Komatsu PC160LC-7K PC180LC-7K Excavator Shop Manual UEBM002200 PDF

Description

Komatsu PC160LC-7K PC180LC-7K Excavator Shop Manual UEBM002200- PDF DOWNLOAD

FILE DETAILS:

Komatsu PC160LC-7K PC180LC-7K Excavator Shop Manual UEBM002200- PDF DOWNLOAD 

Language : English
Pages : 676
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC160LC-7K PC180LC-7K Excavator Shop Manual UEBM002200- PDF DOWNLOAD 

MACHINE MODEL     SERIAL NUMBER
PC160LC-7K                K40001 AND UP
PC180LC-7K               K40001 AND UP

Sec 00 pdf 0
SAFETY 3
SAFETY NOTICE 3
IMPORTANT SAFETY NOTICE 3
GENERAL PRECAUTIONS 3
PREPARATIONS FOR WORK 3
PRECAUTIONS DURING WORK 4
GENERAL 5
HOW TO READ THE SHOP MANUAL 6
volumes 6
DISTRIBUTION AND UPDATING 6
FILING METHOD 6
REVISED EDITION MARK 6
REVISIONS 6
SYMBOLS 6
HOISTING INSTRUCTIONS 7
HOISTING 7
WIRE ROPES 7
PUSH-PULL TYPE COUPLERS 8
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 12
TIGHTENING TORQUE OF HOSE NUTS 13
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 13
TIGHTENING TORQUE FOR FLARED NUTS 13
Tightening torque for 102 engine series (bolts and nuts) 14
Tightening torque for 102 engine series (eye joints) 14
Tightening torque for 102 engine series (tapered screws) 14
ELECTRIC WIRE CODE 15
CLASSIFICATION BY THICKNESS 15
CLASSIFICATION BY COLOR AND CODE 15
CONVERSION TABLES 16
METHOD OF USING THE CONVERSION TABLE 16
UNITS 22
01(01-08) pdf 0
01 GENERAL 23
SPECIFICATION DIMENSION DRAWINGS 24
SPECIFICATIONS 26
WEIGHT TABLE 28
FUEL, COOLANT, AND LUBRICANTS 30
20-1– pdf 0
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 222
20 TESTING AND ADJUSTING 221
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 223
20-101– pdf 0
TOOLS for testing, adjusting and troubleshooting 234
INSPECTION AND ADJUSTMENT OF ENGINE RPM 236
MEASUREMENT OF EXHAUST GAS COLOR 238
ADJUSTMENT OF VALVE CLEARANCE 224
MEASUREMENT OF COMPRESSION PRESSURE 241
MEASUREMENT OF BLOW-BY PRESSURE 242
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING 243
MEASUREMENT OF ENGINE OIL PRESSURE 245
ADJUSTMENT OF ENGINE SPEED SENSOR 246
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION 247
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS 248
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION 249
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits 250
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE 253
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE 254
Inspection and adjustment pump LS control circuit oil pressure 257
Measurement of solenoid valve output pressure 260
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE 263
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE 264
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT 265
TESTING AND ADJUSTING TRAVEL DEVIATION 267
Release of residual pressure from hydraulic circuit 269
Measurement of oil leakage 270
Bleeding air from each part 272
INSPECTION PROCEDURES FOR DIODE 274
20-143– pdf 0
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM 300
SPECIAL FUNCTION OF MONITOR PANEL 275
20-201– pdf 0
POINTS TO REMEMBER WHEN TROUBLESHOOTING 308
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 310
CHECKS BEFORE TROUBLESHOOTING 318
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING 319
Classification of troubleshooting 319
Steps for troubleshooting 319
Failure-looking Phenomenon and Troubleshooting No 320
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM 324
Connector table 324
CONNECTOR LOCATION STEREOGRAM 256
Monitor Panel System Circuit Diagram (M Circuit) 336
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controlle 338
SEQUENCE OF EVENTS IN TROUBLESHOOTING 309
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller 340
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 342
T-adapter – boxes and T-adapter table 364
20-301– pdf 0
Before troubleshooting for displayed code 370
Error codes and failure codes and possible causes of them 310
Connection table of fuse box 238
Problems which occur when controller power supply of governor pump controller is defective 373
Problems which occur when solenoid power supply of governor pump controller is defective 374
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 376
Error Code in Electrical System (Abnormal data in error history) 378
Error Code in Electrical System (Short-circuiting in normal rotation system of windshield wiper m 380
Error Code in Electrical System (Short-circuiting in reverse rotation system of windshield wiper 382
Error Code in Electrical System (Short-circuiting in window washer drive system) 384
Error Code in Electrical System (Abnormal operation of windshield wiper) 386
Error Code in Electrical System 388
(Abnormality operation of retracting windshield wiper) 388
Error Code in Electrical System (Short-circuiting in travel junction solenoid) 390
Error Code in Electrical System (Short-circuiting in swing holding brake solenoid) 392
Error Code in Electrical System (Short-circuiting in merge/divide solenoid) 394
Error Code in Electrical System (Short-circuiting in 2-stage relief solenoid) 396
Error Code in Electrical System (Short-circuiting in travel speed shifting solenoid) 398
Error Code in Electrical System (Disconnection in travel junction solenoid) 400
Error Code in Electrical System (Disconnection in swing holding brake solenoid) 402
Error Code in Electrical System (Disconnection of merge/divide solenoid) 404
Error Code in Electrical System (Disconnection in 2-stage relief solenoid) 406
Error Code in Electrical System (Disconnection in travel speed shifting solenoid) 408
Error Code in Electrical System (Abnormality in inputting model code) 410
Error Code in Electrical System Disconnection of S-NET signal) 412
Error Code in Electrical System (Abnormality in F pump pressure sensor) 414
Error Code in Electrical System (Abnormality in R pump pressure sensor) 416
20-351– pdf 0
Failure Code in Mechanical System (Abnormally lowered radiator water level) 455
Failure Code in Mechanical System (Hydraulic oil overheating) 456
Error Code in Electrical System (Abnormality in pressure sensor power source) 418
Error Code in Electrical System (Abnormality in engine rotation sensor) 420
Error Code in Electrical System (Short-circuiting in attachment return switching relay) 422
Error Code in Electrical System (Short-circuiting in PC-EPC solenoid) 424
Error Code in Electrical System (Disconnection in PC-EPC solenoid) 426
Error Code in Electrical System (Disconnection in attachment return switching relay) 428
Error Code in Electrical Equipment (Short-circuiting in attachment oil flow rate adjusting EPC so 430
Error Code in Electrical System (Disconnection in attachment oil flow rate adjusting EPC solenoid) 431
Error Code in Electrical System (Abnormality in governor potentiometer) 432
Error Code in Electrical System (Abnormality in fuel dial) 434
Error Code in Electrical System (Short-circuiting in cold starting solenoid relay) 436
Error Code in Electrical System (Disconnection in cold starting solenoid relay) 438
Error Code in Electrical System (Short-circuiting in battery relay) 440
Error Code in Electrical System (Step-out in governor motor) 442
Error Code in Electrical System (Disconnection in governor motor Phase A and B) 443
Error Code in Electrical System (Short-circuiting in governor motor Phase A and Phase B) 446
Failure Code in Mechanical System (Out-of-rate engine rotation at high idling) 448
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling) 448
Failure Code in Mechanical System (Air cleaner clogging) 449
Failure Code in Mechanical System (Abnormally lowered charging voltage) 450
Failure Code in Mechanical System (Abnormally lowered engine oil pressure) 452
Failure Code in Mechanical System (Abnormally lowered engine oil level) 453
Failure Code in Mechanical System (Engine cooling water overheating) 454
20-401– pdf 0
Before conducting E-mode troubleshooting 238
Connection table of fuse box 418
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 459
E-2 Engine stops while in operation 465
E-3 Engine rotates unstably or hunting 434
E-4 Engine does not stop 468
E-1 Engine does not start 460
E-5 Auto-decelerator does not work 470
E-6 Auto engine warm-up device does not work 471
E-7 Preheater does not operate 472
E-8 All work equipment, swing and travel do not move 474
E-9 One-touch power max switch does not work 476
E-11 No display in monitor panel at all 478
E-12 Monitor panel does not display partially 479
E-13 Contents of monitor panel are different from mounted model 453
E-14 Fuel level monitor lights up in red while engine is running 480
E-15 Engine cooling water temperature gauge does not indicate correctly 455
E-16 Hydraulic oil temperature gauge does not display correctly 456
E-17 Fuel gauge does not display correctly 483
E-18 Swing lock monitor does not display correctly 484
E-19 When monitor switch is operated, nothing is displayed 486
E-20 Windshield wiper and window washer does not work 488
E-21 Alarming buzzer cannot be cancelled 492
E-22 “Boom RAISE” is not correctly displayed in monitor function 493
E-23 “Boom LOWER” is not correctly displayed in monitor function 494
E-24 “Arm IN” is not correctly displayed in monitor function 495
E-25 “Arm OUT” is not correctly displayed in monitor function 496
E-26 “Bucket CURL” is not correctly displayed in monitor function 497
E-27 “Bucket DUMP” is not correctly displayed in monitor function 498
E-28 “SWING” is not correctly displayed in monitor function 499
E-29 “TRAVEL” is not correctly displayed in monitor function 502
E-30 “Travel differential pressure” is not correctly displayed in monitor function 504
E-31 “Service” is not correctly displayed in monitor function 506
E-32 Air Conditioner does not work 508
E-33 Travel alarm does not sound or does not stop sounding 510
20-501– pdf 0
H-1 Speed or power of all work equipment, swing, and travel are low 518
H-2 Engine speed sharply drops or engine stalls 519
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 515
H-3 No work equipment, travel and swing move 520
H-4 Abnormal noise is heard from around hydraulic pump 520
H-5 Auto-decelerator does not work 521
H-6 Fine control mode does not function 521
H-7 Speed or power of boom is low 522
H-8 Speed or power of arm is low 523
H-9 Speed or power of bucket is low 524
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 516
H-10 Work equipment does not move in its single operation 525
H-11 Hydraulic drift of work equipment is large 526
H-12 Time lag of work equipment is large 527
H-13 One-touch power max system does not operate 527
H-14 Work equipment loaded more is slower during compound operation 528
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE 528
H-16 Travel speed lowers largely during compound operation of work equipment/ swing + travel 529
H-17 Machine deviates during travel 530
H-18 Travel speed is low 531
H-19 Machine cannot be steered easily or steering power is low 532
H-20 Travel speed does not change or it is kept low or high 533
H-21 Track does not move (only either side) 533
H-22 Machine does not swing 534
H-23 Swing acceleration or swing speed is low 535
H-24 Excessive overrun when stopping swing 536
H-25 When upper structure stops swinging, it makes large shock 537
H-26 When upper structure stops swinging, it makes large sound 537
H-27 Hydraulic drift of swing is large 538
H-29 Flow rate in attachment circuit cannot be adjusted 539
30(1-)complete pdf 0
Removal and installation of fuel injection pump assembly 552
30 DISASSEMBLY AND ASSEMBLY 541
SPECIAL TOOL LIST 289
how to read this manual 543
PRECAUTIONS WHEN performING OPERATION 545
Removal and installation of starting motor 551
Removal and installation of engine front seal 556
Removal and installation of engine rear seal 558
Removal and installation of cylinder head 560
Removal and installation of radiator assembly 566
Removal and installation of aftercooler 567
Removal and installation of hydraUlic oil cooler assembly 568
Removal and installation of engine and hydraulic pump assembly 569
Expansion and 574
Removal and installation of sprocket 576
Disassembly and 578
disassembly and 590
Disassembly and 591
Removal and installation of swing motor and swing machinery assembly 592
Disassembly and 593
removal and installation of final drive assembly 366
disassembly and 585
disassembly and 588
sketches of special tools 361
Disassembly and 601
Removal and installation of center swivel joint assembly 609
disassembly and 611
Removal and installation of swing circle assembly 617
Removal and installation of hydraulic tank 494
Removal and installation of control valve assembly 621
Disassembly and assembly of control valve 625
Removal and installation of hydraulic pump assembly 627
Removal and installation of hydraulic pump input shaft oil seal 513
Disassembly and assembly of work equipment PPC valve assembly 630
Disassembly and assembly of travel PPC valve assembly 631
Disassembly and assembly of hydraulic cylinder assembly 632
Removal and installation of counterweight 638
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 639
Removal and installation of operator’s cab 642
Removal AND installation of operator’s cab glass (Stuck glass) 645
Removal and installation of front window assembly 656
PC160-7_Sec90 pdf 0
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PC160-7_Sec90_Body pdf 0
HYDRAULIC diagram (1/1) 665
pc160Lc-7K, pc180lc-7K 665
This page left intentionally blank 666
electrical circuit diagram (1/4) 667
pc160LC-7K, pc180LC-7K 667
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electrical circuit diagram (2/4) 669
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electrical circuit diagram (3/4) 671
pc160LC-7K, pc180LC-7K 671
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electrical circuit diagram (4/4) 673
pc160LC-7K, pc180LC-7K 673
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electrical circuit diagram for air conditioner 675
This page left intentionally blank 676

DESCRIPTION:

Komatsu PC160LC-7K PC180LC-7K Excavator Shop Manual UEBM002200- PDF DOWNLOAD 

MACHINE MODEL     SERIAL NUMBER
PC160LC-7K                K40001 AND UP
PC180LC-7K               K40001 AND UP

FOREWORD 
GENERAL

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
  understanding of the product and by showing him the correct way to perform repairs and make judgements.
  Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further
  divided into each main group of components.

GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel,
coolant and lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be
made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are
also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

S.V 24/12/24