Professional-Grade Komatsu PC160LC-7K & PC180LC-7K Workshop Manual - Precision Maintenance & Repair Procedures

Komatsu PC160LC-7K & PC180LC-7K Shop Manual - Comprehensive Guide for Excavator Operation and Maintenance

Professional-grade maintenance and repair require more than just basic knowledge. This comprehensive Shop Manual (UEBM002200) is the definitive technical resource for the Komatsu PC160LC-7K and PC180LC-7K hydraulic excavators. Whether you are performing a routine oil change or a complex hydraulic pump overhaul, this manual provides the factory-sanctioned procedures and specifications you need to get the job done right.

Model Coverage & Serial Numbers

This manual is specifically engineered for the following Komatsu models:

• PC160LC-7K (2003) – Serial Number: K40001 and up
• PC180LC-7K (2003) – Serial Number: K40001 and up

Both models feature the high-performance SAA4D102E-2 4-cylinder, direct injection, turbocharged, after-cooled diesel engine.

Why This Manual is Essential for Every Owner

Maximize your uptime and minimize repair costs. This manual offers deep-dive technical data that goes far beyond a standard operator's guide. You will find precise "Judgment Standards" for inspecting disassembled parts, helping you decide whether to reuse, repair, or replace a component.

Key Technical Specifications Included:

• Engine Performance: Detailed horsepower (82 kW / 111 HP @ 2,200 rpm) and torque (451 Nm @ 1,500 rpm) ratings.
• Hydraulic System: Full data on the HPD71 variable capacity piston pump, including set pressures of 31.4 MPa {320 kg/cm2}.
• Weights & Capacities: Critical data for transport and fluid management, including cooling system capacity (18.6 liters) and hydraulic system refill volumes (121 liters).
• Working Ranges: Digging reach, depth (up to 5,960 mm), and dumping heights to ensure you are operating within the machine's designed limits.

What’s Inside

• General Information: Machine dimensions, performance specs, and a complete weight table for all major components.
• Structure & Function: Exploded views and explanations of how systems like the CLSS (Closed-center Load Sensing System) and various valves (Boom/Arm regeneration) actually work.
• Testing & Adjusting: Step-by-step guides for checking pump PC control oil pressure, adjusting valve clearance, and fine-tuning PPC valves.
• Troubleshooting: Detailed charts correlating symptoms (like low swing power or slow work equipment) with specific mechanical and hydraulic causes.
• Disassembly & Assembly: Professional procedures for removing and installing components, including torque specifications and special tool requirements.
• Maintenance Standards: Precise clearance limits (e.g., Center Swivel Joint clearances) and spring free-length data to ensure factory-spec rebuilds.

Comprehensive Table of Contents

1. General: Specifications, weight tables, and fluid charts.
2. Structure, Function & Maintenance Standard: Detailed look at the engine, power train, swing machinery, and hydraulic equipment.
3. Testing & Adjusting: Performance testing, circuit pressure measurements, and mechanical adjustments.
4. Troubleshooting: Correlation of problems to causes for mechanical, hydraulic, and electrical systems.
5. Disassembly & Assembly: Step-by-step component removal and installation procedures.

Equip yourself with the same information used by factory-trained technicians. This manual is optimized for digital viewing, making it easy to reference specifications directly on your mobile device while you are at the machine.