout error 566
Failure code [CA2185] Throt sens sup volt high error .568
Failure code [CA2186] Throt sens sup volt low error 569
Failure code [CA2249] Rail press very low error 570
Failure code [CA2311] IMV solenoid error .572
Failure code [CA2555] Grid htr relay volt high error .574
Failure code [CA2556] Grid htr relay volt low error 576
Failure code [D110KB] Battery relay drive S/C 580
Failure code [D196KA] Service return relay disc 582
Failure code [D196KB] Service return relay S/C .584
Failure code [DA22KK] Pump solenoid power low error 586
Failure code [DA25KP] Press. sensor power abnormality 588
Failure code [DA2RMC] Pump comm. abnormality .590
Failure code [DA2SKQ] Model selection abnormality 592
Failure code [DAFRMC] Monitor comm. abnormality 594
Failure code [DGH2KB] Hydr oil sensor short 596
Failure code [DHPAMA] F pump press sensor abnormality 598
Failure code [DHPBMA] R pump press sensor abnormality 600
Failure code [DHSAMA] Sw RH PPC press sen. abnormality .602
Failure code [DHSBMA] Sw LH PPC press sen. abnormality .604
40 Troubleshooting .579
Troubleshooting by failure code, Part 3 579
Failure code [DW43KA] Travel speed sol. disc .610
Failure code [DW43KB] Travel speed sol. S/C 612
Failure code [DW45KA] Swing brake sol. disc 614
Failure code [DW45KB] Swing brake sol. S/C .618
Failure code [DW91KA] Travel junction sol. disc 620
Failure code [DW91KB] Travel junction sol. S/C .622
Failure code [DWJ0KA] Merge-divider sol. disc 624
Failure code [DWJ0KB] Merge-divider sol. S/C .626
Failure code [DWK0KA] 2-stage relief sol. disc .628
Failure code [DWK0KB] 2-stage relief sol. S/C 630
Failure code [DXA0KA] PC-EPC sol. disc .632
Failure code [DXA0KB] PC-EPC sol. S/C 634
Failure code [DXE4KA] Service current EPC disc .636
Failure code [DXE4KB] Service current EPC S/C 637
Failure code [DY20KA] Wiper working abnormality 638
Failure code [DY20MA] Wiper parking abnormality 640
Failure code [DY2CKB] Washer drive S/C .642
Failure code [DY2DKB] Wiper drive (for) S/C 644
Failure code [DY2EKB] Wiper drive (rev) S/C 646
40 Troubleshooting .607
Troubleshooting by failure code, Part 4 607
40 Troubleshooting .649
Troubleshooting of electrical system (E-mode) 649
Before carrying out troubleshooting of electrical system .651
Information contained in troubleshooting table .653
E-1 Engine does not start 654
E-2 Auto-decelerator does not operate 657
E-3 Automatic warming-up system does not operate .659
E-4 Preheater does not operate .660
E-5 All work equipment, swing, and travel mechanism do not move 662
E-6 Power maximizing function does not operate .664
E-7 Machine monitor does not display at all 666
E-8 Machine monitor does not display some items 668
E-9 Contents of display by machine monitor are different from applicable machine .668
E-10 Fuel level monitor was lighted in red while engine running 669
E-11 Engine coolant temperature gauge does not indicate normally .670
E-12 Hydraulic oil temperature gauge does not indicate normally 672
E-13 Fuel level gauge does not indicate normally .674
E-14 Swing lock monitor does not indicate normally .676
E-15 When monitor switch is operated, monitor displays nothing .678
E-16 Windshield wiper and window washer do not operate .680
E-17 Monitoring function fails to display “boom raise” normally 684
E-18 Monitoring function fails to display “boom lower” normally 686
E-19 Monitoring function fails to display “arm IN” normally 688
E-20 Monitoring function fails to display “arm OUT” normally .690
E-21 Monitoring function fails to display “bucket CURL” normally .692
E-22 Monitoring function fails to display “bucket DUMP” normally .694
E-23 Monitoring function fails to display “swing left” normally 696
E-24 Monitoring function fails to display “swing right” normally .698
E-25 Monitoring function fails to display “travel” normally 700
E-26 Monitoring function fails to display “travel differential pressure” normally 702
E-27 Monitoring function fails to display “service” normally .704
E-28 KOMTRAX system does not operate normally 706
E-29 Air conditioner does not operate 708
E-30 Travel alarm does not sound or does not stop sounding .710
E-31 Horn does not sound .712
E-32 Attachment circuit does not change 714
Information contained in troubleshooting table .719
System chart for hydraulic and mechanical systems 720
H-1 Speed or power of all work equipment, swing, and travel are low 722
H-2 Engine speed sharply drops or engine stalls 723
H-3 No work equipment, travel and swing move .724
H-4 Abnormal noise is heard from around hydraulic pump .724
H-5 Auto-decelerator does not work .725
H-6 Fine control mode does not function 725
H-7 Speed or power of boom is low 726
H-8 Speed or power of arm is low .727
H-9 Speed or power of bucket is low 728
H-10 Work equipment does not move in its single operation 729
H-11 Hydraulic drift of work equipment is large 730
H-12 Time lag of work equipment is large .731
H-13 One-touch power max system does not operate .731
H-14 Work equipment loaded more is slower during compound operation 732
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE .732
H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel 733
H-17 Machine deviates during travel 734
H-18 Travel speed is low .735
H-19 Machine cannot be steered easily or steering power is low .736
H-20 Travel speed does not change or it is kept low or high 737
H-21 Track does not move (Only either side) 737
H-22 Machine does not swing 738
H-23 Swing acceleration or swing speed is low 739
H-24 Excessive overrun when stopping swing .740
H-25 When upper structure stops swinging, it makes large shock .741
H-26 When upper structure stops swinging, it makes loud sound 741
H-27 Hydraulic drift of swing is large .742
H-28 Attachment circuit does not change 743
H-29 Flow rate in attachment circuit cannot be adjusted 743
Quick coupler 744
40 Troubleshooting .717
Troubleshooting of hydraulic and mechanical system (H-mode) 717
40 Troubleshooting .747
Troubleshooting of engine (S-mode) .747
Method of using troubleshooting chart 749
S-1 Starting performance is poor .752
S-2 Engine does not start 753
S-3 Engine does not pick up smoothly .756
S-4 Engine stops during operations .757
S-5 Engine does not rotate smoothly 758
S-6 Engine lack output (or lacks power) 759
S-7 Exhaust smoke is black (incomplete combustion) .760
S-8 Oil consumption is excessive (or exhaust smoke is blue) 761
S-9 Oil becomes contaminated quickly .762
S-10 Fuel consumption is excessive .763
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .764
S-12 Oil pressure drops 765
S-13 Oil level rises (Entry of coolant/fuel) .766
S-14 Coolant temperature becomes too high (overheating) 767
S-15 Abnormal noise is made 768
S-16 Vibration is excessive 769
50 Disassembly and assembly 771
General information on disassembly and assembly 771
How to read this manual 772
List of adhesives 774
Special tool list 777
Sketches of special tools 780
Removal and installation of fuel supply pump assembly 784
Removal and installation of fuel injector assembly .787
Removal and installation of front oil seal .792
Removal and installation of rear oil seal 794
Removal and installation of cylinder head assembly .797
Removal and installation of radiator assembly 807
Removal and installation of aftercooler assembly .809
Removal and installation of work equipment oil cooler assembly .811
Removal and installation of engine and hydraulic pump assembly .813
50 Disassembly and assembly 783
Engine and cooling system 783
Removal and installation of engine hood assembly .820
Removal and installation of fuel tank assembly .822
Removal and installation of travel motor and final drive assembly 826
Disassembly and assembly of final drive assembly .827
Removal and installation of swing motor and swing machinery assembly .834
Disassembly and assembly of swing motor and swing machinery assembly .836
Removal and installation of swing circle assembly 844
50 Disassembly and assembly 825
Power train 825
Disassembly and assembly of carrier roller .848
Disassembly and assembly of track roller assembly 851
Disassembly and assembly of idler assembly .853
Disassembly and assembly of recoil spring 856
Expansion and installation of track shoe assembly 858
Removal and installation of sprocket .860
Removal and installation of revolving frame assembly .861
Removal and installation of counterweight 863
50 Disassembly and assembly 847
Undercarriage and frame 847
Removal and installation of centre swivel joint assembly .866
Disassembly and assembly of centre swivel joint assembly .868
Removal and installation of hydraulic tank assembly 869
Removal and installation of hydraulic pump assembly 872
Removal and installation of control valve assembly .875
Disassembly and assembly of control valve assembly .879
Removal and installation of hydraulic pump input shaft oil seal 881
Disassembly and assembly of work equipment PPC valve assembly 882
Disassembly and assembly of travel PPC valve assembly 883
Disassembly and assembly of hydraulic cylinder assembly 884
Disassembly and Assembly of Quick Coupler Valve 890
50 Disassembly and assembly 865
Hydraulic system .865
Removal and installation of work equipment assembly 894
50 Disassembly and assembly 893
Work equipment Body 893
Removal and installation of operator’s cab .900
Removal and installation of operator’s cab glass (Stuck glass) .903
Removal and installation of front window assembly 914
Removal and installation of floor frame assembly .920
50 Disassembly and assembly 899
Cab and its attachments 899
Removal and installation of air conditioner compressor assembly 926
Removal and installation of air conditioner condenser 927
Removal and installation of air conditioner unit assembly 928
Removal and installation of machine monitor assembly .930
Removal and installation of governor, pump controller assembly .931
Removal and installation of engine controller assembly .932
Removal and installation of KOMTRAX assembly .933
50 Disassembly and assembly 925
Electrical system 925
90 Diagrams and drawings .935
Hydraulic circuit diagram 935
Hydraulic circuit diagram 1/2 937
Hydraulic circuit diagram 2/2 939
90 Diagrams and drawings .943
Electrical circuit diagram .943
Electrical circuit diagram (1/5) .945
Electrical circuit diagram (2/5) .947
Electrical circuit diagram (3/5) .949
Electrical circuit diagram (4/5) .951
Electrical circuit diagram (5/5) .953
Connector arrangement diagram 955

DESCRIPTION:

Komatsu PC160LC-7E0,PC180LC-7E0,PC180NLC-7E0 Hydraulic Excavator Shop Manual UEN01892-04 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC160LC-7E0 K45001    and up
  PC180LC-7E0 K45001    and up
  PC180NLC-7E0 K45001 and up

G.B 26/12/24