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KOMATSU PC160LC-7K PC180LC-7K SERVICE REPAIR MANUAL (SN:K40001 & UP) KOMATSU PC160LC-7K – PDF DOWNLOAD
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- KOMATSU PC160LC-7K PC180LC-7K SERVICE REPAIR MANUAL
- SERIAL NUMBER:K40001 & UP
- PUBLICATION NUMBER:UEBM002200
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Description
KOMATSU PC160LC-7K PC180LC-7K SERVICE REPAIR MANUAL (SN:K40001 & UP) KOMATSU PC160LC-7K
KOMATSU PC160LC-7K PC180LC-7K SERVICE REPAIR MANUAL (SN:K40001 & UP) KOMATSU PC160LC-7K – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC160LC-7K PC180LC-7K SERVICE REPAIR MANUAL (SN:K40001 & UP) KOMATSU PC160LC-7K
- 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
TABLE OF CONTENTS:
KOMATSU PC160LC-7K PC180LC-7K SERVICE REPAIR MANUAL (SN:K40001 & UP) KOMATSU PC160LC-7K
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 This page left intentionally blank.......................................................................... 16 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 This page left intentionally blank......................................................................668 electrical circuit diagram (2/4)............................................................................669 This page left intentionally blank......................................................................670 electrical circuit diagram (3/4)............................................................................671 pc160LC-7K, pc180LC-7K..................................................................................671 This page left intentionally blank......................................................................672 electrical circuit diagram (4/4)............................................................................673 pc160LC-7K, pc180LC-7K..................................................................................673 This page left intentionally blank......................................................................674 electrical circuit diagram for air conditioner..............................................................675 This page left intentionally blank......................................................................676
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
