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, and 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.
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
Total Pages: 2,533 pages
File Format: PDF
Language: English
EEAM008501 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K, PC200EN-6K, PC200EL-6K Operation & Maintenance Manual…2
EEBM001101 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Shop Manual…268
PEPBK21P0301 – Hydraulic Excavator PC180LC-3K, PC180LLC-3K, PC180NLC-3K Parts Book…937
UEAM000303 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Operation & Maintenance Manual…1289
FOREWORD…1291
SAFETY INFORMATION…1292
SAFETY MESSAGES…1292
NOISE…1293
VIBRATION…1294
INTRODUCTION…1295
INTENDED USE…1295
FEATURES…1295
BREAKING IN YOUR NEW MACHINE…1296
LOCATION OF PLATES, TABLES TO ENTER SERIAL NO. AND DISTRIBUTOR…1297
MACHINE SERIAL NO. PLATE POSITION…1297
ENGINE SERIAL NO. PLATE POSITION…1297
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1297
MACHINE SERIAL PLATE…1298
SAFETY…1303
GENERAL PRECAUTIONS…1304
PRECAUTIONS DURING OPERATION…1312
BEFORE STARTING ENGINE…1312
OPERATING MACHINE…1314
TRANSPORTATION…1321
BATTERY…1322
TOWING…1323
BUCKET WITH HOOK…1324
GENERAL PRECAUTIONS…1324
PRECAUTIONS FOR LIFTING OPERATION…1325
PRECAUTIONS FOR MAINTENANCE…1327
BEFORE CARRYING OUT MAINTENANCE…1327
DURING MAINTENANCE…1330
POSITION FOR ATTACHING SAFETY LABELS…1335
POSITION FOR ATTACHING SAFETY LABELS…1335
OPERATION…1341
GENERAL VIEW…1342
GENERAL VIEW OF MACHINE…1342
GENERAL VIEW OF CONTROLS AND GAUGES…1343
EXPLANATION OF COMPONENTS…1345
MACHINE MONITOR…1345
A: BASIC CHECK ITEMS…1347
B: CAUTION ITEMS…1348
C: EMERGENCY STOP ITEMS…1349
D: METER DISPLAY PORTION…1350
METERS…1351
E: SWITCHES…1353
SWITCHES…1356
CONTROL LEVERS, PEDALS…1362
CEILING WINDOW…1366
CLEAR RAIN VISOR…1366
PULL DOWN SUN VISOR…1366
CUP HOLDER…1367
FRONT WINDOW…1368
DOOR LOCK…1370
CAP, COVER WITH LOCK…1370
LUGGAGE TRAY…1371
ASHTRAY…1372
HEATER…1373
VIEW OF CONTROL PANEL…1373
AIR CONDITIONER (option)…1375
GENERAL LOCATIONS ON CONTROL PANEL…1375
AIR CONDITIONER SWITCH…1377
OFF SWITCH…1377
DEFROSTER SELECTOR LEVER…1377
PRECAUTIONS WHEN USING AIR CONDITIONER…1377
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…1378
CAB RADIO (option)…1378
FUSE…1379
Fuse capacity and name of circuit…1379
FUSIBLE LINK…1380
CONTROLLERS…1380
TOOL BOX…1380
REFUELLING PUMP…1381
HANDLING THE ACCUMULATOR…1382
METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR…1382
OPERATION…1383
CHECK BEFORE STARTING ENGINE…1383
WALK-AROUND CHECK…1383
CHECK BEFORE STARTING…1384
CHECK FUEL LEVEL, ADD FUEL…1386
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…1387
CHECK AIR CLEANER FOR CLOGGING…1388
CHECK ELECTRIC WIRINGS…1388
CHECK FUNCTION OF HORN…1388
CHECK FOR WATER IN FUEL SEDIMENTOR…1389
CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER…1389
ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT…1390
USING THE SEAT BELT…1392
OPERATIONS AND CHECKS BEFORE STARTING ENGINE…1393
STARTING ENGINE…1395
NORMAL STARTING…1395
STARTING IN COLD WEATHER…1396
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1397
WHEN NORMAL…1397
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)…1399
MOVING MACHINE OFF…1403
MOVING MACHINE FORWARD…1403
MOVING MACHINE BACKWARD…1404
STEERING MACHINE…1406
STEERING (changing direction)…1406
STOPPING MACHINE…1408
SWINGING…1409
OPERATION OF WORK EQUIPMENT…1410
HANDLING ACTIVE MODE…1411
WORKING MODE SELECTION…1412
PROHIBITIONS FOR OPERATION…1414
PRECAUTIONS FOR OPERATION…1416
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS…1417
HOW TO ESCAPE FROM MUD…1418
WHEN ONE SIDE IS STUCK…1418
WHEN BOTH SIDES ARE STUCK…1418
WORK POSSIBLE USING HYDRAULIC EXCAVATOR…1419
BACKHOE WORK…1419
SHOVEL WORK…1419
DITCHING WORK…1419
LOADING WORK…1420
REPLACEMENT AND INVERSION OF BUCKET…1420
REPLACEMENT…1420
INVERSION…1421
PARKING THE MACHINE…1422
CHECK AFTER FINISHING WORK…1423
STOPPING ENGINE…1423
CHECK AFTER STOPPING ENGINE…1424
LOCKING…1425
OVERLOAD WARNING DEVICE…1425
TRANSPORTATION…1426
LOADING, UNLOADING WORK…1426
PRECAUTIONS FOR LOADING…1428
PRECAUTIONS FOR TRANSPORTATION…1428
METHOD OF LIFTING MACHINE…1429
COLD WEATHER OPERATION…1431
PRECAUTIONS FOR LOW TEMPERATURE…1431
FUEL AND LUBRICANTS…1431
COOLANT…1431
BATTERY…1432
PRECAUTIONS AFTER COMPLETION OF WORK…1432
AFTER COLD WEATHER…1433
LONG-TERM STORAGE…1434
BEFORE STORAGE…1434
DURING STORAGE…1434
AFTER STORAGE…1435
STARTING MACHINE AFTER LONG-TERM STORAGE…1435
TROUBLESHOOTING…1436
PHENOMENA THAT ARE NOT FAILURES…1436
METHOD OF TOWING MACHINE…1436
USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…1437
PRECAUTIONS ON PARTICULAR JOBSITES…1437
IF BATTERY IS DISCHARGED…1438
STARTING ENGINE WITH BOOSTER CABLE…1439
OTHER TROUBLE…1441
ELECTRICAL SYSTEM…1441
CHASSIS…1442
ENGINE…1443
ENGINE (cont’d)…1444
ELECTRONIC CONTROL SYSTEM…1445
MAINTENANCE…1447
GUIDES TO MAINTENANCE…1448
OUTLINES OF SERVICE…1451
OUTLINE OF OIL, FUEL, COOLANT…1451
OIL…1451
FUEL…1452
COOLANT…1452
GREASE…1453
STORING OIL AND FUEL…1453
FILTERS…1453
EXPLANATION OF LUBRICATION CHART DECAL…1454
OUTLINE OF ELECTRICAL SYSTEM…1456
OUTLINE OF HYDRAULIC SYSTEM…1456
WEAR PARTS LIST…1458
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1459
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…1459
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1463
LIST OF NECESSARY TOOLS…1463
TORQUE LIST…1464
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1465
MAINTENANCE SCHEDULE CHART…1468
MAINTENANCE SCHEDULE CHART…1468
MAINTENANCE WHEN USING HYDRAULIC BREAKER…1471
SERVICE PROCEDURE…1472
INITIAL 250 HOURS SERVICE…1472
WHEN REQUIRED…1472
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1472
CLEAN INSIDE OF COOLING SYSTEM…1474
CHECKING COOLANT LEVEL…1476
DRAINING THE SYSTEM…1476
CLEANING THE SYSTEM…1477
FILLING THE SYSTEM…1477
REFILLING AN OVERHEATED SYSTEM…1478
CLEANING THE RADIATOR…1478
CLEANING THE RADIATOR PRE SCREEN…1478
THERMOSTATS…1479
CHECK AND TIGHTEN TRACK SHOE BOLTS…1479
CHECK and adjust TRACK TENSION…1480
CHECK ELECTRICAL INTAKE AIR HEATER…1482
REPLACE BUCKET SIDE CUTTERS…1482
CHECK ALTERNATOR…1482
CHECK START MOTOR…1483
REPLACE BUCKET TEETH…1484
ADJUST BUCKET CLEARANCE…1484
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1485
CHECK, MAINTAIN AIR CONDITIONER…1486
CHECK BEFORE STARTING…1487
CHECK COOLANT LEVEL, ADD COOLANT…1487
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…1487
CHECK FUEL LEVEL, ADD FUEL…1488
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…1488
CHECK AIR CLEANER FOR CLOGGING…1489
CHECK ELECTRIC WIRINGS…1490
CHECK FUNCTION OF HORN…1490
CHECK FOR WATER IN FUEL SEDIMENTOR…1490
CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER…1491
EVERY 100 HOURS SERVICE…1491
LUBRICATING…1491
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…1493
DRAIN WATER AND SEDIMENT FROM FUEL TANK…1494
CLEAN FRESH AIR INTAKE FILTER…1494
EVERY 250 HOURS SERVICE…1495
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1495
CHECK LEVEL OF BATTERY ELECTROLYTE…1496
LUBRICATE SWING CIRCLE (2 POINTS)…1496
BELTS, GENERAL…1496
CHECK ALTERNATOR AND WATER PUMP BELT TENSION, ADJUST CHECKING TENSION…1497
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…1498
EVERY 500 HOURS SERVICE…1499
REPLACE FUEL FILTER CARTRIDGE…1499
CHECK SWING PINION GREASE LEVEL, ADD GREASE…1501
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…1502
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED W….1503
REPLACE HYDRAULIC FILTER ELEMENT…1504
EVERY 1000 HOURS SERVICE…1505
CHANGE OIL IN SWING MACHINERY CASE…1505
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…1505
CHECK PLAY OF TURBOCHARGER ROTOR…1505
CHECK AND ADJUST VALVE CLEARANCE…1506
CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB…1506
CHECK FAN BELT TENSION…1506
EVERY 2000 HOURS SERVICE…1507
CHANGE OIL IN FINAL DRIVE CASE…1507
CLEAN HYDRAULIC TANK STRAINER…1508
CLEAN, CHECK TURBOCHARGER…1508
CHECK ALTERNATOR, STARTING MOTOR…1508
CHECK ENGINE VALVE CLEARANCE, ADJUST…1508
CHECK VIBRATION DAMPER…1508
CHANGE ANTI FREEZE…1508
CHECK AND ADJUST VALVE CLEARANCE…1509
EVERY 4000 HOURS SERVICE…1509
CHECK WATER PUMP…1509
EVERY 5000 HOURS SERVICE…1509
CHANGE OIL IN HYDRAULIC TANK…1509
SPECIFICATIONS…1515
SPECIFICATIONS…1516
PC160-6K, PC180LC-6K, PC180NLC-6K…1516
explanation of LIFTING CAPACITY CHART…1522
OPTIONS, ATTACHMENTS…1529
PRECAUTIONS RELATED TO SAFETY…1530
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…1531
HANDLING BUCKET WITH HOOK…1532
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…1532
PROHIBITED OPERATIONS…1532
PRECAUTIONS DURING OPERATIONS…1532
MACHINES READY FOR ATTACHMENTS…1533
1. STOP VALVE…1533
3. CONTROL PEDAL FOR ATTACHMENT…1533
4. ACCUMULATOR…1534
5. HYDRAULIC CIRCUIT…1534
Change-over hydraulic circuit…1534
CONNECTING HYDRAULIC CIRCUIT…1535
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…1536
OPERATION…1537
LONG TERM STORAGE…1538
SPECIFICATIONS…1539
INTRODUCTION OF ATTACHMENTS…1540
SPECIFICATION, USE…1540
ATTACHMENT INSTALLATION COMBINATION TABLE…1542
SELECTION OF TRACK SHOES…1543
SELECTION OF BUCKET TEETH…1545
HANDLING TRAPEZOIDAL BUCKET…1545
HANDLING THE CLAMSHELL BUCKET…1547
EXTENDING MACHINE SERVICE LIFE…1548
HYDRAULIC BREAKER…1548
POWER RIPPER…1551
MAIN FIELDS OF APPLICATIONS…1551
FORK GRAB…1553
GRAPPLE BUCKET…1554
SCRAP GRAPPLE…1555
CRUSHER & SMASHER…1556
HYDRAULIC PILE DRIVER…1558
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE…1559
2-PC BOOM…1561
FEATURES OF 2-PIECE BOOM & ARM…1561
OPERATION…1561
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE…1563
TESTING AND ADJUSTING…1563
PERODIC MAINTENANCE…1564
TRANSPORTATION…1565
UEAM002401 – Hydraulic Excavator PC160LC-7KA Operation & Maintenance Manual…1566
FOREWORD…1568
FOREWORD…1569
SAFETY INFORMATION…1571
INTRODUCTION…1573
DIRECTIONS OF MACHINE…1573
PRODUCT INFORMATION…1574
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…1574
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1574
SERVICE METER LOCATION…1575
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1575
MACHINE SERIAL PLATE…1576
FOREWORD…1577
SAFETY…1577
OPERATION…1578
MAINTENANCE…1580
SPECIFICATIONS…1582
ATTACHMENTS AND OPTIONS…1582
SAFETY…1584
SAFETY INFORMATION…1585
SAFETY LABELS…1587
LOCATION OF SAFETY LABELS…1587
SAFETY LABELS…1588
SAFETY INFORMATION…1593
SAFETY MACHINE OPERATION…1601
STARTING ENGINE…1601
OPERATION…1602
TRANSPORTATION…1608
BATTERY…1609
TOWING…1611
LIFTING OBJECTS WITH BUCKET…1612
SAFETY MAINTENANCE INFORMATION…1613
OPERATION…1620
MACHINE VIEW ILLUSTRATIONS…1621
OVERALL MACHINE VIEW…1621
CONTROLS AND GAUGES…1622
DETAILED CONTROLS AND GAUGES…1623
MONITORING SYSTEM…1623
Basic Operation Of Machine Monitor…1624
Basic Check Monitors…1626
Caution Monitors…1628
Emergency Monitors…1630
Meter Display Portion…1632
Monitor Switches Portion…1636
SWITCHES…1646
CONTROL LEVERS AND PEDALS…1650
SUN ROOF…1653
WINDSHIELD…1653
EMERGENCY EXIT FROM OPERATOR'S CAB…1658
DOOR LOCK…1658
CAP WITH LOCK…1659
HOT AND COOL BOX…1660
MAGAZINE BOX…1660
ASHTRAY…1660
AIR CONDITIONER CONTROLS…1661
Air Conditioner Control Panel…1661
Method Of Operation…1666
Use Air Conditioner With Care…1671
Air Conditioner Maintenance…1671
Other Functions…1672
RADIO…1674
Control Panel…1674
Controls Of Radio…1677
Use Radio With Care…1678
AUXILIARY ELECTRIC POWER…1679
12 V power source…1679
FUSE…1679
FUSIBLELINK…1680
CONTROLLERS…1681
TOOL BOX…1681
GREASE GUN HOLDER…1681
ACCUMULATOR…1682
Releasing Hydraulic Pressure With Accumulator…1682
MACHINE OPERATIONS AND CONTROLS…1683
BEFORE STARTING ENGINE…1683
Walk-Around Checks…1683
Checks Before Starting…1684
Adjustment…1690
Seat Belt…1692
Operations Before Starting Engine…1693
STARTING ENGINE…1696
Normal Starting…1696
Starting Engine In Cold Weather…1697
AFTER STARTING ENGINE…1700
Breaking-In The New Machine…1700
Warming-Up Operation…1700
In Cold Weather Areas…1703
STOPPING THE ENGINE…1707
CHECK AFTER SHUT OFF ENGINE…1707
MACHINE OPERATION…1708
Preparations For Moving The Machine Off…1708
Moving Machine Forward…1709
Moving Machine Backward…1710
Stopping Machine…1711
STEERING THE MACHINE…1712
Steering…1712
SWINGING…1714
WORK EQUIPMENT CONTROLS AND OPERATIONS…1715
WORKING MODE…1716
PROHIBITED OPERATIONS…1717
GENERAL OPERATION INFORMATION…1719
TRAVELING ON SLOPES…1720
ESCAPE FROM MUD…1722
Stuck One Side Of Track…1722
Stuck Both Sides Of Tracks…1722
RECOMMENDED APPLICATIONS…1723
Backhoe Work…1723
Shovel Work…1723
Ditching Work…1723
Loading Work…1724
BUCKET REPLACEMENT AND INVERSION…1724
Replacement…1724
Inversion…1725
PARKING MACHINE…1726
MACHINE INSPECTION AFTER DAILY WORK…1728
LOCKING…1728
TRANSPORTATION…1729
TRANSPORTATION PROCEDURE…1729
LOADING AND UNLOADING WITH TRAILER…1729
Loading…1730
Securing Machine…1732
Unloading…1733
LIFTING MACHINE…1736
COLD WEATHER OPERATION…1737
COLD WEATHER OPERATION INFORMATION…1737
Fuel And Lubricants…1737
Cooling System Coolant…1737
Battery…1738
AFTER DAILY WORK COMPLETION…1739
AFTER COLD WEATHER SEASON…1739
LONG TERM STORAGE…1740
BEFORE STORAGE…1740
DURING STORAGE…1740
AFTER STORAGE…1740
STARTING MACHINE AFTER LONG-TERM STORAGE…1740
TROUBLES AND ACTIONS…1741
RUNNING OUT OF FUEL…1741
PHENOMENA THAT ARE NOT FAILURES…1741
TOWING THE MACHINE…1742
LIGHTWEIGHT TOWING HOLE…1742
SEVERE JOB CONDITION…1742
DISCHARGED BATTERY…1743
Battery Removal And Installation…1743
Battery Charges…1744
Starting Engine With Booster Cables…1744
OTHER TROUBLE…1746
Electrical System…1746
Chassis…1747
Engine…1748
Electronic Control System…1750
Point Of Contact To Telephone When Error Occurs…1751
MAINTENANCE…1752
MAINTENANCE INFORMATION…1753
LUBRICANTS, COOLANT AND FILTERS…1755
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1755
Oil…1755
Fuel…1755
Cooling System Coolant…1755
Grease…1756
Carrying out KOWA (Komatsu Oil Wear Analysis)…1756
Oil And Fuel Storage…1757
Filters…1757
ELECTRIC SYSTEM MAINTENANCE…1757
WEAR PARTS…1758
WEAR PARTS LIST…1758
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…1759
PROPER SELECTION…1759
TIGHTENING TORQUE SPECIFICATIONS…1763
TIGHTENING TORQUE LIST…1763
SAFETY CRITICAL PARTS…1765
SAFETY CRITICAL PARTS LIST…1766
MAINTENANCE SCHEDULE…1767
MAINTENANCE SCHEDULE CHART…1767
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1768
USE OF BIO-DEGRADEABLE OIL…1768
Filter changes…1768
Oil changes…1768
.MAINTENANCE PROCEDURE…1769
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…1769
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…1769
WHEN REQUIRED…1770
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1770
CLEAN INSIDE OF COOLING SYSTEM…1774
CHECK AND TIGHTEN TRACK SHOE BOLTS…1776
CHECK AND ADJUST TRACK TENSION…1776
CHECK ELECTRICAL INTAKE AIR HEATER…1778
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…1778
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…1780
ADJUST BUCKET CLEARANCE…1781
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1782
CHECK AND ADJUST AIR CONDITIONER…1783
WASH WASHABLE FLOOR…1784
BLEEDING AIR FROM HYDRAULIC SYSTEM…1787
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…1789
CHECK BEFORE STARTING…1790
EVERY 250 HOURS MAINTENANCE…1791
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…1791
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1791
CHECK LEVEL OF BATTERY ELECTROLYTE…1792
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…1793
EVERY 500 HOURS MAINTENANCE…1795
LUBRICATING…1795
LUBRICATE SWING CIRCLE…1796
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…1797
REPLACE FUEL FILTER CARTRIDGE…1798
CHECK SWING PINION GREASE LEVEL, ADD GREASE…1799
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS…1799
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER…1800
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…1801
EVERY 1000 HOURS MAINTENANCE…1802
REPLACE HYDRAULIC OIL FILTER ELEMENT…1802
CHANGE OIL IN SWING MACHINERY CASE…1803
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…1804
CHECK FAN BELT TENSION AND REPLACE FAN BELT…1804
EVERY 2000 HOURS MAINTENANCE…1805
CHANGE OIL IN FINAL DRIVE CASE…1805
CLEAN HYDRAULIC TANK STRAINER…1805
CHECK ALTERNATOR, STARTING MOTOR…1806
CHECK ENGINE VALVE CLEARANCE, ADJUST…1806
EVERY 4000 HOURS MAINTENANCE…1806
CHECK WATER PUMP…1806
EVERY 5000 HOURS MAINTENANCE…1807
CHANGE OIL IN HYDRAULIC TANK…1807
SPECIFICATIONS…1808
SPECIFICATIONS…1809
ATTACHMENTS AND OPTIONS…1812
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1813
SAFETY FIRST…1813
ATTACHMENT INSTALLATION…1814
BUCKET WITH HOOK…1815
HOOK CONDITION…1815
PROHIBITED OPERATIONS…1815
MACHINE READY FOR ATTACHMENT (DELUXE HCU SYSTEM)…1816
LOCATIONS…1816
HYDRAULIC CIRCUIT…1819
Switching Hydraulic Circuit…1819
Adjusting Oil Flow…1819
Switching Between Breaker and General Attachment…1819
Hydraulic Circuit Connection…1820
Oil Flow Path…1820
Replace Additional Breaker Filter Element…1821
MACHINE READY FOR ATTACHMENTS (SIMPLE HCU SYSTEM)…1822
EXPLANATION OF COMPONENTS…1822
(1) STOP VALVE…1822
(2) SELECTOR VALVE…1823
(3) ATTACHMENT CONTROL PEDAL…1823
(4) LOCK PIN…1823
HYDRAULIC CIRCUIT…1823
SWITCHING HYDRAULIC CIRCUIT…1824
ADJUSTING OIL FLOW…1824
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT…1825
HYDRAULIC CIRCUIT CONNECTION…1826
PATH OF OIL…1826
ATTACHMENT REMOVAL AND INSTALLATION…1827
Attachment Removal…1827
Attachment Installation…1828
ATTACHMENT OPERATIONS…1829
When Using Breaker…1829
When Using General Attachment Such As Crusher…1830
LONG TERM STORAGE…1830
SPECIFICATIONS…1830
ATTACHMENT GUIDE…1831
OTHER ATTACHMENTS…1831
ATTACHMENT COMBINATIONS…1833
TRACK SHOES SELECTION…1834
BUCKET TEETH SELECTION…1835
Teeth Selection…1835
Selection Guide For Horizontal Or Vertical Pin Type Tooth…1835
RECOMMENDED ATTACHMENT OPERATIONS…1836
HYDRAULIC BREAKER…1836
<A>…1840
<B>…1840
<C>…1840
<D>…1840
<E>…1840
<F>…1840
<G>…1840
<H>…1840
<I>…1840
<L>…1840
<M>…1840
<O>…1841
<P>…1841
<R>…1841
<S>…1841
<T>…1841
<W>…1841
<Y>…1841
UEBD000601 – Hydraulic Excavator PC160-6K, PC180LC, 180NLC-6K Shop Manual…1842
COVER…1842
CONTENTS…1842
SAFETY…1842
SAFETY NOTICE…1847
FOREWARD…1849
GENERAL…1849
HOW TO READ THE SHOP MANUAL…1850
HOISTING INSTRUCTIONS…1851
COATING MATERIALS…1852
STANDARD TIGHTENING TORQUE…1853
ELECTRIC WIRE CODE…1855
CONVERSION TABLE…1856
01 GENERAL…1863
SPECIFICATIONS…1864
SPECIFICATION DRAWINGS…1866
WEIGHT TABLE…1870
FUEL, COOLANT AND LUBRICANTS…1874
10 STRUCTURE AND FUNCTION…1876
ENGINE RELATED PARTS…1877
RADIATOR * OIL COOLER…1878
POWER TRAIN…1879
FINAL DRIVE…1880
SWING CIRCLE…1881
SWING MACHINERY…1882
TRACK FRAME, RECOIL SPRING…1884
TRACK SHOE…1885
HYDRAULIC CIRCUIT DIAGRAM…1888
FUEL & HYDRAULIC TANK…1889
HYDRAULIC PUMP…1892
CONTROL VALVE…1899
CLSS…1905
SWING MOTOR…1942
CENTER SWIVEL JOINT…1944
TRAVEL MOTOR…1945
VALVE CONTROL…1953
WORK EQUIPMENT – SWING PPC VALVE…1954
TRAVEL PPC PEDAL…1958
SAFETY LOCK VALVE…1965
PPC ACCUMULATOR…1965
PPC SHUTTLE * TRAVEL JUNCTION VALVE…1966
EPC * SOLENOID VALVE…1973
HYDRAULIC CYLINDER…1978
ADDITIONAL FILTER FOR BREAKING…1980
OVERLOAD WARNING DEVICE…1981
HOSE BURST PROTECTION VALVE (BOOM)…1985
WORK EQUIPMENT…1988
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE…1991
ENGINE CONTROL SYSTEM…1992
ELECTRONIC CONTROL SYSTEM…1998
MACHINE MONITOR SYSTEM…2022
20 TESTING AND ADJUSTING…2034
TABLE OF JUDGEMENT STANDARD VALUE…2035
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…2045
CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…2053
ADJUSTING ENGINE SPEED SENSOR…2054
TESTING AND ADJUSTING GOVERNOR MOTOR LEVEL STROKE…2055
TESTING CLEARANCE OF SWING CIRCLE BEARING…2057
TESTING AND ADJUSTING TRACK SHOE TENSION…2058
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…2059
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)…2067
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…2069
TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE…2072
TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE…2074
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE…2076
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…2078
TESTING TRAVEL DEVIATION…2079
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…2080
MEASURING OIL LEAKAGE…2082
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…2084
BLEEDING AIR…2085
TROUBLESHOOTING…2088
POINTS TO REMEMBER WHEN TROUBLSHOOTING…2089
SEQUENCE OF EVENTS IN TROUBLSHOOTING…2090
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…2091
CHECKS BEFORE TROUBLESHOOTING…2098
CONNECTOR TYPES AND MOUNTING LOCATIONS…2099
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2104
EXPLANATION OF CONTROL MACHANISM FOR ELECTRICAL SYSTEM…2117
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL…2118
METHOD OF USING JUDGEMENT TABLE…2126
METHOD OF USING TROUBLESHOOTING CHARTS…2128
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…2130
SERVICE CODE TABLE…2135
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)…2136
N-1 [E218] COMMUNICATION ABNORMALITY…2137
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)…2139
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM…2140
ACTION BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2141
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS…2145
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE…2147
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)…2149
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…2150
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED…2151
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED…2152
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…2153
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…2154
E-7 [E316] ABNORMALITY (STEP OUT) IN MOTOR IS DISPLAYED…2155
E-8 ENGINE DOES NOT START…2157
E-9 ENGINE SPEED IS IRREGULAR…2159
a) IDLING SPEED IS IRREGULAR…2159
b) THERE IS HUNTING…2161
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)…2163
E-11 ENGINE DOES NOT STOP…2165
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)…2167
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…2170
METHOD OF USING TROUBLESHOOTING CHARTS…2171
S-1 STARTING PERFORMARMANCE IS POOR (STARTING ALWAYS TAKES TIME)…2175
S-2 ENGINE DOES NOT START…2176
1) ENGINE DOES NOT TURN…2176
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEEN INJECTED)…2177
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FEUL IS BEING INJECTED)…2178
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)…2179
S-4 ENGINE STOPS DURING OPERATIONS…2180
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…2181
S-6 ENGINE LACKS OUTPUT (NO POWER)…2182
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…2183
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…2184
S-9 OIL BECOMES CONTAMINATED QUICKLY…2185
S-10 FUEL CONSUMPTION IS EXCESSIVE…2186
S-11 OIL LEVEL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…2187
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…2188
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…2189
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…2190
S-15 ABNORMAL NOISE IS MADE…2191
S-16 VIBRATION IS EXCESSIVE…2192
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)…2193
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…2194
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2195
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS…2201
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE …2203
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)…2205
C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED…2206
C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED…2208
C-6 [E201] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED…2210
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…2212
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…2214
C-10 [E205] SHORT CIRCUIT IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…2216
C-11 [E215] DISCONNECTION IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…2217
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED…2218
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED…2219
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED…2220
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…2222
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS…2223
C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…2224
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED…2225
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…2226
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)…2228
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE…2229
F-1 BIT PATTERN 20- (1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP…2231
F-2 BIT PATTERN 20- (2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…2232
F-3 BIT PATTERN 20- (3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP…2233
F-4 BIT PATTERN 20- (4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP…2234
F-5 BIT PATTERN 20- (5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP…2235
F-6 BIT PATTERN 20- (6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP…2236
F-7 BIT PATTERN 21- (1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP…2237
F-8 BIT PATTERN 21- (2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP…2238
F-9 BIT PATTERN 21- (3) SWING LOCK SWITCH DOES NOT LIGHT UP…2239
F-10 BIT PATTERN 22- (5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP…2240
F-11 BIT PATTERN 22- (6) L.H. KNOB SWITCH DOES NOT LIGHT UP…2241
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…2242
TABLE OF FAILURE MODES AND CAUSES…2243
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…2247
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…2249
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…2250
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…2250
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)…2251
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…2251
H-7 BOOM IS SLOW OR LACKS POWER…2253
H-8 ARM IS SLOW OR LACKS POWER…2255
H-9 BUCKET IS SLOW OR LACKS POWER…2257
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…2258
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…2258
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…2259
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…2259
H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED…2260
H-15 LACK OF POWER WHEN PRESSURE RISES…2260
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…2260
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…2261
H-20 TRAVEL DEVIATION…2262
H-21 TRAVEL SPEED IS SLOW…2263
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER…2265
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…2267
H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…2267
H-25 DOES NOT SWING…2268
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW…2269
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING…2271
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…2272
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…2272
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING…2273
H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED…2274
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…2276
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2277
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE…2279
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED; [E102] ERROR IN CLOCK DATA IS DISPLAYED…2281
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED…2282
M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED…2283
M-4 [E106] DROP IN ENGINE OIL PRESSURE DETECTED IS DISPLAYED…2283
M-5 [E108] ENGINE WATER TEMPERATURE 105 c DETECTED IS DISPLAYED…2284
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL LIGHT UP FOR 3 SECONDS…2285
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT…2287
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)…2287
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES…2288
M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP…2290
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH…2291
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)…2293
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)…2295
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND…2298
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS…2298
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…2299
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE…2300
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)…2300
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…2301
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…2301
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP…2302
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH…2302
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING…2303
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED…2303
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM…2304
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM…2305
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM…2306
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…2307
M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…2308
30 DISASSEMBLY AND ASSEMBLY…2314
METHOD OF USING MANUAL…2316
PRECAUTIONS WHEN CARRYING OUT OPERATION…2318
SPECIAL TOOL LIST…2320
GOVERNOR MOTOR ASSEMBLY…2323
REMOVAL AND INSTALLATION…2323
HYDRAULIC OIL COOLER ASSEMBLY…2324
REMOVAL AND INSTALLATION…2324
RADIATOR * HYDRAULIC OIL COOLER ASSEMBLY…2325
REMOVAL…2325
INSTALLATION…2326
ENGINE * HYDRAULIC PUMP ASSEMBLY…2327
REMOVAL…2327
INSTALLATION…2330
DAMPER ASSEMBLY…2331
REMOVAL AND INSTALLATION…2331
FUEL/HYDRAULIC TANK ASSEMBLY…2332
REMOVAL…2332
INSTALLATION…2333
CENTER SWIVEL JOINT ASSEMBLY…2334
DISASSEMBLY AND ASSEMBLY…2334
TRAVEL MOTOR ASSEMBLY…2335
REMOVAL AND INSTALLATION…2335
FINAL DRIVE ASSEMBLY…2336
REMOVAL AND INSTALLATION…2336
SPROCKET…2338
REMOVAL AND INSTALLATION…2338
SWING MOTOR ASSEMBLY…2339
REMOVAL AND INSTALLATION…2339
SWING MACHINERY ASSEMBLY…2340
REMOVAL AND INSTALLATION…2340
SWING MOTOR…2342
DISASSEMBLY AND ASSEMBLY…2342
REVOLVIING FRAME ASSEMBLY…2349
REMOVAL…2349
INSTALLATION…2350
SWING CIRCLE ASSEMBLY…2351
REMOVAL…2351
INSTALLATION…2352
IDLER * RECOIL SPRING ASSEMBLY…2353
REMOVAL AND INSTALLATION…2353
RECOIL SPRING ASSEMBLY…2354
DISASSEMBLY…2354
ASSEMBLY…2355
IDLER ASSEMBLY…2356
DISASSEMBLY…2356
ASSEMBLY…2357
TRACK ROLLER…2359
REMOVAL AND INSTALLATION…2359
DISASSEMBLY…2360
ASSEMBLY…2361
CARRIER ROLLER ASSEMBLY…2363
REMOVAL AND INSTALLATION…2363
DISASSEMBLY…2364
ASSEMBLY…2365
TRACK SHOE ASSEMBLY…2367
REMOVAL AND INSTALLATION…2367
MAIN PUMP ASSEMBLY…2370
REMOVAL…2370
INSTALLATION…2371
CONTROL VALVE ASSEMBLY…2372
REMOVAL…2372
INSTALLATION …2373
DISASSEMBLY…2374
ASSEMBLY…2376
LS SELECT VALVE ASSEMBLY…2378
DISASSEMBLY AND ASSEMBLY…2378
LS SHUTTLE VALVE…2379
DISASSEMBLY AND ASSEMBLY…2379
PRESSURE COMPENSATION VALVE ASSEMBLY…2380
DISASSEMBLY…2380
ASSEMBLY…2381
MAIN RELIEF VALVE ASSEMBLY…2382
DISASSEMBLY…2382
ASSEMBLY…2383
LS CONTROL EPC VALVE ASSEMBLY…2384
REMOVAL AND INSTALLATION…2384
SOLENOID VALVE ASSEMBLY…2385
REMOVAL AND INSTALLATION…2385
PPC SHUTTLE VALVE ASSEMBLY…2386
REMOVAL…2386
INSTALLATION…2387
DISASSEMBLY…2388
ASSEMBLY…2389
WORK EQUIPMENT SWING PPC VALVE ASSEMBLY…2390
REMOVAL AND INSTALLATION…2390
TRAVEL PPC VALVE ASSEMBLY…2391
REMOVAL AND INSTALLATION…2391
DISASSEMBLY AND ASSEMBLY…2392
BOOM CYLINDER ASSEMBLY…2394
REMOVAL…2394
INSTALLATION…2395
ARM CYLINDER ASSEMBLY…2396
REMOVAL…2396
INSTALLATION…2397
BUCKET CYLINDER ASSEMBLY…2398
REMOVAL…2398
INSTALLATION…2399
HYDRAULIC CYLINDER ASSEMBLY…2400
DISASSEMBLY…2400
ASSEMBLY…2402
WORK EQUIPMENT ASSEMBLY…2405
REMOVAL…2405
INSTALLATION…2406
BUCKET ASSEMBLY…2407
REMOVAL AND INSTALLATION…2407
ARM ASSEMBLY…2407
REMOVAL AND INSTALLATION…2407
ARM, BUCKET ASSEMBLY…2409
REMOVAL AND INSTALLATION…2409
BOOM ASSEMBLY…2411
REMOVAL…2411
INSTALLATION …2412
OPERATOR'S CAB ASSEMBLY…2413
REMOVAL…2413
INSTALLATION…2415
COUNTERWEIGHT ASSEMBLY…2416
REMOVAL AND INSTALLATION…2416
GOVERNOR, PUMP CONTROLLER ASSEMBLY…2417
REMOVAL AND INSTALLATION…2417
MONITOR PANEL ASSEMBLY…2418
REMOVAL AND INSTALLATION…2418
FINAL DRIVE ASSEMBLY…2424
DISASSEMBLY…2424
ASSEMBLY…2435
(SPECIAL TOOLS)…2447
SWING MACHINERY ASSEMBLY…2454
DISASSEMBLY…2454
ASSEMBLY…2470
(SPECIAL TOOLS)…2490
40 MAINTENANCE STANDARD…2494
ENGINE MOUNT…2495
SWING MACHINERY…2496
SWING CIRCLE…2498
FINAL DRIVE…2499
TRACK FRAME, RECOIL SPRING…2501
IDLER…2502
CARRIER ROLLER…2504
TRACK ROLLER…2505
TRACK SHOE…2506
CONTROL VALVE…2508
SUCTION-SAFETY VALVE…2516
SWING MOTOR…2517
WORK EQUIPMENT, SWING PPC VALVE…2518
TRAVEL PPC VALVE…2519
SERVICE PPC VALVE…2520
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE…2521
EPC SOLENOID VALVE…2522
CENTER SWIVEL JOINT…2523
ARM, BOOM SAFETY VALVE…2524
HYDRAULIC CYLINDER…2525
WORK EQUIPMENT…2526
Komatsu Hydraulic Excavator PC160K, PC180LC-K, PC180NLC-K Repair Service Manuals