Komatsu Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,563 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN01892-05 - Hydraulic Excavator PC160LC-7E0 Shop Manual.pdf
UEN01892-04 - Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Shop Manual.pdf
TEN00175-06 - Hydraulic Excavator GALEO PC160LC-7E0 Operation & Maintenance Manual.pdf
UEAM006800 - Hydraulic Excavator PC160LC-7E0 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
00 Index and foreword...0
Index...2
Composition of shop manual...3
Table of contents...5
Foreword and general information...14
Safety notice...15
How to read the shop manual...20
Explanation of terms for maintenance standard...22
Handling of electric equipment and hydraulic component...24
Handling of connectors newly used for engines...33
How to read electric wire code...36
Precautions when carrying out operation...39
Method of disassembling and connecting push-pull type coupler...42
Standard tightening torque table...45
Conversion table...49
01 Specification...0
Specification and technical data...56
Specification dimension drawings...57
Specifications...59
Weight table...61
Table of fuel, coolant and lubricants...63
10 Structure, function and maintenance standard...0
Engine and cooling system...66
Engine related parts...67
Radiator, oil cooler, aftercooler and fuel cooler...68
Power train system...70
Power train...71
Swing circle...72
Swing machinery...73
Final drive...74
Sprocket...76
Undercarriage and frame...79
Track frame, recoil spring...80
Idler...82
Carrier roller...84
Track roller...85
Track shoe...86
Hydraulic system, Part 1...91
Hydraulic equipment layout drawing...92
Hydraulic tank...94
Hydraulic pump...95
Hydraulic system, Part 2...121
Control valve...122
CLSS...135
Functions and operation by valve...138
Hydraulic system, Part 3...173
Valve control...174
PPC valve...175
Solenoid valve...191
Accumulator...193
Return oil filter...194
Center swivel joint...195
Travel motor...196
Swing motor...206
Attachment circuit selector valve...207
Hydraulic cylinder...210
Work equipment...213
Work equipment...214
Dimensions of components...216
Cab and its attachments...221
Air conditioner piping...222
Electrical system...224
Engine control...225
Electronic control system...234
Monitor system...260
Sensor...278
KOMTRAX terminal system...281
20 Standard value table...0
Standard service value table...286
Standard value table for engine...287
Standard value table for chassis related parts...288
30 Testing and adjusting...0
Testing and adjusting, Part 1...299
Tools for testing, adjusting, and troubleshooting...300
Measuring engine speed...303
Measuring intake air pressure (boost pressure)...304
Checking exhaust gas color...305
Adjusting valve clearance...306
Measuring compression pressure...308
Measurement of blow-by pressure...310
Measuring engine oil pressure...311
Handling fuel system parts...312
Releasing residual pressure from fuel system...312
Measuring fuel pressure...313
Measuring fuel discharge, return and leakage...315
Bleeding air from fuel circuit...319
Checking fuel circuit for leakage...321
Checking and adjusting air conditioner compressor belt tension...322
Replacing the fan belt...323
Testing and adjusting, Part 2...325
Testing of clearance in swing circle bearings...326
Checking and adjusting track shoe tension...327
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits...328
Inspection and adjustment of control circuit oil pressure...331
Inspection and adjustment of pump PC control circuit oil pressure...332
Inspection and adjustment of pump LS control circuit oil pressure...335
Measurement of solenoid valve output pressure...339
Testing of PPC valve output pressure...342
Adjustment of work equipment and swing PPC valve...343
Inspection of locations of hydraulic drift of work equipment...344
Testing and adjusting travel deviation...346
Release of residual pressure from hydraulic circuit...348
Measurement of oil leakage...349
Bleeding air from each part...351
Inspection procedures for diode...353
Adjusting mirrors...354
Testing and adjusting, Part 3...357
Special functions of machine monitor...358
Handling voltage circuit of engine controller...386
Procedure for turning on KOMTRAX terminal...387
Indication by KOMTRAX terminal lamps...390
Preparation work for troubleshooting of electrical system...393
Pm-clinic service...395
40 Troubleshooting...0
Failure code table and fuse locations...401
Failure code table...402
Fuse locations...405
General information on troubleshooting...408
Points to remember when troubleshooting...409
Sequence of events in troubleshooting...410
Checks before troubleshooting...411
Classification and troubleshooting steps...412
Information in troubleshooting table...413
Possible problems and troubleshooting No...415
Connection table for connector pin numbers...418
T- branch box and T- branch adapter table...454
Troubleshooting by failure code, Part 1...458
Failure code [AA10NX] Air cleaner clogging...460
Failure code [AB00KE] Charge voltage low...461
Failure code [B@BAZG] Eng. oil press. low...463
Failure code [B@BAZK] Eng. oil level low...464
Failure code [B@BCNS] Eng. coolant overheat...465
Failure code [B@BCZK] Eng. coolant level low...467
Failure code [B@HANS] Hydr oil overheat...468
Failure code [CA111] EMC critical internal failure...468
Failure code [CA115] Eng Ne and bkup speed sens error...469
Failure code [CA122] Chg air press sensor high error...470
Failure code [CA123] Chg air press sensor low error...472
Failure code [CA131] Throttle sensor high error...474
Failure code [CA132] Throttle sensor low error...476
Failure code [CA144] Coolant temp sens high error...478
Failure code [CA145] Coolant temp sens low error...480
Failure code [CA153] Chg air temp sensor high error...482
Failure code [CA154] Chg air temp sensor low error...484
Failure code [CA155] Chg air temp high speed derate...486
Failure code [CA187] Sens supply 2 volt low error...487
Failure code [CA221] Ambient press sens high error...489
Failure code [CA222] Ambient press sens low error...491
Failure code [CA227] Sens supply 2 volt high error...493
Failure code [CA234] Eng. overspeed...494
Failure code [CA238] Ne speed sens supply volt error...495
Failure code [CA271] IMV/PCV1 short error...496
Failure code [CA272] IMV/PCV1 open error...497
Failure code [CA322] Inj #1 open/short error...498
Failure code [CA324] Inj #3 open/short error...500
Troubleshooting by failure code, Part 2...503
Failure code [CA331] Inj #2 open/short error...506
Failure code [CA332] Inj #4 open/short error...508
Failure code [CA342] Calibration code incompatibility...510
Failure code [CA351] Injectors drive circuit error...512
Failure code [CA352] Sens supply 1 volt low error...514
Failure code [CA386] Sens supply 1 volt high error...516
Failure code [CA428] Water in fuel sensor high error...518
Failure code [CA429] Water in fuel sensor low error...520
Failure code [CA435] Eng oil press sw error...522
Failure code [CA441] Engine controller battery voltage low error...524
Failure code [CA442] Engine controller battery voltage high error...526
Failure code [CA449] Rail press very high error...528
Failure code [CA451] Rail press sensor high error...530
Failure code [CA452] Rail press sensor low error...532
Failure code [CA488] Chg air temp high torque derate...534
Failure code [CA553] Rail press high error...534
Failure code [CA559] Rail press low error...535
Failure code [CA689] Eng Ne speed sensor error...536
Failure code [CA731] Eng Bkup speed sens phase error...538
Failure code [CA757] All continuous data lost error...540
Failure code [CA778] Eng Bkup speed sensor error...542
Failure code [CA1633] KOMNET Datalink timeout error...544
Failure code [CA2185] Throt sens sup volt high error...546
Failure code [CA2186] Throt sens sup volt low error...547
Failure code [CA2249] Rail press very low error...548
Failure code [CA2311] IMV solenoid error...550
Failure code [CA2555] Grid htr relay volt high error...552
Failure code [CA2556] Grid htr relay volt low error...554
Troubleshooting by failure code, Part 3...557
Failure code [D110KB] Battery relay drive S/C...558
Failure code [D196KA] Service return relay disc...560
Failure code [D196KB] Service return relay S/C...562
Failure code [DA22KK] Pump solenoid power low error...564
Failure code [DA25KP] Press. sensor power abnormality...566
Failure code [DA2RMC] Pump comm. abnormality...568
Failure code [DA2SKQ] Model selection abnormality...570
Failure code [DAFRMC] Monitor comm. abnormality...572
Failure code [DGH2KB] Hydr oil sensor short...574
Failure code [DHPAMA] F pump press sensor abnormality...575
Failure code [DHPBMA] R pump press sensor abnormality...577
Failure code [DHSAMA] Sw RH PPC press sen. abnormality...579
Failure code [DHSBMA] Sw LH PPC press sen. abnormality...581
Troubleshooting by failure code, Part 4...584
Failure code [DW43KA] Travel speed sol. disc...586
Failure code [DW43KB] Travel speed sol. S/C...588
Failure code [DW45KA] Swing brake sol. disc...590
Failure code [DW45KB] Swing brake sol. S/C...593
Failure code [DW91KA] Travel junction sol. disc...595
Failure code [DW91KB] Travel junction sol. S/C...597
Failure code [DWJ0KA] Merge-divider sol. disc...599
Failure code [DWJ0KB] Merge-divider sol. S/C...601
Failure code [DWK0KA] 2-stage relief sol. disc...603
Failure code [DWK0KB] 2-stage relief sol. S/C...605
Failure code [DXA0KA] PC-EPC sol. disc...607
Failure code [DXA0KB] PC-EPC sol. S/C...609
Failure code [DXE4KA] Service current EPC disc...611
Failure code [DXE4KB] Service current EPC S/C...612
Failure code [DY20KA] Wiper working abnormality...613
