Komatsu PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Excavator Manual
FILE DETAILS:
Komatsu PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Excavator Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0
Serial Number: K45001 and up
Book Code: UEN01892-04
Language: English
Pages: 958
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Excavator Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Excavator Manual
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
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted