Komatsu Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K 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: 2,533 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
UEBD000601 - Hydraulic Excavator PC160-6K, PC180LC, 180NLC-6K Shop Manual.pdf
EEBM001101 - Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Shop Manual.pdf
EEAM008501 - Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K, PC200EN-6K, PC200EL-6K Operation & Maintenance Manual.pdf
PEPBK21P0301 - Hydraulic Excavator PC180LC-3K, PC180LLC-3K, PC180NLC-3K Parts Book.pdf
UEAM000303 - Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Operation & Maintenance Manual.pdf
UEAM002401 - Hydraulic Excavator PC160LC-7KA Operation & Maintenance Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...1
SAFETY...1
SAFETY NOTICE...6
FOREWARD...8
GENERAL...8
HOW TO READ THE SHOP MANUAL...9
HOISTING INSTRUCTIONS...10
COATING MATERIALS...11
STANDARD TIGHTENING TORQUE...12
ELECTRIC WIRE CODE...14
CONVERSION TABLE...15
01 GENERAL...22
SPECIFICATIONS...23
SPECIFICATION DRAWINGS...25
WEIGHT TABLE...29
FUEL, COOLANT AND LUBRICANTS...33
10 STRUCTURE AND FUNCTION...35
ENGINE RELATED PARTS...36
RADIATOR * OIL COOLER...37
POWER TRAIN...38
FINAL DRIVE...39
SWING CIRCLE...40
SWING MACHINERY...41
TRACK FRAME, RECOIL SPRING...43
TRACK SHOE...44
HYDRAULIC CIRCUIT DIAGRAM...47
FUEL & HYDRAULIC TANK...48
HYDRAULIC PUMP...51
CONTROL VALVE...58
CLSS...64
SWING MOTOR...101
CENTER SWIVEL JOINT...103
TRAVEL MOTOR...104
VALVE CONTROL...112
WORK EQUIPMENT - SWING PPC VALVE...113
TRAVEL PPC PEDAL...117
SAFETY LOCK VALVE...124
PPC ACCUMULATOR...124
PPC SHUTTLE * TRAVEL JUNCTION VALVE...125
EPC * SOLENOID VALVE...132
HYDRAULIC CYLINDER...137
ADDITIONAL FILTER FOR BREAKING...139
OVERLOAD WARNING DEVICE...140
HOSE BURST PROTECTION VALVE (BOOM)...144
WORK EQUIPMENT...147
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE...150
ENGINE CONTROL SYSTEM...151
ELECTRONIC CONTROL SYSTEM...157
MACHINE MONITOR SYSTEM...181
20 TESTING AND ADJUSTING...193
TABLE OF JUDGEMENT STANDARD VALUE...194
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...204
CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...212
ADJUSTING ENGINE SPEED SENSOR...213
TESTING AND ADJUSTING GOVERNOR MOTOR LEVEL STROKE...214
TESTING CLEARANCE OF SWING CIRCLE BEARING...216
TESTING AND ADJUSTING TRACK SHOE TENSION...217
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...218
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...226
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE...228
TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE...231
TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE...233
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...235
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...237
TESTING TRAVEL DEVIATION...238
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...239
MEASURING OIL LEAKAGE...241
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...243
BLEEDING AIR...244
TROUBLESHOOTING...247
POINTS TO REMEMBER WHEN TROUBLSHOOTING...248
SEQUENCE OF EVENTS IN TROUBLSHOOTING...249
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...250
CHECKS BEFORE TROUBLESHOOTING...257
CONNECTOR TYPES AND MOUNTING LOCATIONS...258
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...263
EXPLANATION OF CONTROL MACHANISM FOR ELECTRICAL SYSTEM...276
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...277
METHOD OF USING JUDGEMENT TABLE...285
METHOD OF USING TROUBLESHOOTING CHARTS...287
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...289
SERVICE CODE TABLE...294
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)...295
N-1 [E218] COMMUNICATION ABNORMALITY...296
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)...298
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM...299
ACTION BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...300
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS...304
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE...306
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...308
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...309
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED...310
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED...311
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...312
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...313
E-7 [E316] ABNORMALITY (STEP OUT) IN MOTOR IS DISPLAYED...314
E-8 ENGINE DOES NOT START...316
E-9 ENGINE SPEED IS IRREGULAR...318
a) IDLING SPEED IS IRREGULAR...318
b) THERE IS HUNTING...320
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)...322
E-11 ENGINE DOES NOT STOP...324
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)...326
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...329
METHOD OF USING TROUBLESHOOTING CHARTS...330
S-1 STARTING PERFORMARMANCE IS POOR (STARTING ALWAYS TAKES TIME)...334
S-2 ENGINE DOES NOT START...335
1) ENGINE DOES NOT TURN...335
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEEN INJECTED)...336
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FEUL IS BEING INJECTED)...337
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)...338
S-4 ENGINE STOPS DURING OPERATIONS...339
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...340
S-6 ENGINE LACKS OUTPUT (NO POWER)...341
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...342
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...343
S-9 OIL BECOMES CONTAMINATED QUICKLY...344
S-10 FUEL CONSUMPTION IS EXCESSIVE...345
S-11 OIL LEVEL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...346
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...347
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...348
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...349
S-15 ABNORMAL NOISE IS MADE...350
S-16 VIBRATION IS EXCESSIVE...351
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)...352
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...353
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...354
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...360
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE ...362
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...364
C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED...365
C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED...367
C-6 [E201] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED...369
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...371
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...373
C-10 [E205] SHORT CIRCUIT IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...375
C-11 [E215] DISCONNECTION IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...376
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...377
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED...378
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED...379
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED...381
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS...382
C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...383
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED...384
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...385
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)...387
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...388
F-1 BIT PATTERN 20- (1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...390
F-2 BIT PATTERN 20- (2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP...391
F-3 BIT PATTERN 20- (3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP...392
F-4 BIT PATTERN 20- (4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP...393
F-5 BIT PATTERN 20- (5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP...394
F-6 BIT PATTERN 20- (6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...395
F-7 BIT PATTERN 21- (1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...396
F-8 BIT PATTERN 21- (2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP...397
F-9 BIT PATTERN 21- (3) SWING LOCK SWITCH DOES NOT LIGHT UP...398
F-10 BIT PATTERN 22- (5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP...399
F-11 BIT PATTERN 22- (6) L.H. KNOB SWITCH DOES NOT LIGHT UP...400
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...401
TABLE OF FAILURE MODES AND CAUSES...402
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...406
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...408
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...409
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...409
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)...410
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...410
H-7 BOOM IS SLOW OR LACKS POWER...412
H-8 ARM IS SLOW OR LACKS POWER...414
H-9 BUCKET IS SLOW OR LACKS POWER...416
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)...417
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...417
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...418
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED...418
H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED...419
H-15 LACK OF POWER WHEN PRESSURE RISES...419
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...419
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...420
H-20 TRAVEL DEVIATION...421
H-21 TRAVEL SPEED IS SLOW...422
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER...424
