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.
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
PRODUCT DETAILS:
Total Pages: 2,413 pages
File Format: PDF
Language: English
SEN01892-05 – Hydraulic Excavator PC160LC-7E0 Shop Manual…2
COVER…2
00 Index and foreword…0
Index…3
Composition of shop manual…4
Table of contents…6
Foreword and general information…15
Safety notice…16
How to read the shop manual…21
Explanation of terms for maintenance standard…23
Handling of electric equipment and hydraulic component…25
Handling of connectors newly used for engines…34
How to read electric wire code…37
Precautions when carrying out operation…40
Method of disassembling and connecting push-pull type coupler…43
Standard tightening torque table…46
Conversion table…50
01 Specification…0
Specification and technical data…57
Specification dimension drawings…58
Specifications…60
Weight table…62
Table of fuel, coolant and lubricants…64
10 Structure, function and maintenance standard…0
Engine and cooling system…67
Engine related parts…68
Radiator, oil cooler, aftercooler and fuel cooler…69
Power train system…71
Power train…72
Swing circle…73
Swing machinery…74
Final drive…75
Sprocket…77
Undercarriage and frame…80
Track frame, recoil spring…81
Idler…83
Carrier roller…85
Track roller…86
Track shoe…87
Hydraulic system, Part 1…92
Hydraulic equipment layout drawing…93
Hydraulic tank…95
Hydraulic pump…96
Hydraulic system, Part 2…122
Control valve…123
CLSS…136
Functions and operation by valve…139
Hydraulic system, Part 3…174
Valve control…175
PPC valve…176
Solenoid valve…192
Accumulator…194
Return oil filter…195
Center swivel joint…196
Travel motor…197
Swing motor…207
Attachment circuit selector valve…208
Hydraulic cylinder…211
Work equipment…214
Work equipment…215
Dimensions of components…217
Cab and its attachments…222
Air conditioner piping…223
Electrical system…225
Engine control…226
Electronic control system…235
Monitor system…261
Sensor…279
KOMTRAX terminal system…282
20 Standard value table…0
Standard service value table…287
Standard value table for engine…288
Standard value table for chassis related parts…289
30 Testing and adjusting…0
Testing and adjusting, Part 1…300
Tools for testing, adjusting, and troubleshooting…301
Measuring engine speed…304
Measuring intake air pressure (boost pressure)…305
Checking exhaust gas color…306
Adjusting valve clearance…307
Measuring compression pressure…309
Measurement of blow-by pressure…311
Measuring engine oil pressure…312
Handling fuel system parts…313
Releasing residual pressure from fuel system…313
Measuring fuel pressure…314
Measuring fuel discharge, return and leakage…316
Bleeding air from fuel circuit…320
Checking fuel circuit for leakage…322
Checking and adjusting air conditioner compressor belt tension…323
Replacing the fan belt…324
Testing and adjusting, Part 2…326
Testing of clearance in swing circle bearings…327
Checking and adjusting track shoe tension…328
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits…329
Inspection and adjustment of control circuit oil pressure…332
Inspection and adjustment of pump PC control circuit oil pressure…333
Inspection and adjustment of pump LS control circuit oil pressure…336
Measurement of solenoid valve output pressure…340
Testing of PPC valve output pressure…343
Adjustment of work equipment and swing PPC valve…344
Inspection of locations of hydraulic drift of work equipment…345
Testing and adjusting travel deviation…347
Release of residual pressure from hydraulic circuit…349
Measurement of oil leakage…350
Bleeding air from each part…352
Inspection procedures for diode…354
Adjusting mirrors…355
Testing and adjusting, Part 3…358
Special functions of machine monitor…359
Handling voltage circuit of engine controller…387
Procedure for turning on KOMTRAX terminal…388
Indication by KOMTRAX terminal lamps…391
Preparation work for troubleshooting of electrical system…394
Pm-clinic service…396
40 Troubleshooting…0
Failure code table and fuse locations…402
Failure code table…403
Fuse locations…406
General information on troubleshooting…409
Points to remember when troubleshooting…410
Sequence of events in troubleshooting…411
Checks before troubleshooting…412
Classification and troubleshooting steps…413
Information in troubleshooting table…414
Possible problems and troubleshooting No…416
Connection table for connector pin numbers…419
T- branch box and T- branch adapter table…455
Troubleshooting by failure code, Part 1…459
Failure code [AA10NX] Air cleaner clogging…461
Failure code [AB00KE] Charge voltage low…462
Failure code [B@BAZG] Eng. oil press. low…464
Failure code [B@BAZK] Eng. oil level low…465
Failure code [B@BCNS] Eng. coolant overheat…466
Failure code [B@BCZK] Eng. coolant level low…468
Failure code [B@HANS] Hydr oil overheat…469
Failure code [CA111] EMC critical internal failure…469
Failure code [CA115] Eng Ne and bkup speed sens error…470
Failure code [CA122] Chg air press sensor high error…471
Failure code [CA123] Chg air press sensor low error…473
Failure code [CA131] Throttle sensor high error…475
Failure code [CA132] Throttle sensor low error…477
Failure code [CA144] Coolant temp sens high error…479
Failure code [CA145] Coolant temp sens low error…481
Failure code [CA153] Chg air temp sensor high error…483
Failure code [CA154] Chg air temp sensor low error…485
Failure code [CA155] Chg air temp high speed derate…487
Failure code [CA187] Sens supply 2 volt low error…488
Failure code [CA221] Ambient press sens high error…490
Failure code [CA222] Ambient press sens low error…492
Failure code [CA227] Sens supply 2 volt high error…494
Failure code [CA234] Eng. overspeed…495
Failure code [CA238] Ne speed sens supply volt error…496
Failure code [CA271] IMV/PCV1 short error…497
Failure code [CA272] IMV/PCV1 open error…498
Failure code [CA322] Inj #1 open/short error…499
Failure code [CA324] Inj #3 open/short error…501
Troubleshooting by failure code, Part 2…504
Failure code [CA331] Inj #2 open/short error…507
Failure code [CA332] Inj #4 open/short error…509
Failure code [CA342] Calibration code incompatibility…511
Failure code [CA351] Injectors drive circuit error…513
Failure code [CA352] Sens supply 1 volt low error…515
Failure code [CA386] Sens supply 1 volt high error…517
Failure code [CA428] Water in fuel sensor high error…519
Failure code [CA429] Water in fuel sensor low error…521
Failure code [CA435] Eng oil press sw error…523
Failure code [CA441] Engine controller battery voltage low error…525
Failure code [CA442] Engine controller battery voltage high error…527
Failure code [CA449] Rail press very high error…529
Failure code [CA451] Rail press sensor high error…531
Failure code [CA452] Rail press sensor low error…533
Failure code [CA488] Chg air temp high torque derate…535
Failure code [CA553] Rail press high error…535
Failure code [CA559] Rail press low error…536
Failure code [CA689] Eng Ne speed sensor error…537
Failure code [CA731] Eng Bkup speed sens phase error…539
Failure code [CA757] All continuous data lost error…541
Failure code [CA778] Eng Bkup speed sensor error…543
Failure code [CA1633] KOMNET Datalink timeout error…545
Failure code [CA2185] Throt sens sup volt high error…547
Failure code [CA2186] Throt sens sup volt low error…548
Failure code [CA2249] Rail press very low error…549
Failure code [CA2311] IMV solenoid error…551
Failure code [CA2555] Grid htr relay volt high error…553
Failure code [CA2556] Grid htr relay volt low error…555
Troubleshooting by failure code, Part 3…558
Failure code [D110KB] Battery relay drive S/C…559
Failure code [D196KA] Service return relay disc…561
Failure code [D196KB] Service return relay S/C…563
Failure code [DA22KK] Pump solenoid power low error…565
Failure code [DA25KP] Press. sensor power abnormality…567
Failure code [DA2RMC] Pump comm. abnormality…569
Failure code [DA2SKQ] Model selection abnormality…571
Failure code [DAFRMC] Monitor comm. abnormality…573
Failure code [DGH2KB] Hydr oil sensor short…575
Failure code [DHPAMA] F pump press sensor abnormality…576
Failure code [DHPBMA] R pump press sensor abnormality…578
Failure code [DHSAMA] Sw RH PPC press sen. abnormality…580
Failure code [DHSBMA] Sw LH PPC press sen. abnormality…582
Troubleshooting by failure code, Part 4…585
Failure code [DW43KA] Travel speed sol. disc…587
Failure code [DW43KB] Travel speed sol. S/C…589
Failure code [DW45KA] Swing brake sol. disc…591
Failure code [DW45KB] Swing brake sol. S/C…594
Failure code [DW91KA] Travel junction sol. disc…596
Failure code [DW91KB] Travel junction sol. S/C…598
Failure code [DWJ0KA] Merge-divider sol. disc…600
Failure code [DWJ0KB] Merge-divider sol. S/C…602
Failure code [DWK0KA] 2-stage relief sol. disc…604
Failure code [DWK0KB] 2-stage relief sol. S/C…606
Failure code [DXA0KA] PC-EPC sol. disc…608
Failure code [DXA0KB] PC-EPC sol. S/C…610
Failure code [DXE4KA] Service current EPC disc…612
Failure code [DXE4KB] Service current EPC S/C…613
Failure code [DY20KA] Wiper working abnormality…614
Failure code [DY20MA] Wiper parking abnormality…616
Failure code [DY2CKB] Washer drive S/C…618
Failure code [DY2DKB] Wiper drive (for) S/C…620
Failure code [DY2EKB] Wiper drive (rev) S/C…622
Troubleshooting of electrical system (E-mode)…625
Before carrying out troubleshooting of electrical system…627
Information contained in troubleshooting table…629
E-1 Engine does not start…630
E-2 Auto-decelerator does not operate…633
E-3 Automatic warming-up system does not operate…635
E-4 Preheater does not operate…636
E-5 All work equipment, swing, and travel mechanism do not move…638
E-6 Power maximizing function does not operate…640
E-7 Machine monitor does not display at all…642
E-8 Machine monitor does not display some items…644
E-9 Contents of display by machine monitor are different from applicable machine…644
E-10 Fuel level monitor was lighted in red while engine running…645
E-11 Engine coolant temperature gauge does not indicate normally…646
E-12 Hydraulic oil temperature gauge does not indicate normally…648
E-13 Fuel level gauge does not indicate normally…650
E-14 Swing lock monitor does not indicate normally…651
E-15 When monitor switch is operated, monitor displays nothing…653
E-16 Windshield wiper and window washer do not operate…654
E-17 Monitoring function fails to display "boom raise" normally…658
E-18 Monitoring function fails to display "boom lower" normally…660
E-19 Monitoring function fails to display "arm IN" normally…662
E-20 Monitoring function fails to display "arm OUT" normally…664
E-21 Monitoring function fails to display "bucket CURL" normally…666
E-22 Monitoring function fails to display "bucket DUMP" normally…668
E-23 Monitoring function fails to display "swing left" normally…670
E-24 Monitoring function fails to display "swing right" normally…672
E-25 Monitoring function fails to display "travel" normally…674
E-26 Monitoring function fails to display "travel differential pressure" normally…676
E-27 Monitoring function fails to display "service" normally…678
E-28 KOMTRAX system does not operate normally…680
E-29 Air conditioner does not operate…682
E-30 Travel alarm does not sound or does not stop sounding…684
E-31 Horn does not sound…686
E-32 Attachment circuit does not change…688
Troubleshooting of hydraulic and mechanical system (H-mode)…691
Information contained in troubleshooting table…693
System chart for hydraulic and mechanical systems…694
H-1 Speed or power of all work equipment, swing, and travel are low…696
H-2 Engine speed sharply drops or engine stalls…697
H-3 No work equipment, travel and swing move…698
H-4 Abnormal noise is heard from around hydraulic pump…698
H-5 Auto-decelerator does not work…699
H-6 Fine control mode does not function…699
H-7 Speed or power of boom is low…700
H-8 Speed or power of arm is low…701
H-9 Speed or power of bucket is low…702
H-10 Work equipment does not move in its single operation…703
H-11 Hydraulic drift of work equipment is large…704
H-12 Time lag of work equipment is large…705
H-13 One-touch power max system does not operate…705
H-14 Work equipment loaded more is slower during compound operation…706
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE…706
H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel…707
H-17 Machine deviates during travel…708
H-18 Travel speed is low…709
H-19 Machine cannot be steered easily or steering power is low…710
H-20 Travel speed does not change or it is kept low or high…711
H-21 Track does not move (Only either side)…711
H-22 Machine does not swing…712
H-23 Swing acceleration or swing speed is low…713
H-24 Excessive overrun when stopping swing…714
H-25 When upper structure stops swinging, it makes large shock…715
H-26 When upper structure stops swinging, it makes large sound…715
H-27 Hydraulic drift of swing is large…716
H-28 Attachment circuit does not change…717
H-29 Flow rate in attachment circuit cannot be adjusted…717
Troubleshooting of engine (S-mode)…719
Method of using troubleshooting chart…722
S-1 Starting performance is poor…726
S-2 Engine does not start…727
S-3 Engine does not pick up smoothly…730
S-4 Engine stops during operations…731
S-5 Engine does not rotate smoothly…732
S-6 Engine lack output (or lacks power)…733
S-7 Exhaust smoke is black (incomplete combustion)…734
S-8 Oil consumption is excessive (or exhaust smoke is blue)…735
S-9 Oil becomes contaminated quickly…736
S-10 Fuel consumption is excessive…737
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…738
S-12 Oil pressure drops…739
S-13 Oil level rises (Entry of coolant/fuel)…740
S-14 Coolant temperature becomes too high (overheating)…741
S-15 Abnormal noise is made…742
S-16 Vibration is excessive…743
50 Disassembly and assembly…0
General information on disassembly and assembly…745
How to read this manual…746
Coating materials list…748
Special tool list…751
Sketches of special tools…754
Engine and cooling system…757
Removal and installation of fuel supply pump assembly…758
Removal and installation of fuel injector assembly…761
Removal and installation of front oil seal…767
Removal and installation of rear oil seal…769
Removal and installation of cylinder head assembly…772
Removal and installation of radiator assembly…783
Removal and installation of aftercooler assembly…785
Removal and installation of work equipment oil cooler assembly…787
Removal and installation of engine and hydraulic pump assembly…789
Removal and installation of engine hood assembly…796
Removal and installation of fuel tank assembly…798
Power train…801
Removal and installation of travel motor and final drive assembly…802
Disassembly and assembly of final drive assembly…803
Removal and installation of swing motor and swing machinery assembly…810
Disassembly and assembly of swing motor and swing machinery assembly…812
Removal and installation of swing circle assembly…819
Undercarriage and frame…821
Disassembly and assembly of carrier roller…822
Disassembly and assembly of track roller assembly…825
Disassembly and assembly of idler assembly…827
Disassembly and assembly of recoil spring…830
Expansion and installation of track shoe assembly…832
Removal and installation of sprocket…834
Removal and installation of revolving frame assembly…835
Removal and installation of counterweight…837
Hydraulic system…839
Removal and installation of center swivel joint assembly…840
Disassembly and assembly of center swivel joint assembly…842
Removal and installation of hydraulic tank assembly…843
Removal and installation of hydraulic pump assembly…846
Removal and installation of control valve assembly…849
Disassembly and assembly of control valve assembly…853
Removal and installation of hydraulic pump input shaft oil seal…855
Disassembly and assembly of work equipment PPC valve assembly…856
Disassembly and assembly of travel PPC valve assembly…857
Disassembly and assembly of hydraulic cylinder assembly…858
Work equipment Body…865
Removal and installation of work equipment assembly…866
Cab and its attachments…871
Removal and installation of operator's cab…872
Removal and installation of operator's cab glass (Stuck glass)…875
Removal and installation of front window assembly…886
Removal and installation of floor frame assembly…893
Electrical system…897
Removal and installation of air conditioner compressor assembly…898
Removal and installation of air conditioner condenser…899
Removal and installation of air conditioner unit assembly…900
Removal and installation of machine monitor assembly…902
Removal and installation of governor, pump controller assembly…903
Removal and installation of engine controller assembly…904
Removal and installation of KOMTRAX assembly…906
90 Diagrams and drawings…0
Hydraulic circuit diagram…909
Hydraulic circuit diagram…910
Electrical diagrams and drawings…912
Electrical circuit diagram (1/6)…914
Electrical circuit diagram (2/6)…915
Electrical circuit diagram (3/6)…916
Electrical circuit diagram (4/6)…917
Electrical circuit diagram (5/6)…918
Electrical circuit diagram (6/6)…919
Connectors table and arrangement drawing…920
TEN00175-06 – Hydraulic Excavator GALEO PC160LC-7E0 Operation & Maintenance Manual…923
COVER…923
FOREWORD…924
BEFORE READING THIS MANUAL…925
SAFETY INFORMATION…926
INTRODUCTION…927
USE OF MACHINE…927
DIRECTIONS OF MACHINE…927
VISIBILITY FROM OPERATOR'S SEAT…927
PRODUCT INFORMATION…928
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…928
EPA REGULATIONS, ENGINE NUMBER PLATE…928
SERVICE METER LOCATION…929
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…929
CONTENTS…930
SAFETY…934
SAFETY…935
SAFETY LABELS…938
LOCATION OF SAFETY LABELS…939
SAFETY LABELS…940
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…946
PRECAUTIONS BEFORE STARTING OPERATION…946
PREPARATIONS FOR SAFE OPERATION…946
FIRE PREVENTION…948
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…949
DO NOT GET CAUGHT IN WORK EQUIPMENT…951
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…951
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…951
UNAUTHORIZED MODIFICATION…952
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…952
PRECAUTIONS RELATED TO CAB GLASS…952
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…952
PRECAUTIONS FOR OPERATION…953
PRECAUTIONS FOR JOBSITE…953
STARTING ENGINE…955
OPERATION…957
TRANSPORTATION…965
TOWING…966
LIFTING OBJECTS WITH BUCKET…967
PRECAUTIONS FOR MAINTENANCE…968
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…968
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…972
OPERATION…978
MACHINE VIEW ILLUSTRATIONS…979
OVERALL MACHINE VIEW…979
CONTROLS AND GAUGES…980
DETAILED CONTROLS AND GAUGES…982
MONITORING SYSTEM…982
SWITCHES…1013
CONTROL LEVERS AND PEDALS…1018
SUN ROOF…1021
WINDSHIELD…1022
EMERGENCY EXIT FROM OPERATOR'S CAB…1027
DOOR LOCK…1027
CAP WITH LOCK…1028
DRINK BOX…1029
MAGAZINE BOX…1030
ASHTRAY…1030
AIR CONDITIONER CONTROLS…1031
RADIO…1046
AUXILIARY ELECTRIC POWER…1051
FUSE…1052
FUSIBLE LINK…1053
CONTROLLER…1053
TOOL BOX…1053
GREASE GUN HOLDER…1054
MACHINE OPERATIONS AND CONTROLS…1055
BEFORE STARTING ENGINE…1055
STARTING ENGINE…1072
AFTER STARTING ENGINE…1075
STOPPING THE ENGINE…1086
MACHINE OPERATION…1087
STEERING THE MACHINE…1091
SWINGING…1093
WORK EQUIPMENT CONTROLS AND OPERATIONS…1094
WORKING MODE…1096
PROHIBITED OPERATIONS…1097
GENERAL OPERATION INFORMATION…1100
TRAVELING ON SLOPES…1101
ESCAPE FROM MUD…1103
RECOMMENDED APPLICATIONS…1104
BUCKET REPLACEMENT AND INVERSION…1106
PARKING MACHINE…1110
MACHINE INSPECTION AFTER DAILY WORK…1111
LOCKING…1112
TRANSPORTATION…1113
TRANSPORTATION PROCEDURE…1113
LOADING AND UNLOADING WITH TRAILER…1114
LIFTING MACHINE…1123
COLD WEATHER OPERATION…1125
COLD WEATHER OPERATION INFORMATION…1125
AFTER DAILY WORK COMPLETION…1128
AFTER COLD WEATHER SEASON…1128
LONG TERM STORAGE…1129
BEFORE STORAGE…1129
DURING STORAGE…1129
AFTER STORAGE…1130
STARTING MACHINE AFTER LONG-TERM STORAGE…1130
TROUBLES AND ACTIONS…1131
RUNNING OUT OF FUEL…1131
PHENOMENA THAT ARE NOT FAILURES…1131
TOWING THE MACHINE…1132
LIGHTWEIGHT TOWING HOLE…1133
SEVERE JOB CONDITION…1133
DISCHARGED BATTERY…1134
OTHER TROUBLE…1138
MAINTENANCE…1144
MAINTENANCE INFORMATION…1145
OUTLINE OF SERVICE…1147
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1147
ELECTRIC SYSTEM MAINTENANCE…1150
WEAR PARTS…1151
WEAR PARTS LIST…1151
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1152
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1154
TIGHTENING TORQUE SPECIFICATIONS…1155
TIGHTENING TORQUE LIST…1155
SAFETY CRITICAL PARTS…1156
SAFETY CRITICAL PARTS LIST…1157
MAINTENANCE SCHEDULE…1158
MAINTENANCE SCHEDULE CHART…1158
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1160
MAINTENANCE PROCEDURE…1161
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…1161
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…1161
WHEN REQUIRED…1162
CHECK BEFORE STARTING…1188
EVERY 100 HOURS MAINTENANCE…1189
EVERY 250 HOURS MAINTENANCE…1190
EVERY 500 HOURS MAINTENANCE…1195
EVERY 1000 HOURS MAINTENANCE…1207
EVERY 2000 HOURS MAINTENANCE…1213
EVERY 4000 HOURS MAINTENANCE…1220
EVERY 5000 HOURS MAINTENANCE…1224
EVERY 8000 HOURS MAINTENANCE…1225
SPECIFICATIONS…1226
SPECIFICATIONS…1227
ATTACHMENTS, OPTIONS…1230
GENERAL PRECAUTIONS FOR SAFETY…1231
PRECAUTIONS WHEN SELECTING…1231
READ THE INSTRUCTION MANUAL THOROUGHLY…1231
PRECAUTIONS WHEN REMOVING OR INSTALLING…1231
PRECAUTIONS WHEN USING…1231
BUCKET WITH HOOK…1232
HOOK CONDITION…1232
PROHIBITED OPERATIONS…1232
MACHINE READY FOR ATTACHMENT…1233
LOCATIONS…1233
HYDRAULIC CIRCUIT…1237
ATTACHMENT REMOVAL AND INSTALLATION…1242
ATTACHMENT OPERATIONS…1246
LONG TERM STORAGE…1247
SPECIFICATIONS…1247
ATTACHMENT GUIDE…1248
OTHER ATTACHMENTS…1249
ATTACHMENT COMBINATIONS…1250
TRACK SHOES SELECTION…1251
BUCKET TEETH SELECTION…1252
RECOMMENDED ATTACHMENT OPERATIONS…1253
HYDRAULIC BREAKER…1253
INDEX…1258
UEAM006800 – Hydraulic Excavator PC160LC-7E0 Operation & Maintenance Manual…1262
FOREWORD…1264
FOREWORD…1265
SAFETY INFORMATION…1267
Vibration levels…1269
INTRODUCTION…1271
DIRECTIONS OF MACHINE…1271
BREAKING-IN THE NEW MACHINE…1271
PRODUCT INFORMATION…1273
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1273
EPA REGULATIONS, ENGINE NUMBER PLATE…1273
SERVICE METER LOCATION…1274
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…1274
MACHINE SERIAL PLATE…1275
FOREWORD…1277
SAFETY…1277
OPERATION…1277
MAINTENANCE…1280
SPECIFICATIONS…1282
ATTACHMENTS AND OPTIONS…1282
INDEX…1283
COLOPHON…1283
SAFETY…1284
SAFETY INFORMATION…1285
SAFETY LABELS…1287
LOCATION OF SAFETY LABELS…1288
SAFETY LABELS…1289
SAFETY INFORMATION…1295
SAFETY MACHINE OPERATION…1305
STARTING ENGINE…1305
OPERATION…1307
TRANSPORTATION…1313
BATTERY…1314
TOWING…1316
LIFTING OBJECTS WITH BUCKET…1317
SAFETY MAINTENANCE INFORMATION…1318
OPERATION…1326
MACHINE VIEW ILLUSTRATIONS…1327
OVERALL MACHINE VIEW…1327
CONTROLS AND GAUGES…1328
DETAILED CONTROLS AND GAUGES…1330
MONITORING SYSTEM…1330
Basic Operation of Machine Monitor…1331
Emergency Monitors…1335
Caution Monitors…1337
Basic Check Monitors…1340
Meter Display Portion…1342
Monitor Switches Portion…1347
SWITCHES…1360
CONTROL LEVERS AND PEDALS…1364
SUN ROOF…1367
WINDSHIELD…1367
EMERGENCY EXIT FROM OPERATOR'S CAB…1372
DOOR LOCK…1372
CAP WITH LOCK…1373
DRINK BOX…1374
MAGAZINE BOX…1375
ASHTRAY…1375
AIR CONDITIONER CONTROLS…1376
Air Conditioner Control Panel…1376
Method of Operation…1381
Use Air Conditioner with Care…1388
Air Conditioner Maintenance…1388
Other Functions…1388
RADIO…1390
Control Panel…1390
Controls of Radio…1392
Use Radio with Care…1394
When the battery is replaced, the settings for the preset buttons are all cleared, so set them again…1394
AUXILIARY ELECTRIC POWER…1395
24V Power Source…1395
12V Power Source…1395
FUSE…1396
FUSIBLE LINK…1397
CONTROLLER…1397
TOOL BOX…1397
GREASE GUN HOLDER…1397
REFUELLING PUMP…1398
MACHINE OPERATIONS AND CONTROLS…1399
BEFORE STARTING ENGINE…1399
Walk-around Checks…1399
Checks Before Starting…1401
Adjustment…1408
Seat Belt…1412
Operations Before Starting Engine…1413
STARTING ENGINE…1416
AMBIENT TEMPERATURE RANGE FOR OPERATION…1418
AFTER STARTING ENGINE…1419
Checking of Engine Startability and Noise…1419
Checking of Engine Acceleration and Deceleration…1419
Engine Warm Up…1420
Hydraulic Equipment Warm Up…1422
Operation After Completion Of Warm-Up Operation…1428
STOPPING THE ENGINE…1430
MACHINE OPERATION…1431
Preparations for Moving the Machine…1431
Moving Machine Forward…1432
Moving Machine Backward…1433
Stopping Machine…1434
STEERING THE MACHINE…1435
Steering…1435
SWINGING…1437
WORK EQUIPMENT CONTROLS AND OPERATIONS…1438
WORKING MODE…1439
PROHIBITED OPERATIONS…1440
GENERAL OPERATION INFORMATION…1442
TRAVELING ON SLOPES…1443
ESCAPE FROM MUD…1445
Track on One Side Stuck…1445
Tracks on Both Sides Stuck…1445
RECOMMENDED APPLICATIONS…1446
Backhoe Work…1446
Shovel Work…1446
Ditching Work…1446
Loading Work…1447
BUCKET REPLACEMENT AND INVERSION…1448
Replacement…1448
Inversion…1450
PARKING MACHINE…1451
MACHINE INSPECTION AFTER DAILY WORK…1452
LOCKING…1453
TRANSPORTATION…1454
TRANSPORTATION PROCEDURE…1454
LOADING AND UNLOADING WITH TRAILER…1455
Loading…1456
Securing Machine…1459
Unloading…1462
LIFTING MACHINE…1464
COLD WEATHER OPERATION…1466
COLD WEATHER OPERATION INFORMATION…1466
Fuel and Lubricants…1466
Cooling System Coolant…1466
Battery…1467
Monitor…1468
AFTER DAILY WORK COMPLETION…1469
AFTER COLD WEATHER SEASON…1469
LONG TERM STORAGE…1470
BEFORE STORAGE…1470
DURING STORAGE…1470
AFTER STORAGE…1471
STARTING MACHINE AFTER LONG-TERM STORAGE…1471
TROUBLES AND ACTIONS…1472
RUNNING OUT OF FUEL…1472
PHENOMENA THAT ARE NOT FAILURES…1472
TOWING THE MACHINE…1473
LIGHTWEIGHT TOWING HOLE…1474
SEVERE JOB CONDITION…1474
DISCHARGED BATTERY…1475
Battery Removal and Installation…1475
Battery Charges…1476
Starting Engine with Booster Cables…1477
OTHER TROUBLE…1479
Electrical System…1479
Chassis…1480
Engine…1481
Electronic Control System…1482
Point of Contact to Telephone when Error Occurs…1483
MAINTENANCE…1484
MAINTENANCE INFORMATION…1485
OUTLINE OF SERVICE…1487
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1487
Oil…1487
Fuel…1488
Antifreeze Coolant and Water for Dilution…1488
Grease…1489
Carrying Out KOWA (Komatsu Oil Wear Analysis)…1489
Oil and Fuel Storage…1490
Filters…1490
ELECTRIC SYSTEM MAINTENANCE…1490
WEAR PARTS…1491
WEAR PARTS LIST…1491
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1492
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1494
TIGHTENING TORQUE SPECIFICATIONS…1495
TIGHTENING TORQUE LIST…1495
SAFETY CRITICAL PARTS…1496
SAFETY CRITICAL PARTS LIST…1497
MAINTENANCE SCHEDULE…1498
MAINTENANCE SCHEDULE CHART…1498
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1500
MAINTENANCE PROCEDURE…1501
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…1501
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…1501
WHEN REQUIRED…1502
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1502
CLEAN INSIDE OF COOLING SYSTEM…1508
CHECK AND TIGHTEN TRACK SHOE BOLTS…1511
CHECK AND ADJUST TRACK TENSION…1512
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…1514
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…1517
ADJUST BUCKET CLEARANCE…1519
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1520
CHECK AND MAINTENANCE AIR CONDITIONER…1521
WASH WASHABLE FLOOR…1522
CHECK GAS SPRING…1525
BLEEDING AIR FROM HYDRAULIC SYSTEM…1526
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…1528
CHECK BEFORE STARTING…1529
EVERY 100 HOURS MAINTENANCE…1530
LUBRICATING…1530
EVERY 250 HOURS MAINTENANCE…1531
CHECK LEVEL OF BATTERY ELECTROLYTE…1531
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…1533
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…1534
EVERY 500 HOURS MAINTENANCE…1535
LUBRICATING…1535
LUBRICATE SWING CIRCLE…1536
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…1537
REPLACE FUEL PRE-FILTER CARTRIDGE…1539
CHECK SWING PINION GREASE LEVEL, ADD GREASE…1541
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (only machines equipped with air conditioner)…1542
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…1544
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…1546
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1547
EVERY 1000 HOURS MAINTENANCE…1548
REPLACE HYDRAULIC OIL FILTER ELEMENT…1548
CHANGE OIL IN SWING MACHINERY CASE…1549
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…1550
REPLACE FUEL MAIN FILTER CARTRIDGE…1551
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS…1553
CHECK FAN BELT TENSION AND REPLACE FAN BELT…1553
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)…1553
EVERY 2000 HOURS MAINTENANCE…1554
CHANGE OIL IN FINAL DRIVE CASE…1554
CLEAN HYDRAULIC TANK STRAINER…1555
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)…1556
CHECK ALTERNATOR, STARTING MOTOR…1560
CHECK ENGINE VALVE CLEARANCE, ADJUST…1560
EVERY 4000 HOURS MAINTENANCE…1561
CHECK WATER PUMP…1561
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)…1562
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER…1563
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…1563
CHECK OPERATING CONDITION OF COMPRESSOR…1564
EVERY 5000 HOURS MAINTENANCE…1565
CHANGE OIL IN HYDRAULIC TANK…1565
EVERY 8000 HOURS MAINTENANCE…1566
REPLACE FUEL SPRAY PREVENTION CAP…1566
REPLACE HIGH-PRESSURE PIPING CLAMP…1566
SPECIFICATIONS…1568
SPECIFICATIONS…1569
EXPLANATION OF LIFTING CAPACITY CHART…1571
MONOBOOM (PC160LC- 7E0KA)…1571
ATTACHMENTS AND OPTIONS…1574
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1575
SAFETY FIRST…1575
ATTACHMENT INSTALLATION…1577
BUCKET WITH HOOK…1578
HOOK CONDITION…1578
PROHIBITED OPERATIONS…1578
MACHINE READY FOR ATTACHMENT (DELUXE HCU SYSTEM)…1579
LOCATIONS…1579
HYDRAULIC CIRCUIT…1582
Switching Hydraulic Circuit…1582
Adjusting Oil Flow…1582
Switching Between Breaker and General Attachment…1582
HYDRAULIC CIRCUIT CONNECTION…1583
PATH OF OIL…1583
ATTACHMENT REMOVAL AND INSTALLATION…1584
Attachment Removal…1584
ATTACHMENT OPERATIONS…1586
When Using Breaker…1586
When Using General Attachment Such as Crusher…1587
LONG TERM STORAGE…1587
SPECIFICATIONS…1587
ATTACHMENT GUIDE…1588
OTHER ATTACHMENTS…1588
ATTACHMENT COMBINATIONS…1590
BUCKET TEETH SELECTION…1591
Teeth Selection…1591
Selection Guide for Horizontal or Vertical Pin Type Tooth…1591
RECOMMENDED ATTACHMENT OPERATIONS…1592
HYDRAULIC BREAKER…1592
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1596
BASIC PRECAUTIONS…1596
HYDRAULIC QUICK COUPLER PIPING…1597
LOCATIONS…1597
OPERATION…1598
INDEX…1600
<A>…1602
<B>…1602
<C>…1602
<D>…1602
<E>…1602
<F>…1602
<G>…1602
<H>…1602
<K>…1602
<L>…1602
<M>…1602
<O>…1603
<P>…1603
<R>…1603
<S>…1603
<T>…1603
<W>…1603
<Y>…1603
COLOPHON…1604
UEN01892-04 – Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Shop Manual…1606
Cover…1606
00 Index and foreword…1608
Index…1608
Composition of shop manual…1609
Table of contents…1611
00 Index and foreword…1620
Foreword and general information…1620
Safety notice…1621
How to read the shop manual…1626
Explanation of terms for maintenance standard…1628
Handling electric equipment and hydraulic component…1630
How to read electric wire code…1642
Precautions when carrying out operation…1645
Method of disassembling and connecting push-pull type coupler…1648
Standard tightening torque table…1651
Conversion table…1655
01 Specification…1662
Specification and technical data…1662
Specification dimension drawings…1663
Specifications…1665
Weight table…1667
Table of fuel, coolant and lubricants…1669
Engine related parts…1673
Radiator, oil cooler, aftercooler and fuel cooler…1674
10 Structure, function and maintenance standard…1672
Engine and cooling system…1672
Power train…1677
Swing circle…1678
Swing machinery…1679
Final drive…1681
Sprocket…1683
10 Structure, function and maintenance standard…1676
Power train system…1676
Track frame, recoil spring…1687
Idler…1689
Carrier roller…1691
Track roller…1692
Track shoe…1693
10 Structure, function and maintenance standard…1686
Undercarriage and frame…1686
Hydraulic equipment layout drawing…1699
Hydraulic tank…1701
Hydraulic pump…1703
10 Structure, function and maintenance standard…1698
Hydraulic system, Part 1…1698
Control valve…1731
CLSS…1745
Functions and operation by valve…1749
Hydraulic drift prevention valve…1773
10 Structure, function and maintenance standard…1730
Hydraulic system, Part 2…1730
Valve control…1791
PPC valve…1792
Solenoid valve…1809
Accumulator…1811
Return oil filter…1812
Centre swivel joint…1813
Travel motor…1814
Swing motor…1824
Attachment circuit selector valve…1825
Quick coupler control valve…1829
Hydraulic cylinder…1831
10 Structure, function and maintenance standard…1790
Hydraulic system, Part 3…1790
Work equipment…1835
Work equipment (2 Piece Boom)…1836
Dimensions of components…1839
10 Structure, function and maintenance standard…1834
Work equipment…1834
Air conditioner piping…1845
10 Structure, function and maintenance standard…1844
Cab and its attachments…1844
Engine control…1849
Electronic control system…1858
Monitor system…1884
Sensor…1902
KOMTRAX terminal system…1905
10 Structure, function and maintenance standard…1848
Electrical system…1848
Standard value table for engine…1909
Standard value table for chassis related parts…1910
20 Standard value table…1908
Standard service value table…1908
30 Testing and adjusting…1924
Testing and adjusting, Part 1…1924
Tools for testing, adjusting, and troubleshooting…1925
Measuring engine speed…1928
Measuring intake air pressure (boost pressure)…1929
Checking exhaust gas colour…1930
Adjusting valve clearance…1931
Measuring compression pressure…1933
Measurement of blow-by pressure…1935
Measuring engine oil pressure…1936
Handling fuel system parts…1937
Releasing residual pressure from fuel system…1937
Measuring fuel pressure…1938
Measuring fuel discharge, return and leakage…1940
Bleeding air from fuel circuit…1944
Checking fuel circuit for leakage…1946
Checking and adjusting air conditioner compressor belt tension…1947
Replacing the fan belt…1948
30 Testing and adjusting…1950
Testing and adjusting, Part 2…1950
Measurement of clearance in swing circle bearings…1951
Checking and adjusting track shoe tension…1952
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits…1953
Inspection and adjustment of control circuit oil pressure…1956
Inspection and adjustment of pump PC control circuit oil pressure…1957
Inspection and adjustment of pump LS control circuit oil pressure…1960
Measurement of solenoid valve output pressure…1964
Measurement of PPC valve output pressure…1967
Adjustment of work equipment and swing PPC valve…1968
Measuring and adjusting quick coupler control valve output pressure…1969
Inspection of locations of hydraulic drift of work equipment…1970
Testing and adjusting travel deviation…1972
Release of residual pressure from hydraulic circuit…1974
Measurement of oil leakage…1975
Bleeding air from each part…1977
Inspection procedures for diode…1979
Adjusting mirrors…1980
Special functions of machine monitor…1985
Handling voltage circuit of engine controller…2013
Procedure for turning on KOMTRAX terminal…2014
Indication by KOMTRAX terminal lamps…2017
Preparation work for troubleshooting of electrical system…2020
30 Testing and adjusting…1984
Testing and adjusting, Part 3…1984
Failure code table…2029
Fuse locations…2032
40 Troubleshooting…2028
Failure code table and fuse locations…2028
40 Troubleshooting…2036
General information on troubleshooting…2036
Points to remember when troubleshooting…2037
Sequence of events in troubleshooting…2038
Checks before troubleshooting…2039
Classification and troubleshooting steps…2040
Information in troubleshooting table…2041
Possible problems and troubleshooting No…2043
Wiring table for connector pin numbers…2046
T-adapter box and T-adapter table…2075
40 Troubleshooting…2080
Troubleshooting by failure code, Part 1…2080
Failure code [AA10NX] Air cleaner clogging…2082
Failure code [AB00KE] Charge voltage low…2083
Failure code [B@BAZG] Eng. oil press. low…2085
Failure code [B@BAZK] Eng. oil level low…2086
Failure code [B@BCNS] Eng. coolant overheat…2087
Failure code [B@BCZK] Eng. coolant level low…2089
Failure code [B@HANS] Hydr oil overheat…2091
Failure code [CA111] EMC critical internal failure…2091
Failure code [CA115] Eng Ne and bkup speed sens error…2092
Failure code [CA122] Chg air press sensor high error…2094
Failure code [CA123] Chg air press sensor low error…2096
Failure code [CA131] Throttle sensor high error…2098
Failure code [CA132] Throttle sensor low error…2100
Failure code [CA144] Coolant temp sens high error…2102
Failure code [CA145] Coolant temp sens low error…2104
Failure code [CA153] Chg air temp sensor high error…2106
Failure code [CA154] Chg air temp sensor low error…2108
Failure code [CA155] Chg air temp high speed derate…2110
Failure code [CA187] Sens supply 2 volt low error…2112
Failure code [CA221] Ambient press sens high error…2114
Failure code [CA222] Ambient press sens low error…2116
Failure code [CA227] Sens supply 2 volt high error…2118
Failure code [CA234] Eng. overspeed…2119
Failure code [CA238] Ne speed sens supply volt error…2120
Failure code [CA271] IMV/PCV1 short error…2121
Failure code [CA272] IMV/PCV1 open error…2122
Failure code [CA322] Inj #1 open/short error…2124
Failure code [CA324] Inj #3 open/short error…2126
40 Troubleshooting…2130
Troubleshooting by failure code, Part 2…2130
Failure code [CA331] Inj #2 open/short error…2133
Failure code [CA332] Inj #4 open/short error…2135
Failure code [CA342] Calibration code incompatibility…2137
Failure code [CA351] Injectors drive circuit error…2139
Failure code [CA352] Sens supply 1 volt low error…2141
Failure code [CA386] Sens supply 1 volt high error…2143
Failure code [CA428] Water in fuel sensor high error…2145
Failure code [CA429] Water in fuel sensor low error…2147
Failure code [CA435] Eng oil press sw error…2149
Failure code [CA441] Engine controller battery voltage low error…2151
Failure code [CA442] Engine controller battery voltage high error…2153
Failure code [CA449] Rail press very high error…2155
Failure code [CA451] Rail press sensor high error…2157
Failure code [CA452] Rail press sensor low error…2159
Failure code [CA488] Chg air temp high torque derate…2161
Failure code [CA553] Rail press high error…2161
Failure code [CA559] Rail press low error…2162
Failure code [CA689] Eng Ne speed sensor error…2163
Failure code [CA731] Eng Bkup speed sens phase error…2165
Failure code [CA757] All continuous data lost error…2167
Failure code [CA778] Eng Bkup speed sensor error…2169
Failure code [CA1633] KOMNET Datalink timeout error…2171
Failure code [CA2185] Throt sens sup volt high error…2173
Failure code [CA2186] Throt sens sup volt low error…2174
Failure code [CA2249] Rail press very low error…2175
Failure code [CA2311] IMV solenoid error…2177
Failure code [CA2555] Grid htr relay volt high error…2179
Failure code [CA2556] Grid htr relay volt low error…2181
Failure code [D110KB] Battery relay drive S/C…2185
Failure code [D196KA] Service return relay disc…2187
Failure code [D196KB] Service return relay S/C…2189
Failure code [DA22KK] Pump solenoid power low error…2191
Failure code [DA25KP] Press. sensor power abnormality…2193
Failure code [DA2RMC] Pump comm. abnormality…2195
Failure code [DA2SKQ] Model selection abnormality…2197
Failure code [DAFRMC] Monitor comm. abnormality…2199
Failure code [DGH2KB] Hydr oil sensor short…2201
Failure code [DHPAMA] F pump press sensor abnormality…2203
Failure code [DHPBMA] R pump press sensor abnormality…2205
Failure code [DHSAMA] Sw RH PPC press sen. abnormality…2207
Failure code [DHSBMA] Sw LH PPC press sen. abnormality…2209
40 Troubleshooting…2184
Troubleshooting by failure code, Part 3…2184
Failure code [DW43KA] Travel speed sol. disc…2215
Failure code [DW43KB] Travel speed sol. S/C…2217
Failure code [DW45KA] Swing brake sol. disc…2219
Failure code [DW45KB] Swing brake sol. S/C…2223
Failure code [DW91KA] Travel junction sol. disc…2225
Failure code [DW91KB] Travel junction sol. S/C…2227
Failure code [DWJ0KA] Merge-divider sol. disc…2229
Failure code [DWJ0KB] Merge-divider sol. S/C…2231
Failure code [DWK0KA] 2-stage relief sol. disc…2233
Failure code [DWK0KB] 2-stage relief sol. S/C…2235
Failure code [DXA0KA] PC-EPC sol. disc…2237
Failure code [DXA0KB] PC-EPC sol. S/C…2239
Failure code [DXE4KA] Service current EPC disc…2241
Failure code [DXE4KB] Service current EPC S/C…2242
Failure code [DY20KA] Wiper working abnormality…2243
Failure code [DY20MA] Wiper parking abnormality…2245
Failure code [DY2CKB] Washer drive S/C…2247
Failure code [DY2DKB] Wiper drive (for) S/C…2249
Failure code [DY2EKB] Wiper drive (rev) S/C…2251
40 Troubleshooting…2212
Troubleshooting by failure code, Part 4…2212
40 Troubleshooting…2254
Troubleshooting of electrical system (E-mode)…2254
Before carrying out troubleshooting of electrical system…2256
Information contained in troubleshooting table…2258
E-1 Engine does not start…2259
E-2 Auto-decelerator does not operate…2262
E-3 Automatic warming-up system does not operate…2264
E-4 Preheater does not operate…2265
E-5 All work equipment, swing, and travel mechanism do not move…2267
E-6 Power maximizing function does not operate…2269
E-7 Machine monitor does not display at all…2271
E-8 Machine monitor does not display some items…2273
E-9 Contents of display by machine monitor are different from applicable machine…2273
E-10 Fuel level monitor was lighted in red while engine running…2274
E-11 Engine coolant temperature gauge does not indicate normally…2275
E-12 Hydraulic oil temperature gauge does not indicate normally…2277
E-13 Fuel level gauge does not indicate normally…2279
E-14 Swing lock monitor does not indicate normally…2281
E-15 When monitor switch is operated, monitor displays nothing…2283
E-16 Windshield wiper and window washer do not operate…2285
E-17 Monitoring function fails to display “boom raise” normally…2289
E-18 Monitoring function fails to display “boom lower” normally…2291
E-19 Monitoring function fails to display “arm IN” normally…2293
E-20 Monitoring function fails to display “arm OUT” normally…2295
E-21 Monitoring function fails to display “bucket CURL” normally…2297
E-22 Monitoring function fails to display “bucket DUMP” normally…2299
E-23 Monitoring function fails to display “swing left” normally…2301
E-24 Monitoring function fails to display "swing right" normally…2303
E-25 Monitoring function fails to display “travel” normally…2305
E-26 Monitoring function fails to display “travel differential pressure” normally…2307
E-27 Monitoring function fails to display “service” normally…2309
E-28 KOMTRAX system does not operate normally…2311
E-29 Air conditioner does not operate…2313
E-30 Travel alarm does not sound or does not stop sounding…2315
E-31 Horn does not sound…2317
E-32 Attachment circuit does not change…2319
Information contained in troubleshooting table…2324
System chart for hydraulic and mechanical systems…2325
H-1 Speed or power of all work equipment, swing, and travel are low…2327
H-2 Engine speed sharply drops or engine stalls…2328
H-3 No work equipment, travel and swing move…2329
H-4 Abnormal noise is heard from around hydraulic pump…2329
H-5 Auto-decelerator does not work…2330
H-6 Fine control mode does not function…2330
H-7 Speed or power of boom is low…2331
H-8 Speed or power of arm is low…2332
H-9 Speed or power of bucket is low…2333
H-10 Work equipment does not move in its single operation…2334
H-11 Hydraulic drift of work equipment is large…2335
H-12 Time lag of work equipment is large…2336
H-13 One-touch power max system does not operate…2336
H-14 Work equipment loaded more is slower during compound operation…2337
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE…2337
H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel…2338
H-17 Machine deviates during travel…2339
H-18 Travel speed is low…2340
H-19 Machine cannot be steered easily or steering power is low…2341
H-20 Travel speed does not change or it is kept low or high…2342
H-21 Track does not move (Only either side)…2342
H-22 Machine does not swing…2343
H-23 Swing acceleration or swing speed is low…2344
H-24 Excessive overrun when stopping swing…2345
H-25 When upper structure stops swinging, it makes large shock…2346
H-26 When upper structure stops swinging, it makes loud sound…2346
H-27 Hydraulic drift of swing is large…2347
H-28 Attachment circuit does not change…2348
H-29 Flow rate in attachment circuit cannot be adjusted…2348
Quick coupler…2349
40 Troubleshooting…2322
Troubleshooting of hydraulic and mechanical system (H-mode)…2322
40 Troubleshooting…2352
Troubleshooting of engine (S-mode)…2352
Method of using troubleshooting chart…2354
S-1 Starting performance is poor…2357
S-2 Engine does not start…2358
S-3 Engine does not pick up smoothly…2361
S-4 Engine stops during operations…2362
S-5 Engine does not rotate smoothly…2363
S-6 Engine lack output (or lacks power)…2364
S-7 Exhaust smoke is black (incomplete combustion)…2365
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2366
S-9 Oil becomes contaminated quickly…2367
S-10 Fuel consumption is excessive…2368
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…2369
S-12 Oil pressure drops…2370
S-13 Oil level rises (Entry of coolant/fuel)…2371
S-14 Coolant temperature becomes too high (overheating)…2372
S-15 Abnormal noise is made…2373
S-16 Vibration is excessive…2374
50 Disassembly and assembly…2376
General information on disassembly and assembly…2376
How to read this manual…2377
List of adhesives…2379
Special tool list…2382
Sketches of special tools…2385
Removal and installation of fuel supply pump assembly…2389
Removal and installation of fuel injector assembly…2392
Removal and installation of front oil seal…2397
Removal and installation of rear oil seal…2399
Removal and installation of cylinder head assembly…2402
Removal and installation of radiator assembly…2412
Removal and installation of aftercooler assembly…2414
Removal and installation of work equipment oil cooler assembly…2416
Removal and installation of engine and hydraulic pump assembly…2418
50 Disassembly and assembly…2388
Engine and cooling system…2388
Removal and installation of engine hood assembly…2425
Removal and installation of fuel tank assembly…2427
Removal and installation of travel motor and final drive assembly…2431
Disassembly and assembly of final drive assembly…2432
Removal and installation of swing motor and swing machinery assembly…2439
Disassembly and assembly of swing motor and swing machinery assembly…2441
Removal and installation of swing circle assembly…2449
50 Disassembly and assembly…2430
Power train…2430
Disassembly and assembly of carrier roller…2453
Disassembly and assembly of track roller assembly…2456
Disassembly and assembly of idler assembly…2458
Disassembly and assembly of recoil spring…2461
Expansion and installation of track shoe assembly…2463
Removal and installation of sprocket…2465
Removal and installation of revolving frame assembly…2466
Removal and installation of counterweight…2468
50 Disassembly and assembly…2452
Undercarriage and frame…2452
Removal and installation of centre swivel joint assembly…2471
Disassembly and assembly of centre swivel joint assembly…2473
Removal and installation of hydraulic tank assembly…2474
Removal and installation of hydraulic pump assembly…2477
Removal and installation of control valve assembly…2480
Disassembly and assembly of control valve assembly…2484
Removal and installation of hydraulic pump input shaft oil seal…2486
Disassembly and assembly of work equipment PPC valve assembly…2487
Disassembly and assembly of travel PPC valve assembly…2488
Disassembly and assembly of hydraulic cylinder assembly…2489
Disassembly and Assembly of Quick Coupler Valve…2495
50 Disassembly and assembly…2470
Hydraulic system…2470
Removal and installation of work equipment assembly…2499
50 Disassembly and assembly…2498
Work equipment Body…2498
Removal and installation of operator’s cab…2505
Removal and installation of operator's cab glass (Stuck glass)…2508
Removal and installation of front window assembly…2519
Removal and installation of floor frame assembly…2525
50 Disassembly and assembly…2504
Cab and its attachments…2504
Removal and installation of air conditioner compressor assembly…2531
Removal and installation of air conditioner condenser…2532
Removal and installation of air conditioner unit assembly…2533
Removal and installation of machine monitor assembly…2535
Removal and installation of governor, pump controller assembly…2536
Removal and installation of engine controller assembly…2537
Removal and installation of KOMTRAX assembly…2538
50 Disassembly and assembly…2530
Electrical system…2530
90 Diagrams and drawings…2540
Hydraulic circuit diagram…2540
Hydraulic circuit diagram 1/2…2542
Hydraulic circuit diagram 2/2…2544
90 Diagrams and drawings…2548
Electrical circuit diagram…2548
Electrical circuit diagram (1/5)…2550
Electrical circuit diagram (2/5)…2552
Electrical circuit diagram (3/5)…2554
Electrical circuit diagram (4/5)…2556
Electrical circuit diagram (5/5)…2558
Connector arrangement diagram…2560
Komatsu Hydraulic Excavator PC160LC-E0, PC180LC-E0, PC180NLC-E0 Workshop Service Repair Manuals