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KOMATSU PW180-7K SHOP MANUAL UEBM002701 – PDF DOWNLOAD
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Description
KOMATSU PW180-7K SHOP MANUAL UEBM002701 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PW180-7K SHOP MANUAL UEBM002701 – PDF DOWNLOAD
Language : English
Pages : 954
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PW180-7K SHOP MANUAL UEBM002701 – PDF DOWNLOAD
UEBM002701.............................................................................................................................. 1 SAFETY.............................................................................................................................. 3 GENERAL............................................................................................................................. 11 HOW TO READ THE SHOP MANUAL......................................................................................................... 12 HOISTING INSTRUCTIONS............................................................................................................... 13 PUSH-PULL TYPE COUPLERS............................................................................................................. 14 COATING MATERIALS................................................................................................................... 16 STANDARD TIGHTENING TORQUE.......................................................................................................... 18 ELECTRIC WIRE CODE.................................................................................................................. 21 CONVERSION TABLES................................................................................................................... 22 UNITS............................................................................................................................... 28 01 GENERAL.......................................................................................................................... 29 SPECIFICATION DIMENSION DRAWINGS................................................................................................ 30 WORKING RANGES.................................................................................................................. 34 SPECIFICATIONS.................................................................................................................. 36 WEIGHT TABLE.................................................................................................................... 38 FUEL, COOLANT AND LUBRICANTS.................................................................................................... 40 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD..................................................................................... 41 ENGINE RELATED PARTS............................................................................................................ 42 RADIATOR . OIL COOLER . CHARGE AIR COOLER....................................................................................... 43 POWER TRAIN..................................................................................................................... 44 SWING CIRCLE.................................................................................................................... 46 SWING MACHINERY & MOTOR......................................................................................................... 48 SWING MOTOR..................................................................................................................... 52 UNDERCARRIAGE................................................................................................................... 58 TRANSMISSION.................................................................................................................... 60 TRAVEL MOTOR.................................................................................................................... 64 CLUTCH CONTROL CIRCUIT.......................................................................................................... 68 AXLE............................................................................................................................ 70 SUSPENSION LOCK CYLINDER........................................................................................................ 74 BRAKING SYSTEM.................................................................................................................. 76 BRAKE/STEER PUMP................................................................................................................ 78 PRIORITY VALVE.................................................................................................................. 79 POWER BRAKE VALVE............................................................................................................... 80 ACCUMULATOR FOR BRAKE VALVE..................................................................................................... 82 STEERING SYSTEM................................................................................................................. 83 STEERING COLUMN................................................................................................................. 84 ORBITROL VALVE.................................................................................................................. 85 HYDRAULIC EQUIPMENT LAYOUT DRAWINGS............................................................................................. 87 HYDRAULIC CIRCUIT DIAGRAM....................................................................................................... 89 HYDRAULIC TANK.................................................................................................................. 90 HYDRAULIC PUMP.................................................................................................................. 92 PILOT PRESSURE CONTROL (PPC) SYSTEM.............................................................................................116 CONTROL VALVE...................................................................................................................118 CLSS............................................................................................................................129 CENTRE SWIVEL JOINT.............................................................................................................151 TRAVEL PPC PEDAL................................................................................................................152 WORK EQUIPMENT . SWING PPC VALVE................................................................................................154 SERVICE PPC VALVE...............................................................................................................158 SOLENOID VALVE BLOCK............................................................................................................161 BOOM SAFETY VALVE...............................................................................................................170 HYDRAULIC CYLINDER..............................................................................................................172 OUTRIGGER CYLINDER..............................................................................................................174 DOZER CYLINDER..................................................................................................................176 WORK EQUIPMENT..................................................................................................................178 AIR CONDITIONER.................................................................................................................184 ELECTRICAL WIRING DIAGRAM.......................................................................................................185 ENGINE CONTROL SYSTEM...........................................................................................................186 ELECTRONIC CONTROL SYSTEM.......................................................................................................192 MACHINE MONITOR SYSTEM..........................................................................................................218 OVERLOAD WARNING DEVICE.........................................................................................................245 SENSOR..........................................................................................................................246 1st ATTACHMENT CIRCUIT HYDRAULIC PERFORMANCE (MAIN VALVE BYPASSED)..............................................................253 TRAVEL SYSTEM...................................................................................................................254 STEERING SYSTEM.................................................................................................................273 SERVICE BRAKE AND SUSPENSION SYSTEM.............................................................................................286 20 TESTING AND ADJUSTING............................................................................................................291 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...................................................................................292 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS..................................................................................293 INSPECTION AND ADJUSTMENT OF ENGINE RPM.........................................................................................308 MEASUREMENT OF EXHAUST GAS COLOUR...............................................................................................310 ADJUSTMENT OF VALVE CLEARANCE...................................................................................................312 MEASUREMENT OF COMPRESSION PRESSURE.............................................................................................314 MEASUREMENT OF BLOW-BY PRESSURE.................................................................................................315 INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING..............................................................................316 EMERGENCY SETTING IF FAILURE OCCURS IN ENGINE CONTROL SYSTEM....................................................................321 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS...............................................................................322 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL...................323 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE.......................................................................326 INSPECTION AND ADJUSTMENT OF PUMP PC (VALVE INLET) CONTROL OIL PRESSURE.........................................................328 INSPECTION AND ADJUSTMENT OF PUMP LS VALVE CONTROL OIL PRESSURE.................................................................331 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE...................................................................................335 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE........................................................................................340 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE................................................................................342 TESTING TRAVEL MOTOR RELIEF PRESSURE............................................................................................343 ADJUSTING TRAVEL MOTOR RELIEF PRESSURE..........................................................................................344 TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT.....................................................................................346 MEASUREMENT OF OIL LEAKAGE......................................................................................................351 AIR BLEEDING OF VARIOUS PARTS...................................................................................................354 INSPECTION PROCEDURES FOR DIODE.................................................................................................357 SPECIAL FUNCTION OF MONITOR PANEL...............................................................................................359 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM..............................................................................387 TROUBLESHOOTING.................................................................................................................389 POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................................390 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................................391 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................392 CHECKS BEFORE TROUBLESHOOTING...............................................................................................401 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING................................................................................402 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...........................................................406 CONNECTOR LOCATIONS.....................................................................................................413 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................433 TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED........................461 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................463 E101 Service Code in Electrical System (Abnormal data in Error History).....................................................466 E132 Service Code in Electrical System (Disconnection of S-NET signal)......................................................468 E201 Service Code in Electrical System (Short-circuiting in Travel Neutral Solenoid)........................................470 E202 Service Code in Electrical System (Short-circuiting of Travel F/R solenoid)............................................472 E205 Service Code in Electrical System (Short-circuiting in 2-Stage Relief Solenoid)........................................474 E206 Service Code in Electrical System (Short-circuiting in Transmission Clutch solenoid)...................................476 E207 Service Code in Electrical System (Short-circuiting in Creep solenoid).................................................478 E208 Service Code in Electrical System (Disconnection in Creep solenoid)....................................................480 E211 Service Code in Electrical System (Disconnection in Travel Neutral solenoid)...........................................482 E212 Service Code in Electrical System (Disconnection of Travel F/R solenoid)...............................................484 E213 Service Code in Electrical System (Disconnection in Swing Parking Brake solenoid)......................................486 E215 Service Code in Electrical System (Disconnection in 2-stage Relief solenoid)...........................................488 E216 Service Code in Electrical System (Disconnection in Transmission Clutch solenoid)......................................490 E217 Service Code in Electrical System (Abnormality in inputting model code) 20/25kph.......................................492 E217 Service Code in Electrical System (Abnormality in inputting model code) 35kph..........................................494 E218 Service Code in Electrical System Disconnection of S-NET signal).......................................................496 E222 Service Code in Electrical System (Short-circuiting in LS-EPC solenoid)................................................498 E223 Service Code in Electrical System (Disconnection in LS-EPC solenoid system)............................................499 E224 Service Code in Electrical System (Abnormality in pump pressure sensor)................................................500 E226 Service Code in Electrical System (Abnormality in Pressure sensor power source)........................................502 E227 Service Code in Electrical System (Abnormality in engine rotation sensor in governor • pump controller system).........504 E232 Service Code in Electrical System (Short-circuiting in PC-EPC solenoid)................................................506 E233 Service Code in Electrical System (Disconnection in PC-EPC solenoid system)............................................508 E236 Service Code in Electrical System (Short circuiting in 2-stage back pressure solenoid).................................510 E237 Service Code in Electrical System (Disconnection in 2-stage Back Pressure solenoid)....................................512 E245 Service Code in Electrical System (Short-circuiting in attachment oil flow rate adjusting EPC).........................514 E246 Service Code in Electrical System (Disconnection in attachment oil flow rate adjusting EPC)............................515 E247 Service Code in Electrical System (Abnormality in travel direction control switch).....................................516 E251 Service Code In Electrical System (Abnormality in overload caution sensor).............................................518 E252 Service Code in Electrical System (Abnormality in travel PPC sensor)...................................................520 E254 Service Code in Electrical System (Disconnection in transmission speed sensor in governor • pump controller system)....522 E256 Service Code in Electrical System (Incorrect non-volatile memory data).................................................524 E257 Service Code in Electrical System (Abnormality in travel PPC switch hydraulics)........................................525 E306 Service Code in Electrical System (Abnormality in governor potentiometer)..............................................526 E308 Service Code in Electrical System (Abnormality in fuel dial)...........................................................528 E315 Service Code in Electrical System (Short-circuiting in battery relay)..................................................530 E316 Service Code in Electrical System (Step-out in governor motor).........................................................532 E317 Service Code in Electrical System (Disconnection in governor motor Phase A and B)......................................534 E318 Service Code in Electrical System (Short-circuiting in governor motor Phase A and Phase B).............................536 A000N1 Failure Code in Mechanical System (Out-of-rate engine rotation at high idling).......................................538 A000N2 Failure Code in Mechanical System (Out-of-rate engine rotation at low idling)........................................538 AA10NX Failure Code in Mechanical System (Air cleaner clogging).............................................................539 AB00KE Failure Code in Mechanical System (Charging voltage abnormally low)..................................................540 B@BAZG Failure Code in Mechanical System (Abnormally lowered engine oil pressure)...........................................542 B@BAZK Failure Code in Mechanical System (Abnormally lowered engine oil level)..............................................543 B@BCNS Failure Code in Mechanical System (Engine cooling water overheating).................................................544 B@BCZK Failure Code in Mechanical System (Abnormally low radiator water level)..............................................545 B@HANS Failure Code in Mechanical System (Hydraulic oil overheating)........................................................546 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...................................................................................547 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................548 E-1 Engine does not start (Engine does not rotate)..........................................................................550 E-2 Engine stops while in operation.........................................................................................553 E-3 Engine speed is irregular, or there is hunting..........................................................................554 E-4 Engine does not stop....................................................................................................556 E-5 Auto-decelerator does not work..........................................................................................558 E-6 Auto engine warm-up device does not work................................................................................560 E-7 Pre heater does not work................................................................................................562 E-8 All work equipment, swing and travel do not move........................................................................564 E-9 One-touch Power Max Switch does not work................................................................................566 E-10 No display in monitor panel at all.....................................................................................567 E-11 Part of display on monitor panel is missing............................................................................568 E-12 Monitor panel displays contents irrelevant to the model................................................................568 E-13 Fuel level monitor red lamp lights up while engine is running..........................................................569 E-14 Engine cooling water temperature gauge does not indicate correctly.....................................................570 E-15 Hydraulic oil temperature gauge does not display correctly.............................................................571 E-16 Fuel gauge does not display correctly..................................................................................572 E-17 Swing lock monitor does not display correctly..........................................................................574 E-18 When the monitor switch is operated, no display appears................................................................576 E-19 Windshield wiper does not work.........................................................................................578 E-21 "Boom/Stabiliser RAISE" is not correctly displayed in monitor function.................................................580 E-22 "Boom/Stabiliser LOWER" is not correctly displayed in monitor function.................................................581 E-23 "Arm DIGGING" is not correctly displayed in monitor function...........................................................582 E-24 "Arm DUMPING" is not correctly displayed in monitor function...........................................................583 E-25 "Bucket DIGGING" is not correctly displayed in monitor function........................................................584 E-26 "Bucket DUMPING" is not correctly displayed in monitor function........................................................585 E-27 "SWING" is not correctly displayed in monitor function.................................................................586 E-28 "TRAVEL" is not correctly displayed in monitor function................................................................588 E-29 "Service" is not correctly displayed in monitor function...............................................................590 E-30 Air Conditioner does not work..........................................................................................592 E-31 Travel reverse alarm does not sound....................................................................................594 TROUBLESHOOTING OF ELECTRICAL SYSTEM (Error checking of items without Monitor codes)............................................597 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................598 Radio Cassette & Telephone Socket...........................................................................................600 PPC Circuit & Brake Light Interlock.........................................................................................602 Undercarriage Attachments - Mode Selection..................................................................................604 Undercarriage Attachments - Front Left Outrigger............................................................................606 Undercarriage Attacments - Front Right Outrigger............................................................................608 Undercariage Attachments - Rear Left Outrigger..............................................................................610 Undercarriage Attachments - Rear Right Outrigger............................................................................612 Heated Seat Does Not Warm Up................................................................................................614 Suspension Lock.............................................................................................................616 Lower Wiper Does Not Work (Optional Fitment)................................................................................618 Work Lights (Operator Cab)..................................................................................................620 Worklights (Boom & Counterweight)...........................................................................................622 Cab and Counterweight Beacon Light..........................................................................................624 Air Seat Compressor (Option - Air Suspension Seat)..........................................................................626 Operator Cab Interior Light.................................................................................................628 Cigar Lighter...............................................................................................................630 Park Brake (Not Activating).................................................................................................632 Park Brake (Displayed Symbol)...............................................................................................634 Clamshell Control - Rotate Right (1st Service)..............................................................................636 Clamshell Control - Rotate Left - Check Work Lever Circuit..................................................................638 Clamshell Control - Rotate Left - Check EPC Circuit.........................................................................640 Horns.......................................................................................................................642 Swing Lock - Normal Operation...............................................................................................644 Swing Lock - Emergency Operation............................................................................................646 Neutral Start (Engine)......................................................................................................648 Neutral Start (Engine) cont’d (1)...........................................................................................649 Neutral Start (Engine) cont’d (2)...........................................................................................650 Emergency Travel Control - Forward..........................................................................................652 Emergency Travel Control - Forward (Continued)..............................................................................653 Emergency Travel Control - Forward (Continued)..............................................................................654 Emergency Travel Control - Neutral..........................................................................................656 Emergency Travel Control - Reverse..........................................................................................658 Emergency Travel Control - Reverse cont’d...................................................................................659 Emergency Travel Control - Reverse cont’d...................................................................................660 Driving Lights - Main Beam..................................................................................................662 Driving Lights - Main Beam Flash............................................................................................664 Driving Lights - Main Beam Dipped...........................................................................................666 Driving Lights - Position Lights............................................................................................668 Driving Lights - Position Lights cont’d (1).................................................................................670 Indicators - Right Hand.....................................................................................................672 Indicators - Left Hand......................................................................................................674 Hazard Warning Lights.......................................................................................................676 Hazard Warning Lights cont’d (A)............................................................................................678 Hazard Warning Lights cont’d (B)............................................................................................680 Brake Lock Proximity Switch.................................................................................................682 Swing Lock Proximity Switch.................................................................................................684 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE).....................................................................687 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS...........................................................................688 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................692 H-1 All work equipment lacks power, or travel and swing speeds are slow.....................................................693 H-2 Engine speed sharply drops or engine stalls.............................................................................694 H-3 No work equipment, travel or swing move.................................................................................695 H-4 Abnormal noise is heard from around hydraulic pump......................................................................695 H-5 Auto-decelerator does not work..........................................................................................696 H-6 Fine control mode does not function.....................................................................................696 H-7 Boom moves slowly or lacks power........................................................................................697 H-8 Arm moves slowly or lacks power.........................................................................................698 H-9 Bucket moves slowly or lacks power......................................................................................699 H-10 Work equipment does not move in its single operation...................................................................699 H-11 Work equipment hydraulic drift is too fast.............................................................................700 H-12 Work equipment has big time lag........................................................................................701 H-13 Other work equipment moves when relieving single circuit...............................................................701 H-14 One-touch power max. switch does not operate...........................................................................702 H-15 In compound operation, work equipment with larger load moves slowly....................................................702 H-16 In swing + boom RAISE operation, boom moves slowly.....................................................................702 H-17 In swing + travel, travel speed drops sharply..........................................................................703 H-18 Travel speed does not switch...........................................................................................704 H-19 Travel speed does not shift, or it is too slow or fast.................................................................705 H-20 Machine does not swing.................................................................................................706 H-21 Swing acceleration is poor, or swing speed is slow.....................................................................707 H-22 Excessive overrun when stopping swing..................................................................................708 H-23 There is big shock when stopping swing.................................................................................709 H-24 There is loud abnormal noise caused when stopping swing................................................................709 H-25 Swing natural drift is too big.........................................................................................710 H-26 Swing speed is faster than specified swing speed.......................................................................710 30 DISASSEMBLY AND ASSEMBLY.........................................................................................................711 HOW TO READ THIS MANUAL.........................................................................................................713 SPECIAL TOOLS...................................................................................................................715 PRECAUTIONS WHEN PERFORMING OPERATION...........................................................................................717 GOVERNOR MOTOR..................................................................................................................719 STARTING MOTOR..................................................................................................................720 FUEL INJECTION PUMP.............................................................................................................721 ENGINE FRONT SEAL...............................................................................................................725 ENGINE REAR SEAL................................................................................................................727 CYLINDER HEAD...................................................................................................................729 COMBINATION COOLER..............................................................................................................735 ENGINE AND HYDRAULIC PUMP ASSEMBLIES............................................................................................738 TRAVEL MOTOR....................................................................................................................744 SWING MOTOR AND SWING MACHINERY ASSEMBLY........................................................................................750 SWING MACHINERY.............................................................................................................752 SWING MOTOR.................................................................................................................760 FRONT AXLE......................................................................................................................770 REAR AXLE AND TRANSMISSION......................................................................................................822 REAR AXLE...................................................................................................................825 TRANSMISSION................................................................................................................851 PROPSHAFT.......................................................................................................................879 WHEEL...........................................................................................................................881 SUSPENSION LOCK CYLINDER........................................................................................................882 OUTRIGGER.......................................................................................................................884 DOZER BLADE.....................................................................................................................886 SWING CIRCLE....................................................................................................................888 REVOLVING FRAME.................................................................................................................889 CENTRE SWIVEL JOINT.............................................................................................................892 HYDRAULIC/FUEL COMBINATION TANK ASSEMBLY........................................................................................897 CONTROL VALVE...................................................................................................................900 LS SEPARATION VALVE.............................................................................................................904 PRESSURE COMPENSATION VALVE ASSEMBLY............................................................................................905 MAIN RELIEF VALVE...............................................................................................................906 LS CONTROL EPC VALVE............................................................................................................907 EPC SOLENOID VALVE..............................................................................................................908 PPC SOLENOID VALVE BLOCK........................................................................................................909 OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT..........................................................................................910 WORK EQUIPMENT PPC VALVE........................................................................................................911 HYDRAULIC CYLINDER..............................................................................................................912 MONOBOOM WORK EQUIPMENT.........................................................................................................918 2 PIECE BOOM WORK EQUIPMENT.....................................................................................................921 AIR CONDITIONER UNIT............................................................................................................924 COUNTERWEIGHT...................................................................................................................928 OPERATOR CAB....................................................................................................................931 MONITOR.........................................................................................................................934 GOVERNOR / PUMP CONTROLLER ASSEMBLY.............................................................................................935 90 OTHER............................................................................................................................937 HYDRAULIC CIRCUIT DIAGRAM (1/3).................................................................................................939 HYDRAULIC CIRCUIT DIAGRAM (2/3).................................................................................................941 HYDRAULIC CIRCUIT DIAGRAM (3/3).................................................................................................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
DESCRIPTION:
KOMATSU PW180-7K SHOP MANUAL UEBM002701 – PDF DOWNLOAD
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.S 28/12/24
