PW180-7E0_S_CSS-NET_23-01-2007.pdf

2007 All Rights ReservedPrinted in Europe 01-07

This shop manual may contain attachments and optional equipment that are not available inyour area. Please consult your local Komatsu distributor for those items you may require.

Materials and specifications are subject to change without notice. PW180-7E0 mount the SAA6D107E-1 engine. For details of the engine, see the 107 Series Engine Shop Manual.

MACHINE MODEL SERIAL NUMBERPW180-7E0 00 H55051 AND UP 00

CONTENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. of page

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . 10-1

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

90 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00

FOREWORD SAFETYSAFETY

SAFETY NOTICE

GENERAL PRECAUTIONSMistakes in operation are extremely dangerous. Readthe OPERATION & MAINTENANCE MANUAL carefullyBEFORE operating the machine.

1. Before carrying out any greasing or repairs, readall the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, always wearsafety shoes and helmet. Do not wear loose workclothes, or clothes with buttons missing.

Always wear safety glasses when hitting parts witha hammer.

Always wear safety glasses when grinding partswith a grinder, etc.

3. If welding repairs are needed, always have atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, glasses, cap and otherclothes suited for welding work.

4. When carrying out any operation with two or moreworkers, always agree on the operating procedurebefore starting. Always inform your fellow workersbefore starting any step of the operation. Beforestarting work, hang UNDER REPAIR signs on thecontrols in the operators compartment.

5. Keep all tools in good condition and learn the cor-rect way to use them.

6. Decide a place in the repair workshop to keep toolsand removed parts. Always keep the tools andparts in their correct places. Always keep the workarea clean and make sure that there is no dirt or oilon the floor. Smoke only in the areas provided forsmoking. Never smoke while working.

PREPARATIONS FOR WORK 001. Before adding oil or making repairs, park the

machine on hard, level ground, and block thewheels or tracks to prevent the machine from mov-ing.

2. Before starting work, lower blade, ripper, bucket orany other work equipment to the ground. If this isnot possible, insert the safety pin or use blocks toprevent the work equipment from falling. In addi-tion, be sure to lock all the control levers and hangwarning signs on them.

3. When disassembling or assembling, support themachine with blocks, jacks or stands before start-ing work.

4. Remove all mud and oil from the steps or otherplaces used to get on and off the machine. Alwaysuse the handrails, ladders or steps when getting onor off the machine. Never jump on or off themachine. If it is impossible to use the handrails,ladders or steps, use a stand to provide safe foot-ing.

IMPORTANT SAFETY NOTICEProper service and repair is extremely important for the safe operation of your machine. The service and repairtechniques recommended and described in this manual are both effective and safe methods of operation. Someof these operations require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautionsaccompanying these symbols should always be followed carefully. If any dangerous situation arises or may possi-bly arise, first consider safety, and take the necessary actions to deal with the situation.PW180-7E0 00-1

FOREWORD SAFETYPRECAUTIONS DURING WORK1. When removing the oil filler cap, drain plug or

hydraulic pressure measuring plugs, loosen themslowly to prevent the oil from spurting out. Beforedisconnecting or removing components of the oil,water or air circuits, first remove the pressure com-pletely from the circuit.

2. The water and oil in the circuits are hot when theengine is stopped, so be careful not to get burned.Wait for the oil and water to cool before carryingout any work on the oil or water circuits.

3. Before starting work, remove the leads from thebattery. ALWAYS remove the lead from the nega-tive (-) terminal first.

4. When raising heavy components, use a hoist orcrane. Check that the wire rope, chains and hooksare free from damage. Always use lifting equip-ment which has ample capacity. Install the liftingequipment at the correct places. Use a hoist orcrane and operate slowly to prevent the compo-nent from hitting any other part. Do not work withany part still raised by the hoist or crane.

5. When removing covers which are under internalpressure or under pressure from a spring, alwaysleave two bolts in position on opposite sides.Slowly release the pressure, then slowly loosen thebolts to remove.

6. When removing components, be careful not tobreak or damage the wiring, Damaged wiring maycause electrical fires.

7. When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips on to the floor,wipe it up immediately. Fuel or oil on the floor cancause you to slip, or can even start fires.

8. As a general rule, do not use gasoline to washparts. In particular, use only the minimum of gaso-line when washing electrical parts.

9. Be sure to assemble all parts again in their originalplaces. Replace any damaged part with new parts.

When installing hoses and wires, be sure that theywill not be damaged by contact with other partswhen the machine is being operated.

10. When installing high pressure hoses, make surethat they are not twisted. Damaged tubes are dan-gerous, so be extremely careful when installingtubes for high pressure circuits. Also check thatconnecting parts are correctly installed.

11. When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be particu-larly careful to check that they are installed cor-rectly.

12. When aligning two holes, never insert your fingersor hand. Be careful not to get your fingers caught ina hole.

13. When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

14. Take care when removing or installing the tracks oftrack-type machines. When removing the track, thetrack separates suddenly, so never let anyonestand at either end of the track.00-2 PW180-7E0

FOREWORD LIST OF REVISED PAGESThe affected pages are indicated by the use of thefollowing marks. It is requested that necessaryactions be taken to these pages according to thetable below.

Pages having no marks are those previously revisedor made additions.

LIST OF REVISED PAGES

Mark Indication Action required

Page to be newly added Add

Page to be replaced Replace

() Page to be deleted Discard

Mark Page Time of revision





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FOREWORD GENERALGENERALThis shop manual has been prepared as an aid toimprove the quality of repairs by giving the servicemanan accurate understanding of the product and by show-ing him the correct way to perform repairs and makejudgements. Make sure you understand the contents ofthis manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary tech-nical information for operations performed in a serviceworkshop. For ease of understanding, the manual isdivided into the following sections. These sections arefurther divided into each main group of components.GENERAL

This section lists the general machine dimensions,performance specifications, component weights,and fuel, coolant and lubricant specification charts.

STRUCTURE AND FUNCTIONThis section explains the structure and function ofeach component. It serves not only to give anunderstanding of the structure, but also serves asreference material for troubleshooting.

TESTING, ADJUSTING AND TROUBLESHOOTINGThis section explains checks to be made beforeand after performing repairs, as well as adjust-ments to be made at completion of the checks andrepairs. Troubleshooting charts correlating Prob-lems to Causes are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the order to be followed whenremoving, installing, disassembling or assemblingeach component, as well as precautions to betaken for these operations.

MAINTENANCE STANDARDThis section gives the judgement standards wheninspecting disassembled parts.

NOTICEThe specifications contained in this shop manual are subject to change at any time and without any

advance notice. Contact your distributor for the latest information.PW180-7E0 00-3

FOREWORD HOW TO READ THE SHOP MANUALHOW TO READ THE SHOP MANUALVOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume:Issued for every machine modelEngine volume:Issued for each engine seriesElectrical volume:Each issued as one to cover allmodelsAttachment volume:Each issued as one to cover allmodels

These various volumes are designed to avoid duplica-tion of information. Therefore to deal with all repairs forany model, it is necessary that chassis, engine, electri-cal and attachment be available.

DISTRIBUTION AND UPDATINGAny additions, amendments or other changes will besent to your distributors. Get the most up-to-date infor-mation before you start any work.

FILING METHOD

1. See the page number on the bottom of the page.File the pages in correct order.

2. Following examples show how to read the pagenumber:

Example:

10 - 3

Item number (10. Structure and Function)Consecutive page number for each item

3. Additional pages: Additional pages are indicated bya hyphen (-) and numbered after the page number.File as in the example.

Example:

REVISED EDITION MARK When a manua l i s r ev i sed , an ed i t i on mark() is recorded on the bottom outside cornerof the pages.

REVISIONSRevised pages are shown at the LIST OF REVISEDPAGES between the title page and SAFETY page.

SYMBOLSSo that the shop manual can be of ample practical use,important places for safety and quality are marked withthe following symbols.

10-410-4-1

Added pages10-4-2

10-5

Symbol Item RemarksSafety Special safety precautions

are necessary when perform-ing the work.

Caution Special technical precautionsor other precautions for pre-serving standards are neces-sary when performing thework.

Weight Weight of parts or systems.Caut ion necessary whenselecting hoisting wire orwhen working posture isimportant, etc.

Tightening torque

Places that require specialattention for tightening torqueduring assembly.

Coat Places to be coated withadhesives and lubricants etc.

Oil, water Places where oil, water orfuel must be added, and thecapacity.

Drain Places where oil or watermust be drained, and quantityto be drained.00-4 PW180-7E0

FOREWORD HOISTING INSTRUCTIONSHOISTING INSTRUCTIONSHOISTING

If a part cannot be smoothly removed from themachine by hoisting, the following checks shouldbe made:

1. Check for removal of all bolts fastening the part tothe relative parts.

2. Check for existence of another part causing inter-face with the part to be removed.

WIRE ROPES3. Use adequate ropes depending on the weight of

parts to be hoisted, referring to the table below:

The allowable load value is estimated to be 1/6or 1/7 of the breaking strength of the ropeused.

4. Sling wire ropes from the middle portion of thehook. Slinging near the edge of the hook maycause the rope to slip off the hook during hoisting,and a serious accident can result. Hooks havemaximum strength at the middle portion.

5. Do not sling a heavy load with one rope alone, butsling with two or more ropes symmetrically woundon to the load.

6. Do not sling a heavy load with ropes forming awide hanging angle from the hook. When hoisting aload with two or more ropes, the force subjected toeach rope will increase with the hanging angles.The table below shows the variation of allowableload (kg) when hoisting is made with two ropes,each of which is allowed to sling up to 1000 kg ver-tically, at various hanging angles. When two ropessling a load vertically, up to 2000 kg of total weightcan be suspended. This weight becomes 1000 kgwhen two ropes make a 120 hanging angle. Onthe other hand, two ropes are subject to an exces-sive force as large as 4000 kg if they sling a 2000kg load at a lifting angle of 150

WARNINGHeavy parts (25 kg or more) must be lifted with a hoistetc. In the DISASSEMBLY AND ASSEMBLY section,every part weighing 25 kg or more is indicated clearlywith the symbol

Wire ropes(Standard Z or S twist ropes without galvanizing)

Rope diameter Allowable loadmm kN tons

10 9.8 1.0

11.2 13.7 1.4

12.5 15.7 1.6

14 21.6 2.2

16 27.5 2.8

18 35.3 3.6

20 43.1 4.4

22.4 54.9 5.6

30 98.1 10.0

40 176.5 18.0

50 274.6 28.0

60 392.2 40.0

WARNINGSlinging with one rope may cause turning of the loadduring hoisting, untwisting of the rope, or slipping ofthe rope from its original winding position on the load,which can result in a dangerous accident

SAD00479

41%71%79%88%100%

PW180-7E0 00-5

FOREWORD COATING MATERIALSCOATING MATERIALS The recommended coating materials pre-

scribed in the shop manuals are listed below.

Category Code Part No. Quantity Container Main applications, features

Adhe

sive

s

LT-1A 790-129-9030 150 g Tube Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out

LT-1B 790-129-9050 20 g(2 pes.)

Polyethylene container

Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylene container

Features: Resistance to heat, chemicals Used for anti-loosening and sealant pur-

poses for bolts and plugs.

LT-3 790-129-9060(Set of adhesiveand hardeningagent)

Adhesive:1 kg

Hardening agent: 500 g

Can

Used as adhesive or sealant for metal, glass or plastic.

LT-4 790-129-9040 250 g Polyethylene container Used as sealant for machined holes.

HoltzMH 705

790-126-9120 75 g Tube Used as heat-resisting sealant for repairing engine.

Th reebond1735

179-129-9140 50 g Polyethylene container

Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers,

plastics and woods.

Aron -alpha201

790-129-9130 2 g Polyethylene container

Quick hardening type adhesive. Quick cure type (max. strength after 30 min-

utes). Used mainly for adhesion of rubbers, plastics

and metals.

Loc t i te648-50

79A-129-9110 50 cc Polyethylene container

Features: Resistance to heat, chemicals Used at joint portions subject to high temper-

ature.

Gas

ket

seala

nt

LG-1 790-129-9010 200 g Tube Used as adhesive or sealant for gaskets and packing of power train case, etc.

LG-3 790-129-9070 1 kg Can Features: Resistance to heat Used as sealant for flange surfaces and bolts

at high temperature locations; used to pre-vent seizure.

Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.00-6 PW180-7E0

FOREWORD COATING MATERIALSGas

ket

sea

lant

LG-4 790-129-9020 200 g Tube Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges

with large clearance. Used as sealant for mating surfaces of final

drive case, transmission case.

LG-5 790-129-9080 1 kg Polyethylene container

Used as sealant for various threads, pipe joints, flanges.

Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

LG-6 09940-00011 250 g Tube Features: Silicon based, resistant to heat, cold.

Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case,

etc.

LG-7 09920-00150 150 g Tube Features: Silicon based, quick hardening type.

Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Th reebond1211

790-129-9090 100 g Tube Used as heat-resisting sealant for repairing

engines.

Mol

ybde

num

disu

lphi

delu

bric

an

t

LM-G 09940-00051 60 g Can Used as lubricant for sliding parts (to prevent squeaking).

LM-P 09940-00040 200 g Tube Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting.

Used as lubricant for linkage, bearings, etc.

Gre

ase

G2-LI SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA160CNLI

Various Various

General purpose type

G2-CA SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYG2-160CNCA

Various Various

Used for normal temperature, light load bear-ing at places in contact with water or steam.

Molyb

denu

mdi

sulp

hide

lubr

ica

nt SYG2-400M 400 g

(10 per case)

Belows type

Used for places with heavy load.

Category Code Part No. Quantity Container Main applications, featuresPW180-7E0 00-7

FOREWORD STANDARD TIGHTENING TORQUESTANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTSThe following charts give the standard tighteningtorques of bolts and nuts. Exceptions are given inDISASSEMBLY AND ASSEMBLY.

Thread diameter of bolt Width across flats

mm mm Nm kgm6 10 13.2 1.4 1.35 0.15

8 13 31.4 2.9 3.20 0.3

10 17 65.7 6.8 6.70 0.7

12 19 112 9.8 11.5 1.0

14 22 177 19 18 2.0

16 24 279 29 28.5 3

18 27 383 39 39 4

20 30 549 58 56 6

22 32 745 78 76 8

24 36 927 98 94.5 10

27 41 1320 140 135 15

30 46 1720 190 175 20

33 50 2210 240 225 25

36 55 2750 290 280 30

39 60 3280 340 335 35

Thread diameter of bolt Width across flats

mm mm Nm kgm6 10 7.85 1.95 0.8 0.2

8 13 18.6 4.9 1.9 0.5

10 14 40.2 5.9 4.1 0.6

12 27 82.35 7.85 8.4 0.800-8 PW180-7E0

FOREWORD STANDARD TIGHTENING TORQUETIGHTENING TORQUE OF HOSE NUTSUse these torques for hose nuts.

TIGHTENING TORQUE OF SPLIT FLANGE BOLTSUse these torques for split flange bolts.

TIGHTENING TORQUES FOR HOSES (Taper seal type and face seal type) Unless there are special instructions, tighten the

hoses (taper the hoses (taper seal type and faceseal type) to the torque below.

Apply the following torque when the threads arecoated (wet) with engine oil.

Nominal No. Thread diameter Width across flat Tightening torquemm mm Nm kgm

02 14 19 24.5 4.9 2.5 0.5

03 18 24 49 19.6 5 2

04 22 27 78.5 19.6 8 2

05 24 32 137.3 29.4 14 3

06 30 36 176.5 29.4 18 3

10 33 41 196.1 49 20 5

12 36 46 245.2 49 25 5

14 42 55 294.2 49 30 5

Thread diameter Width across flat Tightening torquemm mm Nm kgm10 14 65.7 6.8 6.7 0.7

12 17 112 9.8 11.5 1

16 22 279 29 28.5 3

Nominal No. of hose

Width across

flat

Tightening torque Nm {kgm} Taper seal Face seal

Range Target Thread size (mm)

Nominal No. - Number of

threads, type of thread

Thread diam-eter (mm)

(Referenced)

02 1934 - 54 {3.5 - 5.5}

44 {4.5} - 9/16 - 18UN 14.334 - 63 {3.5 - 6.5} 14 - -

0322 54 - 93 {5.5 - 9.5} 74 {7.5} - 11/16 - 16UN 17.524 59 - 98 {6.0 - 10.0} 78 {8.0} 18 - -

04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 13/16 - 16UN 20.605 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.406 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 - 3/16 - 12UN 30.2

(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 - -(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 - -(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 - -PW180-7E0 00-9

FOREWORD STANDARD TIGHTENING TORQUETIGHTENING TORQUE FOR 107 ENGINE SERIES (BOLTS AND NUTS) Unless there are special instructions, tighten the

metric bolts and nuts of the 107 engine series tothe torque below.

TIGHTENING TORQUE FOR 107 ENGINE SERIES (EYE JOINTS)Use these torque values for eye joints (unit: mm).

TIGHTENING TORQUE FOR 107 ENGINE SERIES (TAPERED SCREWS)Use these torque values for tapered screws (unit:inch).

Thread diameter Tightening torque

mm Nm kgm Nm kgm

6 10 2 1.02 0.20 8 2 0.81 0.20

8 24 4 2.45 0.41 10 2 1.02 0.20

10 43 6 4.38 0.61 12 2 1.22 0.20

12 77 12 7.85 1.22 24 2 2.45 0.41

14 - - 36 5 3.67 0.51


mm Nm kgm

6 8 2 0.81 0.20

8 10 2 1.02 0.20

10 12 2 1.22 0.20

12 24 4 2.45 0.41

14 36 5 3.67 0.51


inch Nm kgm

1/16 3 1 0.31 0.10

1/8 8 2 0.81 0.20

1/4 12 2 1.22 0.20

3/8 15 2 1.53 0.41

1/2 24 4 2.45 0.41

3/4 36 5 3.67 0.51

1 60 9 6.12 0.9200-10 PW180-7E0

FOREWORD ELECTRIC WIRE CODEELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbolsare employed to indicate the thickness of wires. Thiswire code table will help you understand WIRINGDIAGRAMS.

EXAMPLE:05WB indicates a cable having a nominalnumber 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

CLASSIFICATION BY COLOR AND CODE

Nominal number

Copper wire Cable O.D. (mm)

Currentrating (A)

Applicable circuitNumber of

strandsDia. Of

strand (mm)Cross sec-tion (mm)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.2 26 0.32 2.09 3.1 20 Lighting, signal etc.5 65 0.32 5.23 4.6 37 Charging and signal15 84 0.45 13.36 7.0 59 Starting (Glow plug)40 85 0.80 42.73 11.4 135 Starting60 127 0.80 63.84 13.6 178 Starting100 217 0.80 109.1 17.6 230 Starting

Priority CircuitsClassification

Charging Ground Starting Lighting Instrument Signal Other

1

Prim

ary Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxi

liary

Code WR BW RW YR GW LWColor White &

Red Black &

WhiteRed & White

Yellow & Red

Green & White

Blue & White

3 Code WB BY RB YB GR LRColor White &

Black Black &

YellowRed & Black

Yellow & Black

Green & Red

Blue & Red

4 Code WL BR RY YG GY LYColor White &

Blue Black &

RedRed & Yel-

lowYellow & Green

Green & Yellow

Blue & Yel-low

5 Code WG RG YL GB LBColor White &

Green Red &

GreenYellow &

BlueGreen &

BlackBlue & Black

6 Code RL YW GL Color Red & Blue Yellow &

WhiteGreen &

BluePW180-7E0 00-11

FOREWORD CONVERSION TABLESCONVERSION TABLES

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided toenable simple conversion of figures. For details ofthe method of using the Conversion Table, see theexample given below.

EXAMPLE Method of using the Conversion Table to convert

from millimeters to inches.

1. Convert 55 mm into inches.

A. Locate the number 50 in the vertical column at theleft side, take this as (1), then draw a horizontalline from (1).

B. Locate the number 5 in the row across the top,take this as (2), then draw a perpendicular linedown from (2).

C. Take the point where the two lines cross as (3).This point (3) gives the value when convertingfrom millimeters to inches. Therefore, 55 millime-ters = 2.165 inches.

2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, sodivide by 10 (move the decimal one place to theleft) to convert it to 55 mm.

B. Carry out the same procedure as above to con-vert 55 mm to 2.165 inches.

C. The original value (550 mm) was divided by 10,so multiply 2.165 inches by 10 (move the decimalone place to the right) to return to the originalvalue. This gives 550 mm = 21.65 inches.

(2)Millimeters to inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

(3)(1) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.89800-12 PW180-7E0

FOREWORD CONVERSION TABLES12

Millimeters to Inches 1 mm = 0.03937 in0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1 kg = 2.2046 lb0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12

70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17

80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26PW180-7E0 00-13


Litre to U.S. Gallon 1 L = 0.2642 U.S. Gal0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019

20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661

30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303

40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586

60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228

70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870

80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511

90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Litre to U.K. Gallon 1 L = 0.21997 U.K. Gal0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179

20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579

40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978

60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178

70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378

80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577

90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.77700-14 PW180-7E0


kgm to ft. lb. 1 kgm = 7.233 ft. lb.0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4

20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1

40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8

60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1

70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4

80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7

90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4

110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7

120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1

130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4

140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0

160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4

170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7

180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0

190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4PW180-7E0 00-15


kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2

20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5

30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2

60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266

90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693

120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835

130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977

140 1991 2005 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 354200-16 PW180-7E0

FOREWORD CONVERSION TABLES12TemperatureFahrenheit Centigrade Conversion; a simple way toconvert a Fahrenheit temperature reading into aCentigrade temperature reading or vise versa is toenter the accompanying table in the center or bold-face column of figures. These figures refer to thetemperature in either Fahrenheit or Centigradedegrees. If it is desired to convert from Fahrenheit to

Centigrade degrees, consider the center column as atable of Fahrenheit temperatures and read the corre-sponding Centigrade temperature in the column atthe left. If it is desired to convert from Centigrade toFahrenheit degrees, consider the center column as atable of Centigrade values, and read the correspond-ing Fahrenheit temperature on the right.

C F C F C F C F-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0PW180-7E0 00-17

FOREWORD UNITSUNITSIn this manual, the measuring units are indicated withInternational System of units (SI).As for reference, conventionally used GravitationalSystem of units are indicated in parentheses { }.

Example:N {kg}Nm {kgm} MPa {kg/cm2}kPa {mmH2O} kPa {mmHg}kw/rpm {HP/rpm} g/kwh {g/HPh} 00-18 PW180-7E0

01 GENERALSpecification Dimension Drawings 1 Piece Boom. . . . . . . . . . . . . . . . . . . . . . 00- 2 2 Piece Boom. . . . . . . . . . . . . . . . . . . . . . 00- 8Working range 1 Piece Boom. . . . . . . . . . . . . . . . . . . . . . 00- 6 2 Piece Boom. . . . . . . . . . . . . . . . . . . . . . 00- 7Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 8Weight Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 00- 10Fuel, Coolant, And Lubricants . . . . . . . . . . . . . . 00- 1301-1PW180-7E0

GENERAL SPECIFICATION DIMENSION DRAWINGSSPECIFICATION DIMENSION DRAWINGS

DIMENSIONS1 PIECE BOOM

J H

ID

CB

G

A

F

E01-2 PW180-7E0

GENERAL SPECIFICATION DIMENSION DRAWINGSDescription 2.25m 2.6m 2.9m

A Overall height 3,720

B Front overhang 5,100

C Wheelbase 2,600

D Rear overhang 1,200

E Overall length 8,900

F Front swing radius 6,400

G Work equipment ground clearance 922 800 624

H Overall width2.5 m axle 2,550

2.75 m axle 2,750

I Front axle2.5 m axle 1,914

2.75 m axle 2,124

J Rear axle2.5 m axle 1,914

2.75 m axle 2,124PW180-7E0 01-3

GENERAL SPECIFICATION DIMENSION DRAWINGSDIMENSIONS

2 PIECE BOOM

HJI

DC

B

G

F

E01-4 PW180-7EO

GENERAL SPECIFICATION DIMENSION DRAWINGSDescription 2.25m 2.6m 2.9m

A Overall height 3,972 3,960

B Front overhang 2,994 2,917 3,050

C Wheelbase 2,600

D Rear overhang 1,200

E Overall length 6,794 6,717 6,850

F Front swing radius 4,341

G Work equipment ground clearance 551 205 368

H Overall width2.5 m axle 2,550

2.75 m axle 2,750

I Front axle2.5 m axle 1,914

2.75 m axle 2,124

J Rear axle2.5 m axle 1,914

2.75 m axle 2,124PW180-7E0 01-5

GENERAL WORKING RANGESWORKING RANGES

1 PIECE BOOM

Arm length mm 2250 2600 2900

A Max. digging height 9,948 9,562 9,756

B Max. dumping height 6,915 7,064 7,236

C Max. digging depth 5,321 5,676 5,966

D Min. swing radius 3,543 3,829 4,057

E Max. digging reach GL 8,907 9,227 9,509

E Max. digging reach 9,061 9,345 9,929

D

E

E

C

B

A01-6 PW180-7EO

GENERAL WORKING RANGES2 PIECE BOOM

Arm length mm 2250 2600 2900

A Max. digging height 9,942 10,129 10,350

B Max. dumping height 7,283 7,489 7,709

C Max. digging depth 5,400 5,742 6,044

D Min. swing radius 3,065 3,311 3,511

E Max. digging reach GL 8,907 9,227 9,509

E Max. digging reach 9,080 9,401 9,683

D

E

E

C

B

APW180-7E0 01-7

GENERAL SPECIFICATIONSSPECIFICATIONS

Machine model PW180-7E0

Serial Number H55051 and up

Bucket capacity m 0.8

Operating weight kg 17,160

Perfo

rma

nce

Max. digging force (using power max. function)

2.25

kN {kg} 102.0 {10,400}

2.6

2.9

Swing speed rpm 11.5

Swing max. slope angle deg. 21.5

Travel speed km/hCr: 2.5Lo: 10 Hi: 35

(Germany:20)

Gradeability deg.kPa {kg cm}35

36.3 {0.37}Standard Tyre Width mm 10.00 - 2001-8 PW180-7EO

GENERAL SPECIFICATIONS12



Engi

ne

ModelType

No. of cylinders - bore x strokePiston displacement

mm l {cc}

SAA6D107E-14-cycle, water-cooled, in-line, vertical, direct

injection, with turbo charger6 - 107 x 1246.69 {6690}

Perfo

rma

nce Flywheel horsepower

Max. torqueMax. speed at no loadMin. speed at no load

kW/rpm Nm/rpm

rpmrpm

108.4/2000 622.9/1500

2,0601,050

Starting motorAlternatorBattery

24V, 5.5 kW24V, 60 A

12V, 120 Ah x 2

Radiator core type Triple Cooler

Hyd

rau

lic sy

ste

m

Hyd

raul

icpu

mp

Type x No.DeliverySet pressure

l/minMPa (kg/cm)

HPV140, variable displacement Piston type: 308 x 1

Piston type: 37.2 {380}

Con

trol

valv

e

Type x No.Control method

1 Piece Boom 7-spool + 1 service spool type x 1 Hydraulic

2 Piece Boom 8-spool + 1 service spool type x 1 Hydraulic

Hyd

raul

icm

oto

r

Travel motor

Swing motor

A6VM120 HAXT/63W-VZB380A-SK, Piston type(with counter balance valve): x 1

MSF85P, Piston type(with safety valve, holding brake): x 1

Hyd

rau

lic cy

linde

r

1 Pi

ece

Boo

m

Type

Inside diameter of cylinderDiameter of piston rodStrokeMax. distance between pinsMin. distance between pins

mmmmmmmmmm

Boom Arm Bucket

Double act-ing piston

Double acting piston


12085

1,0152,7001,685

12085

1,3423,2461,904

12085

1,0272,5281,501

2 Pi

ce Bo

om

Type

Inside diameter of cylinderDiameter of piston rodStrokeMax. distance between pinsMin. distance between pins

mmmmmmmmmm

Adjust Boom Arm Bucket


L.H R.HDouble acting

pistonDouble acting

pistonDouble act-ing piston

160100761

2,0411,280

12085

9322,3951,463

12085

1,3423,2461,904

12085

1,0272,5281,501

Hydraulic tank Closed box type

Hydraulic filter Tank return side

Hydraulic cooler CF40-1 (Air cooled)PW180-7E0 01-9

GENERAL WEIGHT TABLEWEIGHT TABLE

This weight table is for use when handling components or when transporting the machine.

Unit: kgMachine model PW180-7E0Serial Number H55051 and upEngine assembly Engine Damper Hydraulic pump

6735536

114

Radiator oil cooler assembly 151.54Hydraulic tank, filter assembly (excluding hydraulic oil) 122Fuel tank (excluding fuel) 120Revolving frame 1,513Operators cab 286

Operators seat Mechanical 38Air Suspension 42

Counterweight 3,501Swing machinery 170Control valve 117Travel motor 75Center swivel joint 9501-10 PW180-7EO

GENERAL WEIGHT TABLE1 PIECE BOOMUnit: kgMachine model PW180-7E0


Boom assembly 1,117

Arm assembly(with no piping)

2.25 m 480

2.6 m 524

2.9 m 590

Bucket assembly 900

Boom cylinders 156.2 x 2

Arm cylinderS/V 165.6

S/V less 169.7Bucket cylinder 96.6

Boom foot pin 28.8

Boom cylinder pins 6.1 x 2 and 28.6

Arm cylinder pins 9.9 and 11.6

Boom/Arm pivot pin 18.9

Bucket linkage and pins 163.2PW180-7E0 01-11

GENERAL WEIGHT TABLE2 PIECE BOOMUnit: kg



Boom assembly1st Boom 430

2nd Boom 598

Arm assembly

2.25 m 480

2.6 m 524

2.9 m 590

Bucket assembly 900

Boom cylinders 144 x 2

Adjust cylinder 201

Arm cylinder S/V 165.6

S/V less 169.7

Bucket cylinder 96.6

Boom foot pin 28.8

Boom cylinder pins 6.1 x 2 and 28.6

Adjust cylinder pins 13.9 and 23.7Arm cylinder pins 9.9 and 11.6

Boom/Arm pivot pin 18.9

Bucket Linkage and pins 163.201-12 PW180-7EO

GENERAL FUEL, COOLANT AND LUBRICANTSFUEL, COOLANT AND LUBRICANTS

For the H-046-HM, use the oil recommendedby Komatsu.

RESERVOIR KIND OFFLUID

AMBIENT TEMPERATURE CAPACITY (l)-22 -4 14 32 50 68 86 104F-30 -20 -10 0 10 20 30 40C

Specified Refill

Engine oil pan

Engineoil

-30C 30C Komatsu EOS0W30

26 26


-20C 40C Komatsu EO10W30DH


0C 40C Komatsu EO30DH

Swing machinery case-30C 50C Komatsu TO30

4.5 4.5

PTO gear case 0.75 0.75

Hydraulic system


160 120-20C 40C Komatsu EO10W30DH


Hydraulicoil

-20C 50C Komatsu HO46-HM

Fuel tankDieselfuel

325 ASTM D975 No. 2

ASTMCooling system Water Add antifreeze 17.6

AxlesFront

Multi oil

11.5

Rear Fuchs titan hydra 20W-40 9.5

Transmission + clutch BP traction 8 4.85 4.85

HubsFront Fuchs titan hydra 20W-40 2.5

Rear 2.0 PW180-7E0 01-13

GENERAL FUEL, COOLANT AND LUBRICANTS01-14 PW180-7EO

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Engine Related Parts . . . . . . . . . . . . . . . . . . . . . 10-2Radiator Oil Cooler Charge air cooler . . . . . . 10-3Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . 10-7Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . 10-16Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22Clutch Control Circuit . . . . . . . . . . . . . . . . . . . . 10-26Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28Suspension Lock Cylinder . . . . . . . . . . . . . . . . 10-32Braking System . . . . . . . . . . . . . . . . . . . . . . . . 10-34Brake/Steer Pump . . . . . . . . . . . . . . . . . . . . . . 10-36Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37Power Brake Valve . . . . . . . . . . . . . . . . . . . . . 10-38Accumulator for Brake System . . . . . . . . . . . . 10-40Steering System. . . . . . . . . . . . . . . . . . . . . . . . 10-41Steering Column . . . . . . . . . . . . . . . . . . . . . . . 10-42Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43Hydraulic Layout Drawing . . . . . . . . . . . . . . . . 10-44Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . 10-46Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . 10-47Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . 10-49Pilot Pressure Control System . . . . . . . . . . . . . 10-73Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75

CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86Centre Swivel Joint . . . . . . . . . . . . . . . . . . . . . 10-108Travel PPC Pedal . . . . . . . . . . . . . . . . . . . . . . 10-109Work Equipment Swing PPC Valve . . . . . . . 10-111Solenoid Valve Manifold . . . . . . . . . . . . . . . . . 10-117Boom Safety Valve . . . . . . . . . . . . . . . . . . . . . 10-126Hydraulic Cylinder (Boom-Arm-Bucket) . . . . . 10-128Outrigger Cylinder. . . . . . . . . . . . . . . . . . . . . . 10-130Dozer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 10-132Work Equipment . . . . . . . . . . . . . . . . . . . . . . . 10-134Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . 10-140Electrical Wiring Diagram . . . . . . . . . . . . . . . . 10-141Engine Control System . . . . . . . . . . . . . . . . . . 10-142Electronic control System . . . . . . . . . . . . . . . . 10-148Machine Monitor System . . . . . . . . . . . . . . . . 10-173Overload Warning Device . . . . . . . . . . . . . . . . 10-201Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2021st Attachment Circuit Hydraulic Performance(Main Valve Bypassed) . . . . . . . . . . . . . . . . . . 10-211Travel System. . . . . . . . . . . . . . . . . . . . . . . . . 10-212Steering System . . . . . . . . . . . . . . . . . . . . . . . 10-231Service Brake and Suspension System . . . . . 10-24410-1PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTSENGINE RELATED PARTS

OUTLINE The damper assembly is a wet type.

34

2

567

1

1. Breather cap 5. Oil catcher tube2. Muffler 6. Brake/Steer pump3. Rear engine mount 7. Front engine mount4. Breather hose10-2 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD RADIATOR OIL COOLER CHARGE AIR COOL-RADIATOR OIL COOLER CHARGE AIR COOLER

SPECIFICATIONS:Combination Cooler

5

6

7

8

9

10

11

12 13 14

1

34 2

1516 17

1. Reservoir tank 7. Radiator outlet hose 13. Shroud2. Charge Air cooler 8. Radiator inlet hose 14. Radiator Cap3. Radiator 9. Fan 15. Condenser assy4. Oil Cooler 10. Charge Air Oil Cooler outlet hose 16. Net5. Oil Cooler outlet tube 11. Charge Air Oil Cooler inlet hose 17. Fuel cooler6. Oil Cooler inlet tube 12. Fan guard

Oil Coolant AirMax working pressure. bar 15 0.5 1.53

Max. working temperature at 45oC ambient oC 100 100 75

Cooler volume l. 2 6.9 -PW180-7E0 10-3

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAINPOWER TRAIN

7 3

4

5

6

8

9

11

12

13

14

15 17

18

1

2

16

1010-4 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN1. Centre swivel joint 9. Clutch control accumulator2. Hydraulic tank 10. Accumulators3. Main pump 11. Power brake valve4. Engine 12. Swing circle5. Gear pump 13. Swing motor / machinery6. PPC solenoid valve inc. 14. Rear axle

Clutch control sol 15. PropshaftTravel direction sol 16. Travel motor

7. Main control valve 17. Transmission8. Priority valve 18. Front axlePW180-7E0 10-5

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLESWING CIRCLE

SPECIFICATIONS

Reduction ratio:

s

1 Swing circle inner race (No. of teeth: 99)2 Ball

3 Swing circle outer race

a Inner race soft zone S position

b Outer race soft zone S position

99 = 7.61513

Amount of grease: 10.5 litres

No Check item Criteria Remedy

4Axial clearance of bearing Standard clearance Clearance limit

Replace(when mounted on chassis) 0.5-1.6 3.210-6 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY & MOTORSWING MACHINERY & MOTOR

4

2

1

3

1. Swing machinery 3. Swing pinion

2. Swing motor 4. DipstickPW180-7E0 10-7

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY & MOTOR12

1150

Nm +

/-50N

m54

9Nm

+

/-59N

m

3.3N

m +

/-0.49

Nm

86N

m +

/-7.5N

m10-8 PW180-7E0

12

1. Pinion shaft 15. O-ring

2. Spacer 16. Toothed ring

3. Sealing 17. Reduction assembly

4. Screw 18. Sun gear

5. Cover 19 Cover

6. Bearing 20. Reduction assembly

7. Gearbox housing 21. Screw

8. Plug 22. Sun gear

9. Output assembly 23. Circlip

10. Lubrication kit 24. Lubrication kit

11. Cock 25. Lubrication kit

12. Seal ring 28. O-ring

13. Bearing 29. Hydraulic motor

14. Nut

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTORSWING MOTORMSF 85P

SPECIFICATIONSA Service portsBM Anti-cavitationDB Drain portGA Pressure gauge portsGBPB Brake port

PW180-7E0

Model MSF85P

Theoretical displacement 87.3 cm/rev

Safety valve set pressure 28.4 MPa {290 kg/cm}Rated revolving speed 1,553 rpm

Brake release pressure 1.9 MPa {19 kg/cm}10-10 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR12PW180-7E0 10-11

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR10-12 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR12Kit Ref. No. Description Kit Ref. No. DescriptionK0 1 Motor housing kit

K2

13 Collar

K1

Base plate assembly 14 Spring29 Pin 15 Collar washer31 Base plate 16 Circlip32A Relief valve 27 Valve plate32B Relief valve K4 6 Motor shaft assembly43 Anti-cavitation valve assembly K5 4 Motor seal ring44 Screw

K6Bearings assembly

52 Anti-swing back valve 5 Bearing53 Plug 28 Bearing54 O-ring

K7

Brake assemblyK1.0 31 Base plate 17 Steel disc

K!.4

Plug assembly 18 Brake disc2 Plug 20 Brake spacer3 O-ring 23 Brake piston46 Plug 24 Spring47 O-ring 25 Spring53 Plug 30 Pin54 O-ring

K8

Seal assemblyK1.5A 32A Relief valve assembly 3 O-ringK1.5B 32B Relief valve assembly 19 O-ring

K1.6

43 Anti-cavitation valve assembly 21 O-ring39 Check valve 22 O-ring40 Spring 26 O-ring41 O-ring 33 O-ring42 Plug 34 Backup ring

K1.9

52 Anti-swing back valve assembly 35 Backup ring45 O-ring 36 O-ring51 Anti-swing back valve 37 O-ring50 Screw 38 O-ring

K2

Cylinder Block Assembly 41 O-ring7 Thrust plate 45 O-ring8 Piston 47 O-ring9 Retainer plate 48 O-ring10 Spherical bush 49 O-ring11 Pin 52 O-ring12 Cylinder blockPW180-7E0 10-13

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR12

Operation of swing lock

1. When swing lock solenoid valve is deactivated

When the swing lock solenoid valve is deactivated,the pressurized oil from the gear pump is shut offand port B is connected to the tank circuit.

As a result, brake piston (7) is pushed down bybrake spring (1), discs (5) and plates (6) are pushedtogether, and the brake is applied.

2. When swing lock solenoid valve is excited

When the swing lock solenoid valve is excited, thevalve is switched and the pressure oil from the gearpump enters port B and flows to brake chamber a.

The pressure oil entering chamber a overcomesbrake spring (1) and pushes brake piston (7) up. Asa result, discs (5) and plates (6) are separated andthe brake is released.

Gear pump

AA

Gear pump

AA10-14 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR12

RELIEF VALVE PORTION

1. Outline

The relief portion consists of check valves (2)and (3), shuttle valves (4) and (5), and reliefvalve (1).

2. Function

When the swing is stopped, the outlet port cir-cuit of the motor from the control valve isclosed, but the motor continues to rotateunder inertia, so the pressure at the outputside of the motor becomes abnormally high,and this may damage the motor.

To prevent this, the abnormally high pressureoil is relieved to port S from the outlet port ofthe motor (high-pressure side) to prevent anydamage.

Operation

1. When starting swing.

When the swing control lever is operated toswing right, the pressure oil from the pumppasses through the control valve and is sup-plied to port MA. As a result, the pressure atport MA rises, the starting torque is generatedin the motor, and the motor starts to rotate.The oil from the outlet port of the motorpasses from port MA through the control valveand returns to the tank. (Fig. 1)

2. When stopping swing.

When the swing control lever is returned toneutral, the supply of pressure oil from thepump to port MA is stopped. With the oil fromthe outlet port of the motor, the return circuit tothe tank is closed by the control valve, so thepressure at port MB rises. As a result, rotationresistance is generated in the motor, so thebraking effect starts.If the pressure at port MB becomes higherthan the pressure at port MA, it pushes shuttlevalve A (4) and chamber C becomes the samepressure as port MB. The oil pressure risesfurther until it reaches the set pressure of reliefvalve (1). As a result, a high braking torqueacts on the motor and stops the motor. (Fig.2)When relief valve (1) is being actuated, therelief oil and oil from port S passes throughcheck valve B (3) and is supplied to port MA.This prevents cavitation at port MA.PW180-7E0 10-15

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD UNDERCARRIAGEUNDERCARRIAGE

2

3

1

14

13

12

9

7

1110-16 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD UNDERCARRIAGE10

5

6

8

4

1. Undercarriage 8. Transmission2. Step 9. Double Wheel Assy3. Wheel Chock 10. Steering Cylinder4. Front Oscillating Steering Axle 11. Suspension Lock Cylinders5. Rear Axle 12. Swivel Joint6. Propshaft 13. Slew Ring7. Travel motor 14 Axle Oscillation pinPW180-7E0 10-17

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRANSMISSIONTRANSMISSION

SPECIFICATIONS:

Engaged

Disengaged

4

3

1

2

P

Q

1. Transmission disengagement pin (for towing) 3. Oil drain plug2. Oil filler plug 4. Breather

Type Single motor two speed automatic power shift

Gear ratioSmall clutch (High gear) 1.32: 1Large clutch (Low gear) 4.93: 1

Pressure required to disengage clutches (Large & Small) 58

+/-

7 bar.

Output shaft DIN 120 (8stud) fixing.Oil capacity 4.85 litres.Oil change interval 1000 hours10-18 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRANSMISSIONFUNCTIONPressure applied in port P will disengage the smallclutch, low speed will be selected. Pressure appliedin port Q will disengage the large clutch, high speedwill be selected. No pressure in port P and Q willengage both small and large clutches. When bothclutches are engaged this locks the input shaft of thetransmission to the housing locking the transmission,this is used for the park brake condition.

Hi = sun + planets locked together, planetary drive =(1.32: 1)Lo = sun drives planets annulus is held, planet carrieris the output = (4.93: 1)

Steering pump

Park brake switch

Controller

Park brake solenoid valve

Transmission clutch solenoid valve

Swivel joint

Travel motor

Small clutch

Large clutch

Power shift Transmission

QPPW180-7E0 10-19

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRANSMISSION1

2

3

4

5

6

7

89

10

13

14

11

12

1. Sleeve 8. Roller Bearing

2. Small clutch pack (high gear) 9. Spur Gear3. Large clutch pack (low gear) 10. Coupling4. Ball Bearing 11. Bearing

5. Bearing 12. Flange

6. Epicyclic Gearbox 13. Pin

7. Spur Gear 14. Casing10-20 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRANSMISSIONPW180-7E0 10-21

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTORTRAVEL MOTORA6VM120 HAXT/63W-VZB380A-SK

SPECIFICATIONSA Service portB Service port

G1Port for synchronous control of a number of units and for remote control pressure

X Pilot pressure portT1 Case drain portT2 Case drain portU Flushing portS BoostingMA:MB Gauge ports (one either side)Gext Brake release port - externalM1 Gauge port control pressure

Type 120cc unit

Min displacement setting 41cc/rev

Brake relief valve setting 420 bar

Counterbalance valve pressure setting 7 bar10-22 PW180-7E0

FUNCTIONThe travel motor is a device for driving the transmis-sion by converting the hydraulic power into mechani-cal torque.Oil is delivered via the main valve to ports A/B and

this flow rotates a rotary group which is connected tothe motor output splines which are positioned to thetransmission input.

Travel Motor

2

13

1. Counterbalance valve2. Motor3. Relief valve

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOROPERATION OF TRAVEL MOTOR1. During normal travel

Oil is supplied to the travel motor from the controlvalve by the travel spool. When the spool isopened the machine accelerates from the sta-tionary the pressure at the travel motor rises tomaximum. This high pressure is used to set thedisplacement of the travel motor to maximum togive maximum torque.

As the machine speed increases, so pressurerequired to move the machine will reduce. Thisreducing pressure is used to reduce the dis-placement of the travel motor to allow increasingspeed. The travel motor changes from maximumdisplacement to preset minimum. Displacementchanges according to the diagram.

1 2

3

45 6

1. Travel motor2. Transmission and clutch3. Drive shafts4. Main control valve5. Main pump6. Swivel joint

120

41

275 303 380

Max Angle

Min Angle

Disp

lace

men

t(cc

/rev)

Pressure (kg/cm2)10-24 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR122. Control of speed downhillAt high speed when the machine is travellingdownhill, machine speed must be limited to pre-vent overspeed of travel motor, transmission andaxles. In the downhill condition the machineweight is driving the machine and pressure at thetravel motor inlet becomes low. This low pres-sure is used to close the counterbalancevalve.This allows the counterbalance valve

springs to centralise the spool. The travel motorwill rotate because it is driven from the wheelsand so oil in the travel motor is circulated at highpressure through the brake valves. This oil circu-lated at high pressure through the brake valvesslows the machine speed down.

1

3 4

12

1. Counterbalance valve2. Relief valve3. Swivel joint4. Main control valvePW180-7E0 10-25

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLUTCH CONTROL CIRCUITCLUTCH CONTROL CIRCUIT

Park brake switch

Controller

Park brake solenoid valve

Transmission clutch solenoid valve

Swivel joint

Travel motor

Small clutch

Large clutch

Power shift Transmission

QP

E

Gear pumpon Engine10-26 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLUTCH CONTROL CIRCUITFUNCTIONThe clutches maintain the drive between the travelmotor and the transmission low or high sped. Thelow and high gear are combined within the sameclutch pack and gear selection is provided by the Hi/Lo speed transmission clutch solenoid.A clutch is disengaged by applying pressure to thatparticular clutch piston and the system does notallow pressure to be applied to both clutch pistons atthe same time.1. Pressure applied to transmission port P dis-

engages the high speed clutch pack meaning thelow speed clutch pack is engaged - low speedhas been selected.

2. Pressure applied to transmission port Q dis-engages the low speed clutch pack meaning thehigh speed clutch pack is engaged - high speedhas been selected.

3. When there is no pressure applied to port Q andport P, both low speed and high speed clutchesare engaged meaning the parking brake hasbeen applied.PW180-7E0 10-27

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLEAXLEOUTLINE Each axle consists of an axle housing supporting

the chassis weight, a differential set in the axlehousing, a final drive, and a brake provided ateach end.

FRONT AXLE

A trunnion-type axle shaft with a king pin at thefinal drive end is used to enable the direction ofthe machine to be changed.

Front Axle Oil Capacity

Front Hub Oil Capacity

55

2 1 4 2

3

66

7

1. Steer cylinder 3. Axle housing 5. Brake line input 7. Oil level plug

2. Track control arms 4. Drive shaft input 6. Wheel hub

PW180 11.5 Litres PW180 2.5 Litres10-28 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLE2 3 4 5 6710

111 2324 25 26

27, 28 29

30

31

323334

35363738

1213

14151617

181920

21 22

1. Planetary holder 20. Screw2. O-ring 21. Axle body long steering3. Seal ring 22. Air valve4. Screw 23. Screw5. Pin 24. Shim ring6. Disk/Washer 25. O-ring7. Bushing 26. Roller bearing8. Lip seal 27. Protection cap9. Bushing 28. Nipple10. Pressure pad 29. Bevel gear11. Axle body short steering 30. Shim ring12. O-ring 31. Planetary holder13. Disk/Washer 32. Flange14. Bushing 33. Lip seal15. Seal ring 34. Roller bearing16. Ring 35. Shim ring17. Parallel pin 36. Bushing18. Pin 37. Shim ring19. Security dowel 38. Roller bearingPW180-7E0 10-29

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLE12REAR AXLE

Rear Axle Oil Capacity

Rear Hub Oil Capacity

3 3

5

1

2

4 4

1. Axle housing

2. Drive shaft input

3. Brake line input

4. Wheel hub

5 Oil level plug

PW180 2.5m Axle 9.5 Litres PW180 2 Litres10-30 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLE12

When the service brake is applied, braking iscarried out in pairs to diagonally oppositewheels, the braking is after the final gear reduc-tion giving improved axle lock.

1 2 3 4 5

6891011

1213

1415

1617

1819

20 21 2223

24

2526

2728

293132

33

34

30

7

1. Screw 18. Hub2. O-ring 19. O-ring3. Roller Bearing 20. Plug4. Beval Gear 21. Circlip5. Roller Bearing 22. Hollow Wheel6. Nut 23. Gear Pinion7. Flange 24. Planetary Holder8. Lip Seal 25. Screw Plug9. Roller Bearing 26. Screw10. Bushing 27. Disk/Washer11. Roller Bearing 28. Brake12. Shaft 29. Bushing13. Adjusting Ring 30. Cylinder Head Screw14. Tube Fitting 31. Circlip15. Roller Bearing 32. Gasket16. Sleeve 33. Seal Ring17. Roller Bearing 34. Brake DiscPW180-7E0 10-31

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SUSPENSION LOCK CYLINDERSUSPENSION LOCK CYLINDER

SPECIFICATIONS

STRUCTURE AND FUNCTIONPlunger cylinder with in built check valve.The check valve is designed as a leak free ball seatvalve which is released by a control spool.The control conduit is connected to both axle lockcylinders, the pilot pressure piloting the check valvein the cylinder head is also pre loading the cylindersduring pendulum motion therefore only one conduitto the cylinders is necessary.

3

2

1

4

6

5

1. Plunger2. Cylinder housing3. Check valve cartridge4. Switching cylinder5. Control spool6. Wiper

Piston Diameter 100mmStroke 180mmPilot Pressure Min. 2.8 MPa10-32 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SUSPENSION LOCK CYLINDERCIRCUITPURPOSEThe undercarriage of wheeled hydraulic excavatorshas one of the two driven axles mounted so it canoscillate. This makes it possible to fully utilise theexcavators rimpull in rough terrain - all of the wheelsbeing constantly in contract with the ground. A sus-pension cylinder is fitted on each side of the under-carriage to lock the axle during digging or lifting work.Locking the axle increases the excavators stability.The oscillating axle (3) is mounted on axle mount pin(2) in the centre of the excavator. The two cylinders(1) which are full of hydraulic oil are connected

through pipelines to the suspension lock solenoidvalve (4).When the excavator is being moved on the jobsite,the suspension lock solenoid valve should be enger-nised so that the hydraulic oil in the cylinder can bereturned to tank as the axle is oscillating up anddown. Before commencing excavating operations,the osci l lation lock solenoid valve should bede-energised to pressurise the oil in the cylinders.This will lock the axle in the position it is in.

AXLE OSCILLATION

Axle oscillation: = 10o

Minimum turning radius PW180 = 6.8m.

7

6

2

3

5

4

1

9

8

1. Cylinder2. Axle mount pin3. Oscillating axle4. Oscillation lock solenoid valve5. Pump6. Hydraulic tank7. Swivel joint8. PPC operated check valve9. AccumulatorPW180-7E0 10-33

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKING SYSTEMBRAKING SYSTEM

Lo Gear clutch

(17)

Hi Gear clutch

(16)

T1

T2

T'

T'2

1 7 6 5 8 1012

13

15

1415

14

11

4

9

2

310-34 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKING SYSTEMSTRUCTURE AND FUNCTION

The brake system is fully hydraulic. Hydraulic oil issupplied at high pressure by gear pump to a priorityvalve giving priority to the steering circuit first andsecondly to the braking circuit, when the steering isnot being used in the steering circuit. The brake sys-tem gets the full flow when braking, oil is sent to thebrake valve which provides braking pressure to twoseparate braking circuits (service brakes). In theevent of failure of the power supply, the accumulatorsprovide brake pressure to allow the machine to besafely stopped.A parking brake is provided which is operated byselecting park brake switch in cab. This de-energisesboth high and low gear signals and locks the trans-mission gears.If there is no pressure the parking brake will activate.

1. Hydraulic oil filter

2. Gear pump

3. Priority valve

4. Brake control valve

5. Accumulator - service brake (0.75 l.)6. Accumulator - service brake (0.75 l.)7. Accumulator - parking brake (0.75 l.)8. Pressure switch - stop light (5 +/

-

2 bar)

9. Pressure switch - accumulator (70 +/-

5 bar)10. Transmission clutch control solenoid

11. Pressure switch (parking brake) - (40 +/-

1 bar) < less than activates12. Brake pedal

13. Swivel joint14. Service brake cylinder

15. Service brake cylinder

16. Small (high speed) clutch17. Large (low speed) clutchPW180-7E0 10-35

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKE/STEER PUMPBRAKE/STEER PUMP

SPECIFICATIONS

* Rotation direction when viewed on shaft.

FUNCTIONThe brake/steer pumps function is to produce thenecessary oil flow/pressure to operate the brake,steering and pilot pressure control circuits.The pump is directly driven off the engine ancillaryPower Take Off (P.T.O.)

21

3 45

1. Delivery port (outlet)2. Suction port (inlet)3. Washer

4. Nut

5. Pump assembly

5

5

Type gear pump

Rated speed 2500 RPM

Displacement 25cc/REV

Rated pressure 250 bar

Max. input shaft torque 250Nm

Rotation Anti-clockwise*10-36 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PRIORITY VALVEPRIORITY VALVE

SPECIFICATION

FUNCTION

When the steering wheel is turned, the oil flow is dis-tributed in such a way that the oil flow necessary forsteering is led to the steering unit through the CFconnection.The remaining oil flow is available for use of thebrake valve, through the EF connection.The distribution is controlled by the LS signal fromthe steering unit; so that the oil flow to the steeringunit is always determined by the actual steering rate.Steering takes priority

P

EF CF

LS

P Pressure port (from pump)EF Output port to brake system

CF Output port to steering system

LS Load sensing port from steering valve

Priority valve control spring pressure 7 barPW180-7E0 10-37

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER BRAKE VALVEPOWER BRAKE VALVE

SPECIFICATIONS

A T1 T2X

View A

R1R2

F

P

NR3

X1

BR

N T2T1

1

23

5

7

8

6

9

1

4

10

1 Brake system support pedal with hook F Accumulator pressure switch P Feed from priority valve

2 Brake module R Accumulator (charging valve stabiliser) B Return

3 Accumulator charging valve R1 Accumulator (service brake) N Tank4 3 ways complete solenoid valve R2 Accumulator (service brake) N Tank (plugged)5 Pedal rubber T1 Service brake pressure switch R3 Plugged (Accumulator on italian

machine)6 Latch pedal T2 Service brake pressure switch (plugged)7 Latch pedal fixing screw T2 Service brake8 Latch pin T1 Service brake9 Latch pin stirrup X Parking brake

10 Brake proximity switch mount-ing hole X1 Parking brake pressure switch

Accumulator charge pressure(cut in) = 120 +/

-

5 bar

(cut out) = 155 +0/-2 bar

Service brake pressure 63 bar

Park brake pressure 58 +/-

7 bar10-38 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER BRAKE VALVEFUNCTIONThe main function of the power brake valve is togradually reduce the machines travelling speed whenthe pedal is slowly depressed. The higher the forceapplied to depress the pedal, the greater the deceler-ation of the machine, until the machine is eventuallyin a stationary position.An alternative function of the power brake valve isthe digging brake application, if the machine is to beused for digging, the power brake valve should befully depressed until the pedal is locked and thelatching hook is secured on its location pin. This willprevent the machine from "Travelling" when it isbeing used for diggingPW180-7E0 10-39

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ACCUMULATOR FOR BRAKE VALVEACCUMULATOR FOR BRAKE VALVE

SPECIFICATIONS STRUCTURE AND FUNCTION The accumulators are installed below the opera-

tors cab accessible from the under covers.

Installed into the brake circuit the accumulatorsprovide pressure to the brakes in the event of apower failure ensuring the machine is stoppedsafely.

NOTE: Accumulator A is only installed on italianspecification machines.

A

1. Nominal capacity 0.75L2. Max. working pressure 210 bar3. Max. p dynamic 175 bar

4. Working temperature- 30o to 125o C

5. Diaphragm NBR6. Fluid Mineral oil7. Body Forged steel8. Surface finish Rust preventative coating9. Pre-charge gas Nitrogen10. Pre-charge pressure 50 bar10-40 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEMSTEERING SYSTEM

STRUCTURE AND FUNCTION The steering is fully hydraulic. The oil sent by the

brake/steer pump (2) mounted on the PTO at thefront of the engine, flows via the priority valve (3)to the steering valve (4). From here it is passedthrough swivel joint to steering cylinder (5). thesteering cylinder then extends or retracts tomove the tie-rod and steer the machine

In the event of a failure of the hydraulic systemthe machine can be steered by emergency steer-ing. The steering valve acts as a pump to sendoil to the steering cylinder.

1

23

4

5

6

1. Hydraulic filter 4. Steering valve

2. Brake/steer pump 5. Steering cylinder

3. Priority valve 6. Steering wheelPW180-7E0 10-41

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING COLUMNSTEERING COLUMN

1

2

3

4

5

6

7

1. Steering wheel2. Steering column3. Pedal4. Hose connections5. Orbitrol valve6. Mounting bracket7. Sunshine sensor10-42 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ORBITROL VALVEORBITROL VALVE

Specifications

Structure and Function

The steering is fully hydraulic, the oil sent by thebrake/steer pump on the front of the engine flowsvia the priority valve to the orbitrol valve, andfinally to the steering cylinder which controls,extends or retracts the tie rod on the axle to steerthe machine.

In the event of failure of the power supply themachine can be steered by Emergency steer-ing, the steering valve acts as a pump to send oilto the steering cylinders.

240 ~ 250BAR

240 ~ 250BAR

70 CC/REV

100 CC/REV 190 ~ 195BAR

P Pressure port (from priority valve)T Tank portL Left turn portR Right turn portLS Load sensing port (to priority valve)

Nominal displacement (normal operation) 240cc/revNominal displacement (emergency operation) 80cc/revRelief valve setting 190+5/

-0 barPW180-7E0 10-43

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC EQUIPMENT LAYOUT DRAWINGSHYDRAULIC EQUIPMENT LAYOUT DRAWINGS1. L.H PPC valve 12. Transmission

2. HCU pedal 13. Brake accumulators

3. 2nd boom adjust pedal 14. Suspension cylinder4. R.H PPC valve 15. Safety lock lever

5. Front axle 16. Hydraulic tank

6. Swivel joint 17. Combination cooler7. Swing motor 18. Travel motor

8. Control valve 19. Arm cylinder

9 Hydraulic filter 20. 2nd boom adjust cylinder10 Main pump 21. 1st boom cylinder

11 Rear axle 22. Bucket cylinder

3

4

5

6 7

8

9

10

11

12

131210-44 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC EQUIPMENT LAYOUT DRAWINGS12

16

17

15

14

18

19

20

21

22PW180-7E0 10-45

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CIRCUIT DIAGRAMHYDRAULIC CIRCUIT DIAGRAM(Please refer to Section 90)

.10-46 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANKHYDRAULIC TANK

1

23

5

6

7

4

1. Sight gauge2. Oil filler cap3. Hydraulic tank4. Suction strainer 5. Filter element 6. Strainer7. Bypass valvePW180-7E0 10-47

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANKSPECIFICATIONS

Tank 166 LitresAmount of oil inside tank 120 LitresPressure valve

Relief cracking pressure16.7 +/

-

6.9 kPa

{0.17 +/-

0.07 kg/cm2}

Suction cracking pressure0 - 0.49 kPa

{0 - 0.005 kg/cm2}

Bypass valve set pressure150 +/

-

30 kPa

{1.5 +/-

0.3 kg/cm2}10-48 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMPHYDRAULIC PUMPHPV125

Pd1

PM

PEPC

PB

PSIGPen

Isig

Im

PA

1

4

5

32

PLSC

PA

PLS

11.8~14.7Nm{1.2~1.5kgm}

19.6~27.4Nm{2.0~2.8kgm}

58.8~78.4Nm{6~8kgm}

PEPC

Pd2PS

1. Main pump2. LS valve3. PC valve4. LS-EPC valve5. PC-EPC valve

Im :PC mode selector currentIsig :S set selector currentPA :Pump delivery portPA :Pump delivery pressure

detection portPB :Pump pressure input portPd1 :Case drain portPen :Pump control pressure detection portPd2 :Drain port

PLS :Load pressure input portPLSC :Load pressure detection portPS :Pump suction portPLSC:LS set selector pressure detection portPM:PC set selector pressure detection portPEPC:EPC basic pressure input portPEPC:EPC basic pressure checking portPSIG :LS set change pressure checking port

OutlineThis pump consists of a variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.PW180-7E0 10-49

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP12

A

58.8~78.4Nm{6~8kgm}

1 2 3 4 5 6 7 8 9 10

1. Shaft (Front)2. Cradle3. Case (Front)4. Rocker cam5. Shoe

6. Piston7. Cylinder block8. Valve plate9. End cap10. Servo piston10-50 PW180-7E0


FUNCTION The rotation and torque transmitted to the pump

shaft are converted into hydraulic energy, andpressurized oil is discharged according to theload.

It is possible to change the discharge amount bychanging the swash plate angle.

STRUCTURE Cylinder block (7) is supported to shaft (1) by a

spline, and shaft (1) is supported by the front andrear bearings.

The tip of piston (6) is a concave ball, and shoe(5) is caulked to it to form one unit. Piston (6) andshoe (5) form a spherical bearing.

Rocker cam (4) has flat surface A, and shoe (5)is always pressed against this surface while slid-ing in a circular movement.

Rocker cam (4) brings high pressure oil at cylin-der surface B with cradle (2), which is secured tothe case, and forms a static pressure bearingwhen it slides.

Piston (6) carries out relative movement in theaxial direction inside each cylinder chamber ofcylinder block (7).

The cylinder block seals the pressure oil to valveplate (8) and carries out relative rotation. Thissurface is designed so that the oil pressure bal-ance is maintained at a suitable level. The oilinside each cylinder chamber of cylinder block(7) is sucked in and discharged through valveplate (8).

987654321

ABSJP09037AAPW180-7E0 10-51


Operation

1. Operation of pump

Cylinder block (7) rotates together with shaft (1),and shoe (5) slides on flat surface A.

When this happens, rocker cam (4) moves alongcylindrical surface B, so angle between centerline X of rocker cam (4) and the axial direction ofcylinder block (7) changes. (Angle is called theswash plate angle.)

Center line X of rocker cam (4) maintains swashplate angle in relation to the axial direction ofcylinder block (7), and flat surface A moves as acam in relation to shoe (5).

In this way, piston (6) slides on the inside of cylin-der block (7), so a difference between volumes Eand F is created inside cylinder block (7). The suc-tion and discharge is carried out by this differenceF - E.

In other words, when cylinder block (7) rotates andthe volume of chamber E becomes smaller, the oilis discharged during that stroke. On the otherhand, the volume of chamber F becomes larger,and as the volume becomes bigger, the oil issucked in.

If center line X of rocker cam (4) is in line with theaxial direction of cylinder block (7) (swash plateangle = 0), the difference between volumes E andF inside cylinder block (7) becomes 0, so thepump does not carry out any suction or dischargeof oil.

(In actual fact, the swash plate angle neverbecomes 0.)10-52 PW180-7E0

STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP122. Control of discharge amount

If the swash plate angle becomes larger, thedifference between volumes E and F becomeslarger and discharge amount Q increases.

Swash plate angle is changed by servo piston(102).

Servo piston (10) moves in a reciprocal move-ment () according to the signal pressure fromthe PC and LS valves. This straight line move-ment is transmitted through rod (11) to rockercam (4), and rocker cam (4), which is supportedby the cylindrical surface to cradle (2), slides in arotating movement in direction of arrow.

With servo piston (10), the area receiving thepressure is different on the left and the right, somain pump discharge pressure (self pressure)PP is always brought to the chamber receivingthe pressure at the small diameter piston end.

Output pressure Pen of the LS valve is broughtto the chamber receiving the pressure at thelarge diameter end. The relationship in the sizeof pressure PP at the small diameter piston endand pressure Pen at the large diameter end, andthe ratio between the area receiving the pressureof the small diameter piston

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