DOWNLOAD PDF Komatsu PC160LC-7 Hydraulic Excavator Shop Manual SEBM028606 by www.heydownloads.com

SEBM028606

MACHINE MODEL

SERIAL NUMBER

PC160LC-7

10001 and up

•

This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.

• •

PC160LC-7 mount the SAA4D102E-2 engine. For details of the engine, see the 102 Series Engine Shop Manual.

00-1 (6)

CONTENTS No. of page

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

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

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

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

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

00-2 (2)

PC160LC-7

The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below.

Mark

Indication

Action required

Page to be newly added

Add

Page to be replaced

Replace

( )

Page to be deleted

Discard

Pages having no marks are those previously revised or made aditions.

LIST OF REVISED PAGES Mark

Page

q 00-1 00-2

q 00-2-1 q 00-2-2 q 00-2-3 00-2-4 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22

Revision Mark number

(6) (2) (6) (6) (6) (5)

01-1 01-2 01-3 01-4 01-5 01-6 01-7 01-8 10-1 10-2 10-3 10-4 10-5 PC160LC-7

(3)

Page

10-6 10-8 10-9 10-10 q 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31 10-32 10-33 10-34 10-35 10-36 10-37 10-38 10-39 10-40 10-41 10-42 10-43 10-44 10-45 10-46 10-48

Revision Mark number

(6)

Page

10-49 10-50 10-52 10-53 10-54 10-55 10-56 10-57 10-58 10-59 10-60 10-61 10-62 10-63 10-64 10-66 10-67 10-68 10-69 10-70 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 10-80 10-81 10-82 10-83 10-84 10-85 10-86 10-87 10-88 10-89 10-90 10-91

Revision Mark number

Page

10-92 10-93 10-94 10-95 10-96 10-97 10-98 10-99 10-100 10-101 10-102 10-103 10-104 10-105 10-106 10-107 10-108 10-109 10-110 10-111 10-112 10-113 10-114 10-115 10-116 10-117 10-118 10-119 10-120 10-121 10-122 10-123 10-124 10-125 10-126 10-127 10-128 10-129 10-130 10-131 10-132

Revision Mark number

Page

10-133 10-134 10-135 10-136 10-137 10-138 10-139 10-140 10-142 10-143 10-145 10-146 10-147 10-148 10-149 10-150 10-151 10-152 10-153 10-154 10-155 10-156 10-157 10-158 10-159 10-160 10-161 10-162 10-163 10-164 10-165 10-166 10-167 10-168 10-169 10-170 10-171 10-172 10-173 10-174 10-175

Revision number

(5) (5)

00-2-1 (6)

Mark

Page

Revision number Mark

10-176 10-177 10-178 10-179 10-180 10-181 10-182 10-183 10-184 10-185 10-186 10-187 10-188 10-189 10-191 10-192 10-193 10-194 10-195 10-196 10-197 10-198 10-199 10-200

(5) (5)

20-1 20-2 20-3 20-4 20-5 20-6 20-7 20-8 20-9 20-10 20-11 20-101 20-102 20-103 20-104 20-105 20-106 20-107 20-108 20-109 20-110 20-111 20-112 20-113 20-114 20-115

(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (3) (4) (4) (4) (1) (4) (1) (1) (1) (1) (1) (1) (4) (1) (1)

00-2-2 (6)

(3) (3) (3) (3) (3) (3) (3) (5) (3) (3)

Page

20-116 20-117 20-118 20-119 20-120 20-121 20-122 20-123 20-124 20-125 20-126 20-127 20-128 20-129 20-130 20-131 20-132 20-133 20-134 20-135 20-136 20-137 20-138 20-139 20-140 20-141 20-142 20-143 20-144 20-145 20-146 20-147 20-148 20-149 20-150 20-151 20-152 20-153 20-154 20-155 20-156 20-157 20-158 20-159 20-160 20-161 20-162 20-163 20-164 20-165 20-166

Revision number Mark

(1) (1) (4) (1) (1) (4) (4) (1) (1) (4) (1) (1) (4) (1) (1) (4) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

Page

20-167 20-169 20-170 20-171 20-172 20-173 20-174 20-175 20-176 20-177 20-178 20-179 20-180 20-181 20-182 20-183 20-184 20-186 20-186-1 20-187 20-188 20-189 20-190 20-191 20-201 20-202 20-203 20-204 20-205 20-206 20-207 20-208 20-209 20-210 20-211 20-212 20-213 20-214 20-215 20-216 20-218 20-219 20-220 20-221 20-222 20-223 20-223-1 20-223-2 20-223-3 20-223-4 20-223-5

Revision number Mark

(1) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (3) (4) (4) (3) (3) (3) (3) (3) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (4) (4) (4) (4) (4) (4) (4) (4) (1) (4) (4) (4) (4) (4)

Page

20-224 20-225 20-226 20-227 20-228 20-229-1 20-229-2 20-229-3 20-229-4 20-229-5 20-230 20-231 20-231-1 20-231-2 20-232 20-233 20-233-1 20-233-2 20-234 20-235 20-235-1 20-235-2 20-236 20-237 20-238 20-239 20-240 20-241 20-242 20-243 20-244 20-245 20-246 20-247 20-248 20-249 20-250 20-251 20-252 20-253 20-254 20-255 20-256 20-257 20-257-1 20-258 20-259 20-260 20-301 20-302 20-304

Revision number Mark

(4) (1) (1) (4) (1) (4) (4) (4) (4) (4) (4) (1) (4) (4) (4) (1) (4) (4) (4) (1) (4) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (1) (1) (4) (1) (1) (4)

Page

Revision number

20-305 20-306 20-307 20-308 20-310 20-311 20-312 20-313 20-314 20-315 20-316 20-317 20-318 20-319 20-319-1 20-319-2 20-320 20-321 20-322 20-323 20-324 20-325 20-325-1 20-325-2 20-326 20-327 20-327-1 20-327-2 20-328 20-329 20-329-1 20-329-2 20-330 20-331 20-331-1 20-331-2 20-332 20-333 20-333-1 20-333-2 20-334 20-335 20-335-1 20-335-2 20-336 20-337 20-337-1 20-337-2 20-338 20-339 20-339-1

(4) (4) (1) (1) (1) (1) (1) (4) (1) (1) (1) (1) (4) (1) (4) (4) (1) (1) (1) (1) (4) (1) (4) (4) (4) (1) (4) (4) (4) (1) (4) (4) (4) (1) (4) (4) (4) (1) (4) (4) (4) (1) (4) (4) (4) (1) (4) (4) (4) (1) (4)

PC160LC-7

Mark

Page

20-339-2 20-340 20-341 20-341-1 20-341-2 20-342 20-343 20-343-1 20-343-2 20-344 20-345 20-346 20-347 20-348 20-349 20-350 20-351 20-352 20-353 20-354 20-355 20-356 20-357 20-358 20-359 20-360 20-361 20-362 20-363 20-364 20-365 20-366 20-367 20-368 20-369 20-370 20-371 20-372 20-373 20-374 20-375 20-376 20-377 20-378 20-380 20-381 20-382 20-383 20-384 20-385 20-386 PC160LC-7

Revision number Mark

(4) (4) (1) (4) (4) (4) (1) (4) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (1) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

Page

20-387 20-388 20-389 20-390 20-401 20-402 20-403 20-404 20-405 20-406 20-407 20-408 20-409 20-410 20-411 20-412 20-413 20-414 20-415 20-416 20-417 20-418 20-419 20-420 20-421 20-422 20-422-1 20-423 20-424 20-425 20-426 20-427 20-428 20-429 20-430 20-431 20-432 20-433 20-434 20-435 20-435-1 20-435-2 20-436 20-437 20-438 20-439 20-440 20-441 20-442 20-443 20-444

Revision number Mark

(1) (1) (1) (1) (4) (4) (1) (4) (1) (1) (1) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (4) (1) (1) (4) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (1) (4) (4) (1) (1) (1) (1) (1) (1) (1) (4) (1)

Page

20-446 20-447 20-448 20-449 20-450 20-451 20-452 20-453 20-453-1 20-453-2 20-453-3 20-453-4 20-453-5 20-453-6 20-453-7 20-453-8 20-453-9 20-453-10 20-453-11 20-454 20-455 20-501 20-502 20-503 20-504 20-505 20-506 20-507 20-508 20-509 20-510 20-511 20-512 20-513 20-514 20-515 20-516 20-517 20-518 20-519 20-520 20-521 20-522 20-523 20-524 20-525 20-526 20-527 20-601 20-602 20-603

Revision number Mark

(1) (1) (1) (1) (1) (1) (4) (1) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (4) (4)

Page

Revision number Mark

20-604 20-605 20-606 20-607 20-608 20-609 20-610 20-611 20-612 20-613 20-614 20-615 20-616 20-617 20-618 20-619 20-620 20-621 20-622 20-623 20-624

(4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4)

30-1 30-2 30-3 30-4 30-5 30-6 30-7 30-8 30-9 30-9-1 30-10 30-11 30-12 30-13 30-14 30-15 30-16 30-17 30-17-1 30-17-2 30-18 30-19 30-20 30-21 30-22 30-23 30-24 30-25 30-26

(4) (4) (2) (2) (2) (2) (4) (4) (4) (4) (2) (2) (2) (2) (2) (2) (4) (4) (4) (4) (4) (4) (2) (2) (2) (2) (2) (2) (2)

Page

30-27 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-46 30-47 q 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74 30-75 30-76 30-77

Revision number

(2) (2) (2) (2) (2) (2) (2) (4) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (6) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)

00-2-3 (6)

Mark

Page

30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-96 30-97 30-98 30-99 30-100 30-101 30-101-1 30-101-2 30-102 30-103 30-104 30-104-1 30-104-2 30-104-3 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-114 30-115 30-116 30-117 30-118 30-119 30-120 30-121 30-122

00-2-4 (5)

Revision number Mark

(2) (2) (2) (4) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (4) (4) (4) (4) (4) (4) (2) (2) (4) (4) (4) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (4) (4) (4) (4) (4) (4) (4)

Page

90-1 90-3 90-5 90-7 90-9 90-11 90-13 90-15 90-17 90-19

Revision number Mark

Page

Revision number Mark

Page

Revision number Mark

Page

Revision number

(4) (4) (4) (4) (4) (4) (4) (4) (4)

PC160LC-7

SAFETY

SAFETY NOTICE

SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

FOREWORD

GENERAL

FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information 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 page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

00-6

Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water m u s t b e d r a i n ed , a n d quantity to be drained.

3 2

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter

Allowable load

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.

k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

! The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ! The adapter can be pushed in about 3.5 mm. ! Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ! Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ! Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ! When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

•

Disassembly

Type 2

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS ! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. ! For coating materials not listed below, use the equivalent of products shown in this list. Category

Komatsu code

Part No.

LT-1A

790-129-9030

LT-1B

790-129-9050

LT-2

09940-00030

LT-3

790-129-9060 (Set of adhesive and hardening agent)

LT-4

790-129-9040

Holtz MH 705

790-126-9120

Three bond 1735

790-129-9140

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

LG-1

790-129-9010

LG-5

790-129-9080

LG-6

790-129-9020

LG-7

790-129-9070

Three bond 1211

790-129-9090

Three bond 1207B

419-15-18131

Adhesives

Gasket sealant

00-10

Q’ty

Container

Main applications, features

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, 20 g Polyethylene polyprophylene, tetrafluoroethlene and (2 pcs.) container vinyl chloride), rubber, metal and nonmetal. • Features: Resistance to heat and chemicals Polyethylene 50 g • Used for anti-loosening and sealant container purpose for bolts and plugs. • Used as adhesive or sealant for metal, Adhesive: glass and plastic. 1 kg Hardening Can agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene (max. strength after 30 minutes) 2g container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene • Used at joint portions subject to high 50 cc container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold 200 g Tube • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, 1 kg Tube intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case 150 g

Tube

FOREWORD

Molybdenum disulphide lubricant

Komatsu code

Part No.

Q’ty

Container

LM-G

09940-00051

60 g

Can

LM-P

09940-00040

200 g

Tube

Various

G2-LI

G2-CA

Grease

Primer

Caulking material

Various

Molybdenum SYG2-400M 400 g × 10 Bellows type disulphide SYG2-400M-A 400 g × 20 Bellows type grease SYGA-16CNM 16 kg Can LM-G (G2-M) Hyper White SYG2-400T-A Grease G2-T SYG2-16CNT 400 g Bellows type G0-T (*) SYG0-400T-A (*) 16 kg Can *: For use in SYG0-16CNT (*) cold district Biogrease G2B SYG2-400B G2-BT (*) 400 g Bellows type SYGA-16CNB *: For high 16 kg Can SYG2-400BT (*) temperature SYGA-16CNBT (*) and large load SUNSTAR Glass PAINT PRIMER 20 ml container 580 SUPER 417-926-3910 SUNSTAR Glass GLASS PRIMER 20 ml container 580 SUPER SUNSTAR Glass 22M-54-27230 20 ml PAINT PRIMER container 435-95 SUNSTAR GLASS PRIMER 435-41

Adhesive

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27240

150 ml

Can

22M-54-27250

20 ml

Glass container

22M-54-27210

320 ml

Ecocart (Special container)

417-926-3910

320 ml

Polyethylene container

20Y-54-39850

310 ml

Polyethylene container

417-926-3920

320 ml

Polyethylene container

20Y-54-55130

333 ml

Polyethylene container

22M-54-27220

333 ml

Cartridge

Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type

• Used for normal temperature, light load bearing at places in contact with water or steam.

• Used for heavy load portion

• Seizure resistance and heat resistance higher than molybdenum disulfide grease • Since this grease is white, it does not stand out against machine body. • Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants.

• Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months)

Adhesive for cab glass

Category

COATING MATERIALS

• Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt

Width across flats

kgm

6 8 10 12 14

10 13 17 19 22

11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190

1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5

16 18 20 22 24

24 27 30 32 36

235 – 285 320 – 400 455 – 565 610 – 765 785 – 980

23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100

27 30 33 36 39

41 46 50 55 60

1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630

118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Thread diameter of bolt

Width across flats

kgm

6 8 10 12

10 13 14 27

5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

Tightening torque

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ! In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

SAD00483

Thread diameter

Width across flat

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49

2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

Tightening torque

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter

Width across flat

Tightening torque

kgm

10 12 16

14 17 22

59 – 74 98 – 123 235 – 285

6 – 7.5 10 – 12.5 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

Tightening torque (Nm {kgm})

Range

Target

14 20 24 33 42

Varies depending on type of connector.

35 – 63 {3.5 – 6.5} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 363 – 480 {37.0 – 49.0} 746 – 1010 {76.0 – 103}

44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

Norminal No.

02 03, 04 05, 06 10, 12 14

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

Tightening torque (Nm {kgm})

Range

Target

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 — 36 — —

5.88 – 8.82 {0.6 – 0.9} 9.8 – 12.74 {1.0 – 1.3} 14.7 – 19.6 {1.5 – 2.0} 19.6 – 24.5 {2.0 – 2.5} 24.5 – 34.3 {2.5 – 3.5} 34.3 – 44.1 {3.5 – 4.5} 44.1 – 53.9 {4.5 – 5.5} 58.8 – 78.4 {6.0 – 8.0} 93.1 – 122.5 {9.5 – 12.5} 107.8 – 147.0 {11.0 – 15.0} 127.4 – 176.4 {13.0 – 18.0} 181.3 – 240.1 {18.5 – 24.5} 274.4 – 367.5 {28.0 – 37.5}

7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

Norminal No.

08 10 12 14 16 18 20 24 30 33 36 42 52

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

kgm

6 8 10 12

10 ± 2 24 ± 4 43 ± 6 77 ± 12

1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

kgm

6 8 10 12 14

8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5

0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter

Tightening torque

inch

kgm

1 / 16 1/8 1/4 3/8 1/2 3/4 1

3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9

0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ! Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats

Taper seal type

Face seal type

Thread size Nominal thread Root diameter size - Threads per (mm) (Reference) (mm) inch, Thread series

Range

Target

34 – 54 {3.5 – 5.5}

44 {4.5}

–

9 — – 18UN 16

14.3

34 – 63 {3.5 – 6.5}

44 {4.5}

–

54 – 93 {5.5 – 9.5}

74 {7.5}

–

11 — – 16UN 16

17.5

59 – 98 {6.0 – 10.0}

78 {8.0}

–

84 – 132 {8.5 – 13.5}

103 {10.5}

13 — – 16UN 16

20.6

128 – 186 {13.0 – 19.0}

157 {16.0}

1 – 14UNS

25.4

177 – 245 {18.0 – 25.0}

216 {22.0}

3 1 — – 12UN 16

30.2

(10)

177 – 245 {18.0 – 25.0}

216 {22.0}

–

(12)

197 – 294 {20.0 – 30.0}

245 {25.0}

–

(14)

246 – 343 {25.0 – 35.0}

294 {30.0}

–

00-14

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.88

2.4

Starting, lighting, signal etc.

0.32

2.09

3.1

Lighting, signal etc.

0.32

5.23

4.6

Charging and signal

0.45

13.36

7.0

Starting (Glow plug)

0.80

42.73

11.4

135

Starting

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal number

Number of strands

Dia. of strands (mm2)

Cross section (mm2)

0.85

0.32

CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

Color

White

Black

Red

Yellow

Green

Blue

Code

—

2 Color White & Red

—

Code

—

White & Black Red & White Rellow & Red Green & White Blue & White BY

Auxiliary

Color White & Black

—

Code

—

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR

Color White & Blue

—

Code

—

Color White & Green

—

Code

—

Color

—

Black & Red Red & Yellow RG

Yellow & Green

Green & Yellow

Blue & Yellow

5 Red & Green Yellow & Blue Green & Black Blue & Black RL

—

6 Red & Blue Yellow & White Green & Blue

—

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). (2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). (3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. (B) Millimeters to inches 1 mm = 0.03937 in

(A)

00-16

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

FOREWORD

CONVERSION TABLE

Millimeters to Inches 1 mm = 0.03937 in

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

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 lb

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb 1 kgm = 7.233 ft. lb

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

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

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

FOREWORD

CONVERSION TABLE

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

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

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

1934

1949

1963

1977

140

1991

2005

2020

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

3542

00-20

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F

°C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 0

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-21

FOREWORD

UNITS

UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System 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}

00-22

04-05

01 GENERAL Specification dimension drawings ....................... 01-2 Specifications ...................................................... 01-4 Weight table ........................................................ 01-6 Fuel, coolant, and lubricants ............................... 01-8

PC160LC-7

01-1

GENERAL

SPECIFICATION DIMENSION DRAWINGS

SPECIFICATION DIMENSION DRAWINGS DIMENSIONS

WORKING RANGES

01-2

PC160LC-7

SPECIFICATION DIMENSION DRAWINGS

GENERAL

DIMENSIONS Item

Unit

PC160LC-7

Overall length

8,525

Overall height

3,000

Overall width

2,590

Track shoe width

600

Height of cab

2,970

Tail swing radius

2,435

Track overall length

3,965

Length of track on ground

3,170

Min. ground clearance

440

Item

Unit

PC160LC-7

Max. digging reach

8,960

Max. digging depth

5,960

Max. digging height

8,980

Max. vertical wall depth

5,040

Max. dumping height

6,370

Min. dumping height

2,400

Max. reach at ground level

8,800

WORKING RANGES

PC160LC-7

01-3

SPECIFICATIONS

GENERAL

SPECIFICATIONS PC160LC-7

Serial Number

10001 and up

Bucket capacity

0.6

Operating weight

16,620

Max. digging depth

5,960

Max. vertical wall depth

5,040

Max. digging reach

8,960

Max. reach at ground level

8,800

Max. digging height

8,980

Max. dumping height

6,370

kN {kg}

112.8 {11,500} (122.6 {12,500})

Swing speed

rpm

Swing max. slope angle

deg.

Travel speed

km/h

Lo: 3.4 Hi: 5.5

Gradeability

deg.

kPa {kg/cm2} (mm)

46.1 {0.47} (600)

Overall length (for transport)

8,565

Overall width

2,490

Overall width of track

2,590

Overall height (for transport)

3,025

Overall height to chassis

2,970

Ground clearance to bottom of upper structure

1,034

Min. ground clearance

440

Tail swing radius

2,435

Min. swing radius of work equipment

2,990

Height of work equipment at min. swing radius

7,185

Length of track on ground

3,170

Track gauge

1,990

Height of machine cab

2,305

Working ranges Performance

Machine model

Max. digging force (using power max. function)

Engine

Dimensions

Ground pressure (standard shoe width)

Model

SAA4D102E-2

Type

4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler

No. of cylinders - bore x stroke

4 – 102 x 120

Piston displacement

{cc}

3.92 {3,920}

01-4

PC160LC-7

SPECIFICATIONS

GENERAL

Machine model

PC160LC-7

Serial Number

10001 and up kW/rpm {HP/rpm} Nm/rpm {kgm/rpm}

83/2,200 {110/2,200} 451/1,500 {46/1,500}

Max. speed at no load

rpm

2,450

Min. speed at no load

rpm

1,050

Min. fuel consumption

g/kWh {g/HPh}

226 {168}

Performance

Engine

Flywheel horsepower Max. torque

Starting motor

24V, 4.5 kW

Alternator

24V, 35 A

Battery

12V, 80 Ah x 2 Corrugated aluminum

Track roller

7 on each side

Track shoe

Assembly-type triple grouser, 44 on each side

Type x No.

6-spool type x 1

Control method

Hydraulic type

Travel motor

HMV110ADT-2, Variable capacity piston type (with brake valve, parking brake x 2)

Swing motor

MSG-85P-17TR fixed capacity, Piston type (with safety valve, holding brake x 2)

Type

Boom (

Hydraulic motor

Hydraulic pump

2 on each side

Control valve

Carrier roller

Hydraulic culinder

Hydraulic system

Under-carriage

Radiator core type

Delivery Set pressure

HPD71, variable capacity piston type {cc}

Piston type: 156 x 2

MPa (kg/cm2)

31.4 {320}

Arm (

Bucket

Double acting piston

Inside diameter of cylinder

110

120

105

Diameter of piston rod

Stroke

1,175

1,342

1,027

Max. distance between pins

2,810

3,246

2,528

Min. distance between pins

1,635

1,904

1,501

Hrdraulic tank

Closed box type

Hydraulic filter

Tank return side

Hydraulic cooler

CF40-1 (Air cooled)

1. With cushion on head side

PC160LC-7

2. With cushion on bottom side

01-5

WEIGHT TABLE

GENERAL

WEIGHT TABLE This weight table is for use when handling components or when transporting the machine. Unit: kg Machine model

PC160LC-7

Serial Number

10001 and up

Engine assembly

572

• Engine

445

• Damper

• Hydraulic pump

121

Radiator, oil cooler assembly

112

Hydraulic tank, filter assembly (excluding hydraulic oil)

116

Fuel tank (excluding fuel)

117

Revolving frame

1,490

Operator's cab

278

Operator's seat

Counterweight

2,850

Swing machinery (including swing motor)

176

Main control valve

125

Travel motor

98 x 2

Center swivel joint

Track frame assembly

3,868

• Track frame

1,934

• Swing circle

222

• Idler

99 x 2

• Idler cushion

130 x 2

• Carrier roller

16 x 4

• Track roller

36 x 14

• Final drive (including travel motor)

343 x 2

01-6

PC160LC-7

WEIGHT TABLE

GENERAL

Unit: kg Machine model

PC160LC-7

Serial Number

10001 and up

Track shoe assembly • Standard triple grouser shoe (600 mm)

1,190 x 2

• Standard triple grouser shoe (700 mm)

1,300 x 2

• Wide triple grouser shoe (800 mm)

1,410 x 2

Boom assembly

1,085

Arm assembly

508

Bucket assembly

500

Boom cylinder assembly

138

Arm cylinder assembly

178

Bucket cylinder assembly

Front link assembly

25 x 2

List link assembly

15 x 2

Boom pin

29 + 6 x 2 + 21 + 10 + 19

Arm pin

11 + 7

Bucket pin

15 x 2

Link pin

15 x 2

PC160LC-7

01-7

FUEL, COOLANT, AND LUBRICANTS

GENERAL

FUEL, COOLANT, AND LUBRICANTS RESERVOIR

KIND OF -22 FLUID -30

AMBIENT TEMPERATURE -4 -20

14 -10

32 0

50 10

68 20

CAPACITY ( ) 86 30

104°F 40°C

Specified

Refill

14.3

14.0

Damper case

0.75

—

Swing machinery case

4.5

4.7

4.5

Idler (1 each)

0.07 – 0.08

Track roller (1 each)

0.19 – 0.20

Carrier roller (1 each)

0.075 – 0.085 0.075 – 0.085

SAE 30 SAE 10W

Engine oil pan

SAE 10W-30 SAE 15W-40

Final drive case (each)

Engine oil

SAE 30

SAE 10W SAE 10W-30 Hydraulic system

SAE 15W-40 Hydraulic oil

Fuel tank

Cooling system

Diesel fuel Coolant

190

121

280

—

18.6

HO46-HM (★) ASTM D975 No. 2 ASTM D975 No. 1 Add antifreeze

★ For the HO46-HM, use the oil recommended by Komatsu.

01-8

PC160LC-7

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD Engine related parts..............................................10- 2 Radiator • oil cooler • aftercooler ..........................10- 3 Power train............................................................10- 4 Swing machinery ..................................................10- 5 Swing circle...........................................................10- 6 Final drive .............................................................10- 8 Track frame • recoil spring ....................................10-10 Idler.......................................................................10-12 Carrier roller..........................................................10-14 Track roller ............................................................10-15 Track shoe ............................................................10-16 Hydraulic equipment layout drawing.....................10-20 Valve control .........................................................10-22 Hydraulic tank .......................................................10-23 Hydraulic pump.....................................................10-24 PC-EPC valve.......................................................10-42 Control valve.........................................................10-48 CLSS ....................................................................10-62 Travel junction valve .............................................10-93 Self-reducing pressure valve ................................10-94 Center swivel joint.................................................10-95 Swing motor..........................................................10-96 Travel motor..........................................................10-97 Work equipment • swing PPC valve ...................10-106 Travel PPC valve ................................................ 10-110 Service PPC valve .............................................. 10-119 Solenoid valve ....................................................10-122 Accumulator........................................................10-124 Return oil filter.....................................................10-125 Attachment circuit selector valve ........................10-126 Hydraulic cylinder ...............................................10-128 Work equipment..................................................10-130 Air conditioner.....................................................10-136 Engine control.....................................................10-137 Electronic control system....................................10-145 Multi monitor system...........................................10-170 7-Segment monitor system.................................10-191 Sensor ................................................................10-198

PC160LC-7

10-1 (3)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE RELATED PARTS

1. Drive plate 2. Torsion spring 3. Stopper pin 4. Friction plate

10-2

5. Damper assembly 6. Muffler 7. Rear engine mount 8. Front engine mount

OUTLINE • The damper assembly is a wet type. Oil capacity: 0.75

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

RADIATOR • OIL COOLER • AFTERCOOLER

1. Radiator cap 2. Radiator inlet hose 3. Radiator 4. Aftercooler 5. Oil cooler 6. Net 7. Fan 8. Radiator outlet hose 9. Shroud 10. Reservoir tank

PC160LC-7

SPECIFICATIONS Radiator : Corrugated aluminum Oil cooler : CF40-1 Aftercooler : Corrugated aluminum

10-3

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

POWER TRAIN

1. Idler 2. Center swivel joint 3. Control valve 4. Final drive 5. Travel motor (HMV 110ADT-2) 6. Hydraulic pump (HPD71)

10-4

7. Engine 8. Travel speed solenoid valve 9. Swing brake solenoid valve 10. Swing motor (MSG-85P-17TR) 11. Swing machinery 12. Swing circle

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

POWER TRAIN

SWING MACHINERY

1. Swing motor assembly 2. Oil level gauge 3. No. 1 sun gear 4. No. 1 planetary gear 5. No. 2 sun gear 6. No. 2 planetary gear 7. No. 2 planetary carrier

PC160LC-7

8. Collar 9. Swing pinion 10. Cover 11. Case 12. No. 1 planetary carrier 13. Ring gear

10-5

SWING CIRCLE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING CIRCLE

1. Swing circle inner race (No. of teeth: 99) 2. Ball 3. Swing circle outer race

SPECIFICATIONS

a. Inner race soft zone S position b. Outer race soft zone S position

Amount of grease: 10.5

Reduction ratio:  13  = 7.615 99

(G2-LI) Unit: mm

No.

Check item

Axial clearance of bearing (when mounted on chassis)

10-6

Criteria

Remedy

Standard clearance

Clearance limit

0.5 – 1.6

3.2

Replace

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

FINAL DRIVE

10-8

PC160LC-7

FINAL DRIVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Level plug 2. Drain plug 3. No. 2 sun gear (No. of teeth: 21) 4. No. 1 sun gear (No. of teeth: 10) 5. No. 1 planetary carrier 6. Cover 7. No. 2 planetary carrier 8. Sprocket 9. Floating seal 10. Travel motor 11. Hub 12. No. 2 planetary gear (No. of teeth: 36) 13. Ring gear (No. of teeth: 95) 14. No. 1 planetary gear (No. of teeth: 42) SPECIFICATIONS Reduction ratio: – 10+95  x 21+95 + 1 = – 57.00  10   21 

Unit: mm

No.

Check item

Backlash between No. 1 sun gear and No. 1 planetary gear

Criteria

Remedy

Standard clearance

Clearance limit

0.14 – 0.46

1.00

Backlash between No. 2 planetary gear and ring gear

0.17 – 0.57

1.10

Backlash between No. 1 planetary carrier and No. 2 sun gear

0.38 – 0.66

—

Backlash between No. 2 sun gear and No. 2 planetary gear

0.15 – 0.49

1.00

Backlash between No. 1 planetary gear and ring gear

0.17 – 0.57

1.10

Backlash between No. 2 planetary carrier and mototr

0.06 – 0.25

1.00

Amount of wear on sprocket tooth

Replace

Repair limit: 6 Standard size

Repair limit

Rebuild or replace

Width of sprocket tooth

PC160LC-7

10-9

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK FRAME • RECOIL SPRING

1. Idler 2. Track frame 3. Carrier roller 4. Final drive 5. Track roller 6. Track shoe 7. Center guard 8. Recoil spring 9. Front guard

10-10

•

Number of track rollers Q’ty

Model

(each side)

PC160LC-7

TRACK FRAME • RECOIL SPRING

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Standard shoe Model Item

PC160LC-7

Shoe width

600 mm

Link pitch

190 mm

No. on track (one side)

44 (pieces)

Unit: mm

No.

Check item

Criteria Standard size

Vertical width of idler guide

Track frame

107

Idler support

105

Track frame

250

Idler support

247.4

Remedy Tolerance

Rebuild or replace

Horizontal width of idler guide

Standard size 12

Repair limit

Recoil spring

PC160LC-7

Repair limit

Free length x O.D.

Installation length

Installation load

Free length

Installation load

558.5 X 237

437

109.0 kN {11,110 kg}

—

Replace

10-11 (6)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

IDLER

10-12

PC160LC-7

IDLER

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm

No. 1

Check item

Criteria

Remedy

Standard size

Repair limit

538

—

Outside diameter of protruding

Outside diameter of tread

500

488

Thickness of tread

Total width

159

—

Width of tread

37.5

43.5 Tolerance

Standard size 6

Clearance between shaft and bushing 65

Shaft

Hole

– 0.250 – 0.350

+ 0.074 – 0.036

Tolerance Standard size 7

Interference between idler and bushing 72

PC160LC-7

Shaft

Hole

+ 0.089 + 0.059

– 0.006 – 0.072

Rebuild or replace

Standard clearance

Clearance limit

0.214 – 0.424

1.5

Standard interference

Interference limit

0.065 – 0.161

—

Replace bushing

10-13

CARRIER ROLLER

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CARRIER ROLLER

Unit: mm

No. 1

Check item

Criteria

Remedy

Standard size

Repair limit

145

—

Outside diameter of flange

Outside diameter of tread

120

106

Width of tread

—

Thickness of tread

36.5

29.5

Width of flange

— Tolerance

Standard size 6

Clearance between shaft and bushing 40

Shaft

Hole

– 0.179 – 0.190

+ 0.284 + 0.169

Tolerance Standard size 7

Interference between roller and bushing 47

Axial clearance of roller

10-14

Shaft

Hole

– 0.061 – 0.036

0 – 0.040

Standard clearance

Clearance limit

0.339 – 0.474

—

Standard interference

Interference limit

0.036 – 0.101

—

Standard clearance

Clearance limit

0.44 – 0.76

—

Replace

PC160LC-7

TRACK ROLLER

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK ROLLER

Unit: mm

No. 1

Check item

Criteria

Remedy

Standard size

Repair limit

188

—

Outside diameter of flange

Outside diameter of tread

156

144

Thickness of tread

44.5

38.5

Overall width

225

—

Inside width

—

Width of tread

44.5

—

Width of flange

25.5

— Tolerance

Standard size 8

Clearance between shaft and bushing 60

Shaft

Hole

– 0.215 – 0.315

+ 0.195 0

Tolerance Standard size 9

Interference between roller and bushing 67

PC160LC-7

Shaft

Hole

+ 0.153 + 0.053

+ 0.030 0

Rebuild or replace

Standard clearance

Clearance limit

0.215 – 0.510

1.5

Standard interference

Interference limit

0.023 – 0.153

—

Replace bushing

10-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRACK SHOE

★ P portion shows the link of bushing press fitting end.

10-16

PC160LC-7

TRACK SHOE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm

No. 1

Check item

Criteria

Remedy

Standard size

Repair limit

190.25

193.25

Link pitch Reverse or replace

When turned Standard size 2

Bushing outside diameter 59.3

Link height Thickness of link metal (bushing press-fitting portion)

4 5

Normal load

Impact load

—

54.3

Standard size

Repair limit

105

28.5

20.5

Repair or replace

160.4 Shoe bolt pitch

8 9

Link

Inside width

84.8

Overall width

45.4

Tread width

39.6

Regular

2.5

Master

2.5

Regular

4.85

Master

0.0

Regular

212

Master

212

Regular

138.5

Master

128.7

Standard

10.4

Protrusion of pin

Adjust or replace

Protrusion of bushing

Overall length of pin

Overall length of bushing

Thickness of bushing metal

When turned / Impact Load

Thickness of spacer

5.4

Reverse or replace

— Bushing

88.2 – 245 kN {9 – 25 ton} —

Press-fitting force

Regular pin

127.4 – 274.4 kN {13 – 28 ton}

Master pin

78.4 – 147 kN {8 – 15 ton}

: Dry type track link

PC160LC-7

10-17

TRACK SHOE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm

No.

Check item

Criteria

Remedy

Tightening torque (Nm {kgm})

Additional tightening angle (deg.)

490 ± 49 {50 ± 5}

120 ± 10

Regular link Shoe bolt

Retighten

Tightening torque (Nm {kgm})

Additional tightening angle (deg.)

Lower limit torque (Nm {kgm})

—

Master link

No. of shoes (each side)

—

Tolerance

Standard interference

Standard size 21

Shaft

Hole

+ 0.434 + 0.394

+ 0.074 0

0.320 – 0.434

+ 0.222 + 0.162

+ 0.138 – 0.200

0.300 – 0.422

Interference between bushing and link

Interference between regular pin and link

Tolerance

Standard clearance

Standard size 23

Clearance between regular pin and bushing 38

Shaft

Hole

+ 0.222 + 0.162

+ 0.902 + 0.402

0.180 – 0.740

Tolerance

Standard interference

Standard size 24

Interference between master pin and link 37.8

Shaft

Hole

+ 0.280 + 0.250

+ 0.062 0

0.188 – 0.280

Tolerance

Standard clearance

Standard size 25

Clearance between master pin and bushing 38

—

Height of grouser

Adjust or replace

Shaft

Hole

– 0.150 – 0.350

+ 0.902 + 0.402

0.552 – 1.252

Standard size

Repair limit

Lug welding, rebuild or replace

: Dry type track link

10-18

PC160LC-7

TRACK SHOE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRIPLE GROUSER SHOE

Unit: mm

No. 1

Check item Height

Criteria

Remedy

Standard size

Repair limit

Thickness

8.5

26 Length of base 19

Rebuild or replace 5 6

20 Length at tip

19 Standard size

Repair limit

34.5

24.5

Thickness

PC160LC-7

10-19

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC EQUIPMENT LAYOUT DRAWING

HYDRAULIC EQUIPMENT LAYOUT DRAWING 1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Hydraulic tank 5. Hydraulic filter 6. R.H. travel motor 7. Hydraulic pump 8. Control valve 9. Oil cooler 10. L.H. travel motor 11. Swing motor 12. L.H. PPC valve 13. Safety lever (electric type) 14. Center swivel joint 15. R.H. PPC valve 16. Travel PPC valve 17. Attachment circuit selector valve 18. Accumulator 19. Solenoid valve assembly 19A PPC lock solenoid 19B Travel junction solenoid 19C Pump merge/divider solenoid 19D Travel speed solenoid 19E Swing holding brake solenoid 19F 2-stage relief solenoid

10-20

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC160LC-7

HYDRAULIC EQUIPMENT LAYOUT DRAWING

10-21

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

VALVE CONTROL

1. Travel PPC valve 2. Service PPC valve 3. Service pedal 4. L.H. travel lever 5. R.H. travel lever 6. R.H. PPC valve 7. R.H. work equipment control lever

10-22

8. Accumulator 9. Hydraulic pump 10. Control valve 11. Solenoid block 12. Junction box 13. L.H. work equipment control lever 14. L.H. PPC valve

Lever positions (1) Hold (2) Boom "RAISE" (3) Boom "LOWER" (4) Bucket "DUMP" (5) Bucket "CURL" (6) Hold (7) Arm "IN" (8) Arm "OUT"

(9) Swing "RIGHT" (10) Swing "LEFT" (11) Neutral (12) Travel "REVERSE" (13) Travel "FORWARD"

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC TANK

1. Hydraulic tank 2. Oil filler cap 3. Sight gauge 4. Bypass valve 5. Strainer 6. Filter element 7. Suction strainer

PC160LC-7

SPECIFICATIONS Tank capacity: 167 Amount of oil inside tank: 121 Pressure valve Relief cracking pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} Suction cracking pressure: 0 - 0.49 kPa {0 - 0.005 kg/cm2} Bypass Valve set pressure: 150 ± 30 kPa {1.5 ± 0.3 kg/cm2}

10-23

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

HYDRAULIC PUMP TEPE: HPD71 Outline • This pump consists of variable capacity swash plate piston pump, PC valve, LS valve, and EPC valve.

IM: PC mode selector current PB: Pump pressure input PM: PC mode selector pressure pickup port PS: Suction port of pump PA1: Discharge port of pump PA2: Discharge port of pump

10-24

PD1: PEN:

Case drain port Pump control pressure pickup port PLS: Load pressure input PA1C: P1 pump discharge pressure pickup port PA2C: P2 pump discharge pressure pickup port PEPC: EPC base pressure input PLSC: Load pressure pickup port

1. Main pump 2. LS valve 3. PC valve 4. PC-EPC valve 5. No. 1 check valve 6. No. 2 check valve 7. Shuttle valve

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Shaft 2. Cradle 3. Case 4. Rocker cam 5. Shoe

PC160LC-7

HYDRAULIC PUMP

6. Piston 7. Cylinder block 8. Valve plate 9. End cap 10. Servo piston

10-25

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

FUNCTION •

•

The rotation and torque transmitted to the pump shaft are converted into hydraulic energy, and pressurized oil is discharged according to the load. It is possible to change the discharge amount by changing the swash plate angle.

STRUCTURE •

•

Cylinder block (7) is supported to shaft (1) by a spline a, and shaft (1) is supported by the front and rear bearings. The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing.

10-26

•

Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylinder surface B with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

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 along cylindrical surface B, so angle α between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle α is called the swash plate angle.) • Center line X of rocker cam (4) maintains swash plate angle α in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). • In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F - E. • In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes bigger, the oil is sucked in. • If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volu m e s E a n d F i n s i d e c y l i n d e r b l o c k ( 7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.) • The number of holes on cylinder block (7) is even and every second one of them is fitted to 2 grooves of valve plate (8). The quantity of the oil equivalent to 1/2 of the all pistons is discharged to each of discharge ports PA1 and PA2.

PC160LC-7

10-27

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

2. Control of discharge amount • If the swash plate angle α becomes larger, the difference between volumes E and F becomes larger and discharge amount Q increases. • Swash plate angle α is changed by servo piston (12). • Servo piston (12) moves in a reciprocal movement (↔) according to the signal pressure from the PC and LS valves. This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), slides in a rotating movement in direction of arrow. • With servo piston (12), the area receiving the pressure is different on the left and the right, so main pump discharge pressure (check valve output pressure) PP is always brought to the chamber receiving the pressure at the small diameter piston end. • Output pressure PEN of the LS valve is brought to the chamber receiving the pressure at the large diameter end. The relationship in the size of pressure PP at the small diameter piston end and pressure PEN at the large diameter end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).

10-28

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

LS VALVE

1. Plug 2. Locknut 3. Sleeve 4. Spring 5. Seat 6. Spool 7. Piston 8. Sleeve

PA : Pump port PP : Pump port PDP : Drain port PLP : LS control pressure output port PLS : LS pressure input port PPL : PC control pressure input port PSIG : Drain port

PC VALVE

1. Servo piston assembly 2. Plug 3. Pin 4. Spool 5. Retainer 6. Seat 7. Cover 8. Wiring

PC160LC-7

PA : Pump port PA2 : Pump pressure pilot port PDP : Drain port PM : PC mode selector pressure pilot port PPL : PC control pressure output port PPL2: LS control pressure output port

10-29

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

FUNCTION 1. LS valve • The LS valve detects the load and controls the discharge amount. • This valve controls main pump discharge amount Q according to differential pressure ∆PLS (= PP – PLS) [called the LS differential pressure] (the difference between main pump pressure PP and control valve outlet port pressure PLS). • Main pump pressure PP, pressure PLS {called the LS pressure} coming from the control valve output. 2. PC valve • When the pump discharge pressure PP1 (check valve output pressure) and PP2 (shuttle valve output pressure) are high, the PC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way, it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. • In other words, If the load during the operation becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (average discharge amount of F, R pumps (PP1 + PP2)/2) and pump discharge amount Q is shown on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. The controller senses the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below the set value, the command current to the PCE P C v a l v e s o l e n o i d f r o m t h e c o n t r ol l e r increases according to the drop in the engine speed to reduce the pump swash plate angle.

10-30

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

OPERATION

1. LS valve 1) When control valve is at neutral position • The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the inlet port of the control valve brought to spring chamber B, and main pump discharge pressure PP brought to port H of sleeve (8). The size of this LS pressure PLS + force Z of spring (4) and the main pump pressure (check valve output pressure) PP determines the position of spool (6). • Before the engine is started, servo piston (12) is pushed to the right. (See the diagram on the right) • When the engine is started and the control lever is at the neutral position, LS pressure PLS is 0 MPa {0 kg/cm2}. (It is interconnected with the drain circuit through the control valve spool.) At this point, spool (6) is pushed to the left,and port C and port D are connected. Pump pressure PP enters the large diameter end of the piston from port K and the same pump pressure PP also enters port J at the small diameter end of the piston, so the swash plate is moved to the minimum angle by the difference in the area of the servo piston (12). PC160LC-7

10-31

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

2) Operation in increase direction for pump discharge amount • When the difference between the main pump pressure PP and LS pressure PLS, in other w o r d s , L S d i ff e r e n t i a l p r e s s u r e ∆ P L S , becomes smaller (for example, when the area of opening of the control valve becomes larger and pump PP drops), spool (6) is pushed to the right by the combined force of LS pressure PLS and the force of spring (4). • When spool (6) moves, port D and port E are joined and connected to the PC valve. When this happens, the PC valve is connected to the drain port, so circuit D - K becomes drain pressure PT. (The operation of the PC valve is explained later).

10-32

HYDRAULIC PUMP

• For this reason, the pressure at the large diameter end of servo piston (12) becomes drain pressure PT, and pump pressure PP enters port J at the small diameter end, so servo piston (12) is pushed to the right. Therefore, the swash plate moves in the direction to make the discharge amount larger.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

3) Operation in decrease direction for pump discharge amount • The following explains the situation if the servo piston (12) moves to the left (the discharge amount becomes smaller). When LS differential pressure ∆ PLS becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (6) to the left. • When spool (6) moves, main port pressure PP flows from port C and port D and from port K, it enters the large diameter end of the piston.

PC160LC-7

HYDRAULIC PUMP

• Main pump pressure PP also enters port J at the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end of servo piston (12), servo piston (12) is pushed to the left. • As a result, the swash plate moves in the direction to make angle smaller.

10-33

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

4) When servo piston is balanced • Let us take the area receiving the pressure at the large diameter end of the piston as A1, the area receiving the pressure at the small diameter end as A0, and the pressure flowing into the large diameter end of the piston as PEN. If the main pump pressure PP of the LS valve and the combined force of force Z of spring (4) and LS pressure PLS are balanced, and the relationship is A0 x PP = A1 x PEN, servo piston (12) will stop in that position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the opening of the throttle from port D to port E and from port C to port D of spool (6) is approximately the same.)

10-34

HYDRAULIC PUMP

• At this point, the relationship between the area receiving the pressure at both ends of piston (12) is A0 : A1 = 1:2, so the pressure applied to both ends of the piston when it is balanced becomes PP : PEN = 2:1. • The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is adjusted so that it is determined when PP - PLS = 2.2 MPa {22.3 kg/cm2}.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

2. PC valve 1) When pump controller is normal a. When the load on the actuator is small and pump pressures PP1 and PP2 are low i. Movement of PC-EPC solenoid (1) • The command current from the pump controller flows to PC-EPC solenoid (1). This command current acts on the PC-EPC valve and outputs the signal pressure. When this signal pressure is received, the force pushing piston (2) is changed. • On the opposite side to the force pushing this piston (2) is the spring set pressure of springs (4) and (6) and pump pressure PP1 (check valve output pressure) and PP2 (shuttle valve output pressure) pushing spool (3). Piston (2) stops at a position where the combined force pushing spool (3) is balanced, and the pressure (pressure of port C) output from the PC valve changes according to this position. PC160LC-7

HYDRAULIC PUMP

• The size of command current X is determined by the nature of the operation (lever operation), the selection of the working mode, and the set value and actual value for the engine speed.

10-35

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ii. Action of spring • The spring load of springs (4) and (6) in the PC valve is determined by the swash plate position. • If piston (9) moves to the left, spring (6) is compressed, and if it moves further to the left, spring (6) contacts seat (5) and is fixed in position. In other words, the spring load is changed by piston (9) extending or compressing springs (4) and (6).

10-36

HYDRAULIC PUMP

• If the command circuit input to PC-EPC valve solenoid (1) changes further, the force pushing piston (2) changes, and the spring load of springs (4) and (6) also changes according to the valve of the PC-EPC valve solenoid command current.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

• Port C of the PC valve is connected to port E of the LS valve (see 1. LS valve). Check valve output pressure PP1 enters port B and the small diameter end of servo piston (9), and shuttle valve output pressure PP2 enters port A. • When pump pressures PP1 and PP2 are small, spool (3) is on the left. At this point, port C and D are connected, and the pressure entering the LS valve becomes drain pressure PT. If port E and port G of the LS valve are connected (see 1. LS valve), the pressure entering the large diameter end of the piston from port J becomes drain pressure PT, and servo piston (9) moves to the right. In this way, the pump discharge amount moves in the direction of increase. • As servo piston (9) moves further, springs (4) and (6) expand and the spring force becomes weaker. When the spring force becomes weaker, spool (3) moves to the right, so the connection between port C and port D is cut, and the pump discharge pressure ports B and C are connected. As a result, the pressure at port C rises, and the pressure at the large diameter end of the piston also rises, so the movement of piston (9) to the right is stopped. • In other words, the stop position for piston (9) (= pump discharge amount) is decided at the point where the force of springs (4) and (6) and the pushing force from the PC-EPC valve solenoid and the pushing force created by the pressures PP1 and PP2 acting on the spool (3) are in balance.

PC160LC-7

10-37

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

b. When load on actuator is large and pump discharge pressure is high • When the load is large and pump discharge pressures PP1 and PP2 are high, the force pushing spool (3) to the left becomes larger and spool (3) moves to the position in the diagram above. When this happens, as shown in the diagram above, part of the pressurized oil from port A flows out through port C where the LS valve is actuated to port D, and the pressurized oil flowing from port C to the LS valve becomes approximately half of main pump pressure PP. • When port E and port G of the LS valve are connected, the pressure from port J enters the large diameter end of servo piston (9), and servo piston (9) stops.

10-38

HYDRAULIC PUMP

• If main pump discharge pressure PP increases further and spool (3) moves further to the left, main pump pressure PP1 flows to port C and acts to make the discharge amount the minimum. When piston (9) moves to the left, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the left, the opening of port C and port D becomes larger. As a result, the pressure at port C (= J) drops, and piston (9) stops moving to the left. • The position in which piston (9) stops when this happens is further to the left than the position when pump discharge pressures PP1 and PP2 are low.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC PUMP

• The relation of average pump discharge pressure (PP1 + PP2)/2 and the position of servo piston (9) forms a bent line because of the double-spring effect of springs (4) and (6). The relationship between average pump discharge pressure (PP1 + PP2)/2 and pump discharge amount Q is shown in the figure at the right. • If command voltage X sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump discharge pressure (PP1 + PP2)/2, and pump discharge amount Q is proportional to the pushing force of the PCEPC valve solenoid and moves in parallel. In other words, the pushing force of PC-EPC solenoid (1) is added to the force pushing to the left because of the pump pressure applied to the spool (3), so the relationship between the average pump discharge pressure (PP1 + PP2)/2 and Q moves from [1] to [2] in accordance with the increase in X.

PC160LC-7

10-39

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

2) When pump controller is abnormal and PC prolix switch is ON a. When load on main pump is light • If there is a failure in the pump controller, turn PC prolix switch ON to switch to the resistor side. In this case, the power source is taken directly from the battery. But if the current is used as it is, it is too large, so use the resistor to control the current flowing to PC-EPC valve solenoid (1). • When this is done, the current becomes constant, so the force pushing piston (2) is also constant. • If the main pump discharge pressure PP1 and PP2 are low, the combined force of the pump discharge pressure and the force of PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the left.

10-40

HYDRAULIC PUMP

• At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the discharge amount larger.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

b. When main pump load is heavy • In the same way as in the previous item, when the PC prolix switch is ON, the command curr e nt se nt t o P C- E P C v al v e s ol en oi d ( 1 ) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. • If main pump pressures PP1 and PP2 increase, spool (3) moves further to the left than when the main pump load is light, and is balanced at the position in the diagram above. • In this case, the pressure from port A flows to port C, so servo piston (9) moves to the left (to make the discharge amount smaller) and stops at a position to the left of the position when the load on the pump is light. In other words, even when the emergency pump drive switch is ON, the curve for the pump pressure PP and discharge amount Q is determined as shown in the diagram for the valve of the current sent to PC160LC-7

HYDRAULIC PUMP

the PC-EPC valve solenoid through the resistor. The curve when the PC prolix switch is ON is curve [2], which is to the left of curve [1] for when the pump controller is normal.

10-41

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC-EPC VALVE

1. Body 2. Spool 3. Spring 4. Rod 5. Coil 6. Plunger 7. Connector

10-42

PM : To PC valve PT : To tank PEPC : From self-reducing pressure valve

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC-EPC VALVE

FUNCTION • •

The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. When it receives signal current i from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the PC valve.

OPERATION 1. When signal current is 0 (coil de-energized) • When there is no signal current flowing from the controller to coil (5), coil (5) is generalized. • For this reason, spool (2) is pushed to the right in the direction of the arrow by spring (3). • As a result, port PEPC closes and the pressurized oil from the main pump does not flow to the PC valve. At the same time, the pressurized oil from the PC valve passes from port PM through port PT and is drained to the tank.

PC160LC-7

10-43

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC-EPC VALVE

2. When signal current is very small (coil energized) • When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated which pushes plunger (6) to the left. • Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port PEPC to port PM. • When the pressure at port PM rises and the load of spring (3) + the force acting on surface a of spool (2) becomes greater than the propulsion force of plunger (6), spool (2) is pushed to the right. The circuit between port PEPC and port PM is shut off, and at the same time, port PM and port PT are connected. • As a result, spool (2) is moved up or down until the propulsion force of plunger (6) is balanced with the load of spring (3) + pressure of port PM. • Therefore, the circuit pressure between the EPC valve and the PC valve is controlled in proportion to the size of the signal current. 3. When signal current is maximum (coil energized) • When the signal current flows to coil (5), coil (5) is energized. • When this happens, the signal current is at its maximum, so the propulsion force of plunger (6) is also at its maximum. • For this reason, spool (2) is pushed fully to the left by push pin (4). • As a result, the maximum flow of pressurized oil from port PEPC flows to port PM, and the circuit pressure between the EPC valve and PC valve becomes the maximum. At the same time, port PT closes and stops the oil from flowing to the tank.

10-44

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC-EPC VALVE

CHECK VALVE FUNCTION A set of 2 check valves is used to select and output the higher discharge pressure of the 2 main pumps.

PA1: Discharge pressure of main pump PA2: Discharge pressure of main pump PP1: Output pressure of check valve

1. Poppet valve 2. Poppet valve

OPERATION 1. When PA1 > PA2 • Discharge pressures PA1 and PA2 of the main pumps are applied to poppet valves (1) and (2). Since PA1 > PA2, however, poppet valve (2) is kept closed and PA1 is output to PP1.

PC160LC-7

2. When PA1 < PA2 • Reversely to 1., poppet valve (1) is kept closed and PA2 is output to PP1.

10-45

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC-EPC VALVE

SHUTTLE VALVE FUNCTION The shuttle valve selects and outputs the lower discharge pressure of the 2 main pumps.

PA1: Discharge pressure of main pump PA2: Discharge pressure of main pump PP2: Output pressure of shuttle valve

1. Poppet valve 2. Poppet valve 3. Pin

OPERATION •

•

The discharge pressures PA1 and PA2 of the 2 main pumps are applied to poppet valves (1) and (2) respectively. Since poppet valves (1) and (2) push each other through pin (3), either one of them receiving higher pressure is closed and the other one receiving lower pressure is opened. Accordingly, lower discharge pressure of the 2 main pumps is output.

10-46

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

CONTROL VALVE OUTLINE The following 4 types of control valve are set. • •

6-spool valve (Without service valve) 6-spool valve (Without service valve, with alarm lock valve)

• •

7-spool valve (6-spool valve + Service valve) 7-spool valve (6-spool valve + Service valve, with alarm lock valve)

The outside view and section of only 7-spool valve (6-spool valve + service valve) are shown here. The specifications of only the arms of the valves having arm lock valves are added, however. A1: To swing motor A2: To left travel motor A3: To right travel motor A4: To boom cylinder bottom A5: To arm cylinder head A6: To bucket cylinder head A7: To attachment B1: To swing motor B2: To left travel motor B3: To right travel motor B4: To boom cylinder head B5: To arm cylinder bottom B6: To bucket cylinder bottom B7: To attachment LS: To pump LS valve P1: From main pump P2: From main pump PP: To main pump PR: To solenoid valve, PPC valve, and EPC valve PS: From merge-divider solenoid valve PX: From 2-stage relief solenoid valve TB: To tank TC: To oil cooler BP1: From boom raise PPC valve BP2: From attachment circuit selector solenoid valve PA1: From swing left PPC valve PA2: From left travel PPC valve PA3: From right travel reverse PPC valve PA4: From boom raise PPC valve PA5: From arm OUT PPC valve PA6: From bucket dump PPC valve PA7: From service 1 PPC valve PB1: From swing right PPC valve

10-48

PB2: From left travel reverse PPC valve PB3: From right travel forward PPC valve PB4: From boom lower PPC valve PB5: From arm IN PPC valve PB6: From bucket CURL PPC valve PB7: From service 1 PPC valve PP1: Pressure sensor port (If equipped with pressure sensor) PP2: Pressure sensor port (If equipped with pressure sensor) PST: From travel junction solenoid valve SA5: From travel PPC valve SA6: From travel PPC valve SB4: From travel PPC valve SB5: From travel PPC valve TS1: To tank TS2: To tank 1. Swing bleed valve 2. LS check valve 3. Travel junction valve + LS check valve 4. Arm regeneration valve 5. Boom hydraulic drift prevention valve 6. Cover 7. Service valve 8. Butterfly valve 9. Arm valve 10. Boom valve 11. Right travel valve 12. Left travel valve 13. Swing valve 14. Block 15. Pump merge-divider valve block

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC160LC-7

CONTROL VALVE

10-49

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CONTROL VALVE

SPECIFICATION WITH ARM LOCK VALVE

16. Arm hydraulic drift prevention valve

10-50

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Safety-suction valve (Service) 2. Suction valve (Bucket) 3. Suction valve (Arm) 4. Suction valve (Boom) 5. Suction valve (Left travel) 6. Suction valve (Right travel) 7. Suction valve (Right travel) 8. Suction valve (Left travel) 9. Safety-suction valve (Boom) 10. Suction valve (Arm) 11. Suction valve (Bucket) 12. Safety-suction valve (Service) 13. Safety-suction valve 14. Main relief valve 15. Lift check valve 16. Unload valve 17. Unload valve

10-52

CONTROL VALVE

18. Spool (Service) 19. Spool (Bucket) 20. Spool (Arm) 21. Spool (Boom) 22. Spool (Left travel) 23. Spool (Right travel) 24. Spool (Swing)

PC160LC-7

CONTROL VALVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm No.

Check item

Criteria

Remedy

Standard size 25

Piston spring

Free length x Installed length Outside diameter

Repair limit Installed load

Free length

Installed load

16 × 16

12.6

4.9 N {0.5 kg}



3.9 N {0.4 kg}

Suction spring

10.5 × 7

6.8

2.0 N {0.21 kg}



1.6 N {0.17 kg}

Suction spring

46.8 × 7.5

40.6

5.5 N {0.56 kg}



4.4 N {0.45 kg}

Suction spring

39.2 × 4.5

33.5

5.1 N {0.52 kg}



4.1 N {0.42 kg}

Spool return spring

45.6 × 28

231 N {23.5 kg}



185 N {18.8 kg}

Spool return spring

45.7× 28

221 N {22.6 kg}



177 N {18.1 kg}

Spool return spring

42.4 × 28

221 N {22.6 kg}



177 N {18.1 kg}

Spool return spring

42.1 × 28

221 N {22.6 kg}



177 N {18.1 kg}

Spool return spring

27.1 × 25.8

25.5

56 N {5.7 kg}



45 N {4.6 kg}

Spool return spring

32.4 × 11

31.4

60 N {6.1 kg}



48 N {4.9 kg}

Spool return spring

41.8 × 19

38.5

141 N {14.4 kg}



113 N {11.5 kg}

PC160LC-7

If damaged or deformed, replace spring

10-53

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1 LS selector valve 2. Cooler bypass valve 3. Pressure compensation valve F (Service) 4. Pressure compensation valve F (Bucket) 5. Pressure compensation valve F (Arm) 6. Pressure compensation valve F (Boom) 7. Pressure compensation valve F (Left travel) 8. Pressure compensation valve F (Right travel) 9. Pressure compensation valve F (Swing) 10. Pressure compensation valve R (Swing)

10-54

CONTROL VALVE

11. Pressure compensation valve R (Right travel) 12. Pressure compensation valve R (Left travel) 13. Pressure compensation valve R (Boom) 14. Pressure compensation valve R (Arm) 15. Pressure compensation valve R (Bucket) 16. Variable pressure compensation valve (Service) 17. Pump merge-divider valve spool F: Flow control valve R: Pressure reducing valve

PC160LC-7

CONTROL VALVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm No.

Check item

Criteria

Remedy

Standard size 18

Check valve spring

Free length x Installed length Outside diameter

Repair limit Installed load

Free length

Installed load

41.5 × 8.5

31.5

5.9 N {0.6 kg}



4.7 N {0.5 kg}

20.3 × 13.7

2.9 N {0.3 kg}



2.3 N {0.24 kg}



7.8 N {0.8 kg}

Flow control valve spring

36.2 × 5.3

9.8 N {1 kg}

Pressure reducing valve spring

29.1 × 15

14.5

9.8 N {1 kg}



7.8 N {0.8 kg}

Pressure reducing valve spring

27.5 × 14.2

17.6 N {1.8 kg}



14 N {1.4 kg}

Pressure reducing valve spring

28 × 14.4

14.5

13.7 N {1.4 kg}



11 N {1.1 kg}

PC160LC-7

If damaged or deformed, replace spring

10-55

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. LS selector valve 2. Pressure compensation valve F (Swing) 3. Pressure compensation valve R (Swing) 4. Spool (Swing) 5. LS bleed valve 6. Pressure compensation valve F (Left travel) 7. Pressure compensation valve R (Left travel) 8. Spool (Left travel) 9. Travel junction valve + LS check valve 10. Suction valve (Left travel) 11. Suction valve (Left travel)

10-56

CONTROL VALVE

12. Pressure compensation valve F (Right travel) 13. Pressure compensation valve R (Right travel) 14. Spool (Right travel) 15. LS check valve 16. Suction valve (Right travel) 17. Suction valve (Right travel) 18. Self-pressure reducing valve F: Flow control valve R: Pressure reducing valve

PC160LC-7

CONTROL VALVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm No.

Check item

Criteria

Remedy

Standard size 19

Check valve spring

Free length x Installed length Outside diameter

Repair limit Installed load

Free length

Installed load

21.9 × 5

15.8

2.0 N {0.2 kg}



1.6 N {0.16 kg}

Travel junction spool return spring

19.3 × 7.5

15.7 N {1.6 kg}



12.6 N {1.3 kg}

Bleed spool return spring

23.3 × 12.5

3.9 N {0.4 kg}



3.1 N {0.3 kg}

PC160LC-7

If damaged or deformed, replace spring

10-57

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Merge-divider spool 2. LS bypass valve 3. LS bypass valve 4. Unload valve 5. Unload valve 6. Main relief valve 7. Lift check valve 8. Cooler bypass valve 9. Pressure compensation valve F (Arm)

10-58

CONTROL VALVE

10. Pressure compensation valve R (Arm) 11. Spool (Arm) 12. Suction valve (Arm) 13. Suction valve (Arm) 14. Hydraulic drift prevention valve (Arm) F: Flow control valve R: Pressure reducing valve

PC160LC-7

CONTROL VALVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm No.

Check item

Criteria

Remedy

Standard size 15

Unload valve spring

Free length x Installed length Outside diameter

Repair limit Installed load

Free length

Installed load

47.2 × 17.3

32.5

180 N {18.9 kg}



144 N {14.7 kg}

Sequence valve spring

58.9 × 13

83.4 N {8.5 kg}



66.7 N {6.8 kg}

Pump merge-divider valve spool return spring

49.8 × 18.8

98 N {10 kg}



78.4 N {8 kg}

Check valve spring

16.4 × 8.9

11.5

13.7 N {1.4 kg}



11 N {1.1 kg}

Lift check valve spring

77.3 × 20.7

135 N {13.8 kg}



108 N {11 kg}

Cooler bypass valve spring

72.7 × 20.6

42.5

135 N {13.8 kg}



108 N {11 kg}

Check valve spring

41.5 × 8.5

31.5

5.9 N {0.6 kg}



4.7 N {0.48 kg}

PC160LC-7

If damaged or deformed, replace spring

10-59

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Hydraulic drift prevention valve (Boom) 2. Pressure compensation valve F (Boom) 3. Pressure compensation valve R (Boom) 4. Spool (Boom) 5. Suction valve 6. Safety-suction valve 7. Pressure compensation valve F (Bucket) 8. Pressure compensation valve R (Bucket) 9. Spool (Bucket) 10. Suction valve 11. Suction valve

10-60

CONTROL VALVE

12. Pressure compensation valve F (Service) 13. Variable pressure compensation valve (Service) 14. Spool (Service) 15. Safety-suction valve 16. Safety-suction valve 17. Safety-suction valve 18. Air bleed plug F: Flow control valve R: Pressure reducing valve

PC160LC-7

CONTROL VALVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm No.

Check item

Criteria

Remedy

Standard size 19

Lock valve spring

Free length x Installed length Outside diameter 33.9 × 17

PC160LC-7

Repair limit Installed load

Free length

Installed load

26.5 N {2.7 kg}



21.2 N {2.2 kg}

If damaged or deformed, replace spring

10-61

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

CLSS OUTLINE OF CLSS Features CLSS stands for Closed center Load Sensing System, and has the following featues. • Fine control not influenced by load • Control enabling digging even with fine control • Ease of compound operation ensured by flow divider function using area of opening of spoll during compund operations • Energy saving using variable pump control

10-62

Structure • The CLSS consists of a variable capacity single piston pump, control valve, and actuators. • The pump body consists of the main pump, PC valve and LS valve.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

BASIC PRINCIPLE 1. Control of pump swash plate angle • The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure ∆PLS (the difference between pump (discharge) pressure PP and control valve outlet port LS pressure PLS) load pressure of actuator) is constant. (LS pressure ∆PLS=Pump discharge pressure PP-LS pressure PLS)

If LS differential pressure ∆PLS becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if the set pressure becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position. ★ For details of the operation, see HYDRAULIC PUMP. •

PC160LC-7

10-63

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

2. Pressure compensation control • A pressure compensation valve is installed to the inlet port side of the control valve spool to balance the load. When to actuators are operated together, this valve acts to make pressure difference ∆P

10-64

CLSS

between the upstream (inlet port) and downstream (outlet port) the same, regardless of the size of the load (pressure). In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of openings S1 and S2 of each valve when it is operated.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

OPERATION FOR EACH FUNCTION AND VALVE Hydraulic circuit diagram and name of valves

10-66

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

1. Unload valve 2. Main relief valve 3. Pressure compensation valve 4. Safety-suction valve 5. Suction valve 6. Lift check valve 7. Cooler bypass valve 8. LS selector valve 9. Swing bleeding valve 10. Travel junction valve 11. Boom hydraulic drift prevention valve 12. Arm check valve

PC160LC-7

10-67

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

SPECIFICATION WITH ARM LOCK VALVE

10-68

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

PC160LC-7

10-69

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Unload valve 1. When control valve is at HOLD

Function • When the control valve is at HOLD, pump discharge amount Q discharged by the minimum swash plate angle is released to the tank circuit. At this time, pump discharge pressure P1/P2 is set by spring (2) in the valve. (LS pressure LS1/ LS2 = 0 MPa {0 kg/cm2}) • Since the pump merge-divider valve is at the merge position, pump discharge pressures P1 and P2 are merged. LS pressures LS1, LS2, and LS3 are also merged.

10-70

Operation • Pump discharge pressures P1 and P2 are acting on the left end of unload spool (1) and LS pressures LS1 and LS2 are acting on the right end. (P1 = P2, LS1 = LS2) • When the control valve is at HOLD, LS pressures LS1 and LS2 are not generated, so only pump discharge pressures P1 and P2 act, and P1 and P2 are set by only the load of spring (2). • As pump discharge pressure P1/P2 rises and reaches the load of spring (2), spool (1) is moved to the right. Pump discharge pressures P1 and P2 are connected to tank circuit T through the cut of spool (1)

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

2. When work equipment valve is operated

Function • When any work equipment valve is operated if the demand flow for the actuator becomes greater than the pump discharge from the minimum swash plate angle, the oil flow to tank circuit T is cut off, and all pump discharge amount Q flows to the actuator circuit. • Since the pump merge-divider valve is at the merge position, pump discharge pressures P1 and P2 are merged. LS pressures LS1, LS2, and PLS3 are also merged.

PC160LC-7

Operation • When any work equipment valve is operated for a long stroke, LS pressures LS1 and LS2 are generated and act on the right end of unload spool (1) (P1 = P2, LS1 = LS2). • For this reason, the difference between pump discharge pressure P1/P2 and LS pressure LS1/ LS2 does not reach the load of spring (2), so spool (1) is pushed to the left by spring (2). • As a result, pump discharge pressures P1 and P2 and tank circuit T are shut off, and all pump discharge amount Q flows to the actuator circuit.

10-71

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

3. During fine control of both travel valves

Function • When the difference between pump discharge pressure P1/P2 and LS pressure LS1/LS2 reaches the load of spring (2), unload spool (1) opens, so excessive oil (maximum pump discharge mount - demand flow) flows into the tank circuit. • Since the pump merge-divider valve is at the separate position, pump discharge pressures P1 and P2 are separated. LS pressures LS1 and LS2 are also separated. • The swash plate angle of the pump becomes maximum, so the pump discharge amount becomes maximum. (For details, see the sections on the pump merge-divider valve.)

10-72

Operation • When fine control is carried out on both travel valves, LS pressures LS1 and LS2 are generated and act on the right end of spool (1) (P1, P2, LS1, and LS2 are separated). • When this happens, the area of the opening of both travel valve spools is small, so LS pressures LS1 and LS2 are very different from pump discharge pressures P1 and P2. • When the difference between pump discharge pressure P1/P2 and LS pressure LS1/LS2 reaches the load of spring (2), spool (1) moves to the right, and pump discharge pressures P1 and P2 are connected to tank circuit T and the excessive oil (maximum pump discharge mount demand flow) flows. • In other words, the excessive oil (maximum pump discharge mount - demand flow) above the strokes of both travel valves flows into tank circuit T.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

4. When both travel valves are operated

Function • During operation of both travel valves, when the demand flow becomes maximum, the oil flow to tank circuit T is cut off, and all pump discharge amount Q flows to both travel circuits. • Since the pump merge-divider valve is at the separate position, pump discharge pressures P1 and P2 are separated. LS pressures LS1 and LS2 are also separated. • The swash plate angle of the pump becomes maximum, so the pump discharge amount becomes maximum. (For details, see the sections on the pump merge-divider valve .)

PC160LC-7

Operation • When both travel valves are operated to the stroke ends, LS pressures LS1 and LS2 are generated and act on the right end of unload spool (1) (P1, P2, LS1, and LS2 are separated). • When this happens, the area of the openings of both travel valve spools is large, so LS pressures LS1 and LS2 are not so different from pump discharge pressures P1 and P2. • For this reason, the difference between pump discharge pressure P1/P2 and LS pressure LS1/ LS2 does not reach the load of spring (2), so spool (1) is pushed to the left by spring (2). • As a result, pump discharge pressures P1 and P2 and tank circuit T are shut off, and all pump discharge amount Q flows to the actuator circuit.

10-73

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

5. When either travel valve is operated

Function • The demand flow decided by the valve stroke is sent to the travel circuit on the operated travel valve side and the all pump discharge amount is sent to the tank circuit on the non-operated travel valve side. • Since the pump merge-divider valve is at the separate position, pump discharge pressures P1 and P2 are separated. LS pressures LS1 and LS2 are also separated. • The swash plate angle of the pump becomes maximum, so the pump discharge amount becomes maximum. (For details, see the sections on the pump merge-divider valve.) Operation When left travel valve is operated to stroke end and right one is at HOLD. • When the left travel valve is operated to the stroke end, LS pressure LS1 is generated and acts on the right end of unload spool (1).

10-74

•

When this happens, the area of the openings of both travel valve spools is large, so LS pressures LS1 is not so different from pump discharge pressures P1. For this reason, the difference between pump discharge pressure P1 and LS pressure LS1 does not reach the load of spring (2), so spool (1) is pushed to the left by spring (2). As a result, pump discharge pressures P1 and tank circuit T are shut off, and all pump discharge amount QP1 on the P1 side flows to the left travel circuit. Since the right travel valve is at HOLD, LS pressure LS2 is not generated, so only pump discharge pressure P2 acts. When pump discharge pressure P2 reaches the load of spring (2), spool (1) moves to the right, and all pump discharge amount QP2 on the P2 side flows into tank circuit T.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Merge-divider valve Function 1. When oil is merged: PS = 0 kg/cm2

•

Pump discharge pressures P1 and P2 are merged in pump merge-divider spool (3). LS1, LS2, and LS3 are also merged.

•

At this time, P1 = P2 and LS1 = LS2 = LS3 and the pump swash plate is controlled by the difference between P and LS.

•

As a result, there is not difference between P and LS and the pump swash plate is set to the maximum position.

2. When oil is divided: PS = 30 kg/cm2

•

Pump discharge pressures P1 and P2 are divided in pump merge-divider spool (3). LS1, LS2, and LS3 are also divided. At this time, higher one of P1 and P2 is applied through pump merge-divider spool (3) to the output port of the LS pressure.

PC160LC-7

10-75

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Introduction of LS pressure 1. Work equipment valve

Function • The LS pressure is the actuator load pressure at the outlet port end of the control valve. • Actually, pump discharge pressure PP is reduced by reducing valve (3) of the pressure compensation valve to the same pressure as actuator circuit pressure A and sent to LS circuit PLS. • In the travel valve, actuator circuit pressure A is directly introduced to LS circuit PLS.

10-76

Operation • When spool (1) is operated, pump discharge pressure PP flows from flow control valve (2) through notch (a) in the spool and bridge passage (b) to actuator circuit A. • At the same time, reducing valve (3) also moves to the right, so pump discharge pressure PP is reduced by the pressure loss at notch (c). It goes to LS circuit PLS, and then goes to spring chamber PLSS. • When this happens, LS circuit PLS is connected to tank circuit T from LS bypass plug (4) (See the section on the LS bypass plug). • The areas at both ends of reducing valve (3) are the same (SA = SLS), and actuator circuit pressure PA acts on the SA end. The reduced pump discharge pressure PP acts on SLS at the other end. • As a result, reducing valve (3) is balanced at a position where actuator circuit pressure PA and the pressure of spring chamber PLSS are the same. Pump discharge pressure PP reduced at notch (c) becomes actuator pressure A and is introduced into LS circuit PLS. PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

2. Travel valve.

Operation • When spool (1) is operated, pump discharge pressure PP flows from flow control valve (2) through notch (a) in the spool and bridge passage (b) to actuator circuit A. • Actuator circuit pressure PA (= A) is introduced through the check valve into LS circuit PLS. ★ The travel circuit is different from the work equipment circuit: actuator circuit pressure PA is directly introduced into LS circuit PLS.

PC160LC-7

10-77

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

LS bypass plug When work equipment valve is operated

When both travel valves are operated

Function • The LS bypass plug releases the residual pressure of LS pressure PLS. • This lowers the rising speed of LS pressure PLS. In addition, the discarded throttled flow causes a pressure loss in the throttled flow in the reducing valve, and that lowers the effective LS differential pressure to improve the stability. Operation 1. When work equipment valve is operated (including compound operation of work equipment + travel) • Since pump merge-divider spool (1) is at the merge position, the hydraulic oil in LS circuits

10-78

PLS1, PLS2, and PLS3 flows from tip filter (a) of LS bypass plug (2) through orifice (b) to tank circuit T. 2. When either or both travel valves are operated (Including operation of only one travel valve) • Since pump merge-divider spool (1) is at the separate position, LS circuits PLS1,and PLS2 are separated. • The hydraulic oil PLS1 flows from tip filter (a) of LS bypass plug (2) on the P1 side through orifice (b) to tank circuit T. • The hydraulic oil PLS2 flows from tip filter (a) of LS bypass plug (3) on the P2 side through orifice (b) to tank circuit T.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Pressure compensation valve Function • When the load pressure becomes lower than another actuator and the flow is going to increase during a compound operation, this valve compensates the load pressure. (At the time, the load pressure of another actuator under compound operation (the upper side) is higher than that of the actuator on this side (the lower side).

PC160LC-7

10-79

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Operation • When the load pressure of another actuator side (the upper side) rises during a compound operation, the flow in the actuator circuit Aa on this side (the lower side) is apt to increase. • In this case, the LS pressure PLS of another actuator is applied to the spring chamber PLS1 and pushes the pressure reducing valve (1) and the flow control valve (2) to the left side. • The flow control valve (2) throttles the opening area between the pump circuit PP and the spool upstream PPA and causes a pressure loss between PP and PPA. • The flow control valve (2) and the pressure reducing valve (1) balance each other where the pressure difference between PA applied to the both end faces of the pressure reducing valve (1) and PLS becomes the same as the pressure loss between PP before and after the flow control valve and PPA. • So, the pressure differences between the upstream pressures PPA and the downstream pressures PA of the both spools under compound operation become the same, and the pump flow is distributed in proportion to the opening area of each spool notch a.

10-80

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Area ratio of pressure compensation valve Function • The pressure compensation valve slightly adjust the ratio (S2/S1) of the area S1 on the left side of the flow control valve (2) and the area S2 on the right side of the pressure reducing valve (1) to suite the characteristics of each actuator and determines the compensation characteristics. S1 : Area of the flow control valve (2) – area of the piston (3) S2 : Area of the pressure reducing valve (1) – area of the piston (3)

Area ratio (S1:S2) and compensation characteristics • When the ratio is 1.00 : The expression [Pump (discharge) pressure PP – Spool notch upstream pressure PPB] [LS circuit pressure PLS – Actuator circuit pressure PA (= A)] can be held, and the flow is distributed as per the spool opening area ratio. • When the ratio is more than 1.00: The expression PP – PPB > PLS – PA (= A) can be held, and the flow is distributed less than the spool opening area ratio. • When the ratio is less than 1.00 : The expression PP – PPB < PLS – PA (= A) can be held, and the flow is distributed more than the spool opening area ratio.

PC160LC-7

10-81

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Variable pressure compensation valve (for service valve) Function • In compound operation of the service valve (for attachment) and work equipment valve like boom RAISE, this variable pressure compensation valve can adjust flow distribution to the service valve. (The equivalent area ratio is variable.) • Spring (4) force can be adjusted with the screw (5). 1. In case of compound operation with high load work equipment (like boom RAISE)

Operation • The pump discharge pressure PP and the LS pressure PLS depends on other work equipment. • When the pressure in the a chamber reaches the set pressure of the spring (4), the poppet (3) will open, and the throttle b maintains the pressure in the a chamber below the pump discharge pressure PP. • Therefore, the force F, which is required for the pressure reducing valve (2) to close the flow control valve (1), becomes smaller. • This means that the flow control valve (1) moves in the right direction and the flow from the pump to the service valve increases just like the area ratio has reduced.

10-82

1. Flow control valve 2. Pressure reducing valve 3. Poppet 4. Spring 5. Screw 6. Lock nut 7. Polyethylene cap

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Boom regeneration circuit 1. At boom lower and own weight fall Function • When the boom is lowered and falls due to its own weight because the bottom pressure A in the cylinder (1) is higher than the head pressure B, this circuit brings the return flow on the bottom side to the head side to increase the cylinder speed.

Operation • When the boom is lowered and falls due to its own weight, the bottom side pressure A in the boom cylinder (1) will rise above the head side pressure B.

•

PC160LC-7

At the time, part of the return flow on the bottom side passes through the regeneration passage a of the boom spool (2), pushes the check valve (3) to open it and flows to the head side. This increases the boom lower speed.

10-83

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

2. At boom lower load process Function • When the head pressure B of the cylinder (1) is higher than the bottom pressure A while the boom is lowered and the boom is in the load process, the check valve (3) will be closed, and the circuits on the head side and the bottom side will be interrupted.

Operation • When the boom is lowered and is in the load process, the head side pressure B of the boom cylinder (1) rises above the bottom side pressure A.

10-84

•

At the time, the head side pressure B and the spring (4) close the check valve (3), and the circuits on the head side and the bottom side are interrupted.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Arm regeneration circuit 1. At arm in and own weight fall Function • When the arm falls due to its own weight because the head pressure A in the arm cylinder (1) is higher than the bottom pressure B during arm digging, this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed.

Operation • When the arm falls for digging due to its own weight, the head side pressure A in the arm cylinder (1) will rise above the bottom side pressure B. • At the time, part of the return flow on the head side passes through the regeneration passage a of the arm spool (2), pushes the check valve (3) to open it and flows to the bottom side. • This increases the arm digging speed.

PC160LC-7

1. Arm cylinder 2. Arm spool 3. Check valve A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)

10-85

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

2. At arm in process Function • When the bottom pressure B of the cylinder (1) rises above the head pressure A and the arm enters the digging process, the check valve (3) will be closed and the circuits on the head side and the bottom side will be interrupted.

Operation • When the arm is in the digging process, the bottom side pressure B of the arm cylinder (1) will rise, close the check valve (3) and interrupt the circuits on the head side and the bottom side.

1. Arm cylinder 2. Arm spool 3. Check valve A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)

10-86

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Hydraulic drive prevention valve (Boom and arm) 1. When boom is raised and arm is moved out

Function • While the boom and arm levers are not operated, the hydraulic drift prevention valve prevents oil from leaking from the boom bottom and arm head through spool (1) to prevent the boom and arm from drifting hydraulically.

PC160LC-7

Operation • If the boom is raised and the arm is moved out, the main pressure from the control valve pushes up poppet (5). As a result, the main pressure from the control valve flows through the valve into the boom cylinder bottom.

10-87

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

2. When boom and arm are set in neutral

Operation • If the control lever is returned to the neutral position while the boom is raised and the arm is moved out, the holding pressure in the boom cylinder bottom and arm cylinder head is blocked by poppet (5) and the pressurized oil flowing in through orifice a is blocked by pilot spool (3). Accordingly, the boom and arm are held.

10-88

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

3. When boom is lowered and arm is moved in

Operation • If the boom is lowered and the arm is moved in pilot pressure P1 from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber b in the poppet is drained. • The oil pressure in port Ab is raised by the pressurized oil from the boom cylinder bottom and arm cylinder head, but the oil pressure in chamber b is lowered by orifice a.

PC160LC-7

•

If the pressure in chamber b is lowered below the pressure in port Aa, poppet (5) opens and the pressurized oil from port Ab flows through port Aa into the control valve.

10-89

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

Swing bleeding valve

Function • When the machine swings, the bleeding valve installed to the pressure reducing valve works so that the LS pressure rises gradually and the machine swings smoothly.

10-90

Operation (In fine control operation) • The pressure reducing valve moves to the right and notch a connects to the LS circuit. As a result, pump circuit PP, bleed-off circuit, and Ls circuit are connected through piston (2). • Bleeding spool (3) moves to the left in proportion as swing PPC pressure PA rises. In the fine control area, notch b chokes the bleed-off circuit and determines the intermediate pressure before the lowered pressure is applied to pump discharge pressure PP and Ls pressure PLS. • Accordingly, the intermediate pressure is set lower than pump discharge pressure PP and raised as bleeding spool (3) moves. As a result, Ls pressure PLS rises gradually. • When the lever is in neutral or operated fully, the bleed-off circuit is closed.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

LS select valve Function • At the time of simultaneous operation of swing + boom RAISE, this valve prevents high swing LS pressure from entering the LS circuit PLS and also prevents the boom RAISE speed from reducing by securing the pump flow at the time of swing drive. 1. During normal operation

Operation • The pilot pressure is not generally applied to the pilot port BP except for boom RAISE operation. • In this state, the pump discharge pressure PP pushes the valve (1) to open it and is led to the pressure reducing valve (4) of the swing valve. At the time of swing operation, there occurs the LS pressure PLS suitable for the load pressure, and the pressure is led to the pump LS valve.

PC160LC-7

10-91

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CLSS

2. At simultaneous operation of swing + boom RAISE

Operation • At the simultaneous operation of swing + boom RAISE, the signal pressure of the PPC circuit is led to the pilot port BP. • When this pilot pressure BP is applied to the piston (2) and reaches a pressure that is stronger than the spring (3), the piston (2) will be pushed to the left side, the valve (1) will close and the pump discharge pressure PP will not come to flow to the pressure reducing valve (4) of the swing valve. • Then, the swing pressure does not cause LS pressure PLS, but the LS pressure PLS cause the boom RAISE pressure is led to the pump LS valve, and the pump delivery is controlled with the boom RAISE LS pressure. • The pilot pressure BP depends on the control lever stroke.

10-92

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL JUNCTION VALVE

TRAVEL JUNCTION VALVE Function • This valve connects both travel circuits to each other so that hydraulic oil will be supplied evenly to both travel motors and the machine will travel straight. • When the machine is steered, outside pilot pressure PST doses the travel junction valve to secure high steering performance.

PC160LC-7

Operation When pilot pressure is turned ON • If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (2), travel junction spool (1) moves to the left stroke end and the junction circuit between pore PTL (Left travel circuit) and PTR (Right travel circuit) is closed.

10-93

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SELF-REDUCING PRESSURE VALVE

Function • The self-reducing pressure valve lowers the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valves, PPC valves, etc. Operation • If the PR pressure rises higher than the set level, poppet (1) opens and the hydraulic oil flows from port PR through orifice a in spool (4) and opening of poppet (1) into seal drain port TS. • Accordingly, differential pressure is generated over orifice a in spool (4) and spool (4) moves in the direction to close the opening between ports P and PR. The P pressure is lowered and controlled to a constant pressure (set pressure) by the opening ratio at this time and supplied as the PR pressure.

10-94

When abnormally high pressure is generated • If the PR pressure of the self-reducing pressure valve is raised abnormally, ball (6) separates from the seat against the force of spring (5). As a result, the hydraulic oil flows from output port PR to TS and the PR pressure lowers. • Accordingly, the devices receiving the oil pressure (PPC valves, solenoid valves, etc.) are protected from abnormally high pressure.

PC160LC-7

CENTER SWIVEL JOINT

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CENTER SWIVEL JOINT

1. Cover 2. Body 3. Slipper seal 4. O-ring 5. Shaft

A1. To L.H. travel motor port PB A2. From control valve port A5 B1. To L.H. travel motor port PA B2. From control valve port B5 C1. To R.H. travel motor port PA C2. From control valve port A2

D1. To R.H. travel motor port PB D2. From control valve port B2 E. To L.H. and R.H. travel motors port P T1. From L.H. and R.H. travel motors port T T2. To tank

Unit: mm No.

Check item

Clearance between rotor and shaft

PC160LC-7

Criteria

Remedy

Standard size

Standard clearance

Repair limit

–

Replace

10-95

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SWING MOTOR

1. Valve plate 2. Oil level gauge 3. Brake piston 4. Piston 5. Drive shaft

10-96

6. Swing machine assembly 7. Motor case 8. Plate 9. Disc 10. Cylinder block

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

TRAVEL MOTOR HMV110ADT-2

P T PA PB MA MB

: From travel speed solenoid valve : To tank : From control valve : From control valve : MA pressure pickup port : MB pressure pickup port

SPECIFICATIONS Type Theoretical Delivery

HMV110ADT-2 Min.

5.5 cm3/rev

Max.

95.4 cm3/rev 37.3 MPa {380 kg/cm2}

Set pressure Min. Capacity

2,851 rpm

Max. Capacity

1,644 rpm

Rated speed

PC160LC-7

Brake releasing pressure

1.2 MPa {12 kg/cm2}

Travel speed switching pressure

0.8 MPa {8 kg/cm2}

Differential pressure

10-97

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Regulator piston 2. Spring 3. Regulator valve 4. Spring 5. Motor case 6. Suction safety valve spring 7. Suction safety valve 8. Check valve

10-98

9. Check valve spring 10. Output shaft 11. Rocker cam 12. Retainer guide 13. Pin 14. Piston 15. Retainer 16. Cylinder

TRAVEL MOTOR

17. Valve plate 18. Counterbalance valve 19. Ring 20. Spool return spring 21. Brake piston 22. Plate 23. Disc 24. Ball

PC160LC-7

TRAVEL MOTOR

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm No.

Check item

Criteria

Remedy

Standard size 1

Check valve spring

Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

32.5 × 6.5

24.2

7.16 N {0.73 kg}



5.69 N {0.58 kg}



1.57 N {0.16 kg}

Check valve spring

13.0 × 6.5

9.5

1.96 N {0.2 kg}

Return spring

58.43 × 30

42.0

427 N {43.5 kg}



341 N {34.8 kg}

Regulator valve spring

21.5 × 11.1

17.1

55 N {5.6 kg}



44 N {4.5 kg}

PC160LC-7

If damaged or deformed, replace spring

10-99

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

OPERATION OF MOTOR 1) Motor swash plate angle at maximum

•

The solenoid valve is deactivated, so the pilot pressure oil from the main pump does not flow to port P. For this reason, regulator valve (9) is pushed to the right in the direction of the arrow by spring (10). Because of this, it pushes check valve (22), and the main pressure oil from the control valve going to end cover (8) is shut off by regulator valve (9). Fulcrum a of rocker cam (4) is eccentric to point of force b of the combined force of the propulsion force of cylinder (6), so the combined force of the piston propulsion force acts as a moment to angle rocker cam (4) in the direction of the maximum swash plate angle.

10-100

•

At the same time, the pressurized oil at regulator piston (15) passes through orifice c in regulator valve (9) and is drained to the motor case. As a result, rocker cam (4) moves in the maximum swash plate angle direction, the motor capacity becomes maximum.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

2) Motor swash plate angle at minimum

•

When the solenoid valve is excited, the pilot pressure oil from the main pump flows to port P, and pushes regulator valve (9) to the left direction of the arrow. Because of this, the main pressure oil from the control valve passes through passage d in regulator valve (9), enters regulator piston (15) at the bottom, and pushes regulator piston (15) to the right in the direction of the arrow. As a result, rocker cam (4) moves in the minimum swash plate angle direction, the motor capacity becomes minimum.

PC160LC-7

10-101

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

OPERATION OF PARKING BRAKE 1) When starting to travel When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (19), opens the circuit to the parking brake, and flows into chamber A of the brake piston (12). It overcomes the force of spring (11), and pushes piston (12) to the left in the direction of the arrow. When this happens, the force pushing plate (13) and disc (14) together is lost, so plate (13) and disc (14) separate and the brake is released.

1. When stopping travel When the travel lever is placed in neutral, counterbalance valve spool (19) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber A of brake piston (12) is drained to the case from the orifice in the brake piston, and brake piston (12) is pushed to the right in the direction of the arrow by spring (11). As a result, plate (13) and disc (14) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (22) when the brake piston returns, and this ensures that the brake is still effective after the machine stops.

10-102

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

OPERATION OF BRAKE VALVE • The brake valve consists of a suction safety valve (18A), counterbalance valve (18) in a circuit as shown in the diagram on the right. (Fig. 1) • The function and operation of each component is as given below. 1) Counterbalance valve, check valve Function • When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load a n d t h e m a c h i n e w i l l r u n aw a y, w h i c h i s extremely dangerous. To prevent this these valves act to make the machine travel according to the engine speed (pump discharge amount). Operation when pressure oil is supplied • When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open suction safety valve (18A) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by suction safety valve (18B) and spool (19), so the pressure at the supply side rises. (Fig. 2)

•

The pressurized oil at the supply side flows from orifice E1 and E2 in spool (19) to chamber S1. When the pressure in chamber S1 goes above the spool switching pressure, spool (19) is pushed to the right in the direction of the arrow. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate. (Fig. 3)

PC160LC-7

10-103

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

Operation of brake when traveling downhill • If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber S1 through orifices E1 and E2 will also drop. When the pressure in chamber S1 drops below the spool switching pressure, spool (19) is returned to the left, in the direction of the arrow by spring (20), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at the outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. (Fig. 4) 2) Safety valve Function • When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve, but the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment. Operation 1. When travel is stopped (or when traveling downhill, rotating to right) • When the motor inlet port pressure (pressure PA) goes down, the pressure in chamber S1 also goes down. When it goes below the switching pressure of the spool, spool is returned to the left by spring (20), and outlet port passage B1 is throttled. When this happens, the motor continues to rotate under inertia, so the outlet pressure (pressure MB) rises. (Fig. 5) • If the pressure goes above the set pressure of suction-safety valve (18A), the poppet opens. The oil then passes through large notch A1 in counterbalance valve spool (19) and flows to chamber MA in the circuit on the opposite side. (Fig. 6) 2. When rotating to left The operation is the reverse of when rotating to the right.

10-104

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL MOTOR

2) When starting travel (or during normal travel) • When the travel lever is operated, the pressure oil from the pump moves counterbalance valve spool (19) to the right. When this happens, the passage to the suction-safety valve becomes the circuit flowing through the small notch B2 in the counterbalance valve spool. As a result, a big difference in pressure is created, and the pump pressure rises to provide a powerful drawbar pull. (Fig. 7)

PC160LC-7

10-105

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT • SWING PPC VALVE

P: From main pump T: To tank

10-106

P1: Left: Arm OUT / Right: Boom LOWER P2: Left: Arm IN / Right: Boom RAISE P3: Left: Swing RIGHT / Right: Bucket CURL P4: Left: SwingLEFT / Right: Bucket DUMP

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Spool 2. Metering spring 3. Centering spring 4. Piston 5. Disc 6. Nut (For connection of lever)

WORK EQUIPMENT • SWING PPC VALVE

7. Joint 8. Plate 9. Retainer 10. Body 11. Filter

Unit: mm No.

Check item

Criteria

Remedy

Standard size 12

Centering spring (For P3 and P4)

Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

42.4 × 15.5

17.1 N {1.8 kg}



13.7 N {1.4 kg}

Centering spring (For P1 and P2)

44.4 × 15.5

29.4 N {3.0 kg}



23.5 N {2.4 kg}

Metering spring

26.5 × 8.2

24.9

16.7 N {1.7 kg}



13.7 N {1.4 kg}

PC160LC-7

If damaged or deformed, replace spring

10-107

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT • SWING PPC VALVE

OPERATION 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1).

2) During fine control (neutral → fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the main pump passes through fine control hole f and goes from port P1 to port A. When the pressure at port P1 becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P1. When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port P1. The relationship in the position of spool (1) and body (10) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber A (the same as the pressure at port P1) and the force of the control valve spool return spring are balanced.

10-108

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT • SWING PPC VALVE

3) During fine control (when control lever is returned) • When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil.

4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D.

PC160LC-7

10-109

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

P : From main pump T : To tank P1 : Left reverse P2 : Left forward

10-110

P3 : Right reverse P4 : Right forward P5 : Travel signal P6 : Steering signal

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Plate 2. Body 3. Piston 4. Collar 5. Centering spring

PC160LC-7

TRAVEL PPC VALVE

6. Metering spring 7. Valve 8. Damper 9. Steering signal 10. Steering signal valve spring

10-111

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

Unit: mm No.

Check item

Criteria

Remedy

Standard size 1

Centering spring

Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

47.5 × 15.5

32.8

129 N {13.2 kg}



107 N {10.9 kg}

Metering spring

26.5 × 8.15

24.9

16.7 N {1.7 kg}



13.7 N {1.4 kg}

Steering signal spring

12.8 × 7.3

8.5

8.8 N {0.9 kg}



7.1 N {0.72 kg}

10-112

If damaged or deformed, replace spring

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

OPERATION 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1).

2) Fine control (neutral → fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed. Spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the main pump is sent from port A through fine control hole f to port P1. When the pressure at port P1 rises, spool (1) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port P1 escapes. As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port P1. The relationship of the position of spool (1) and body (10) (fine control hole f is in the middle between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the spool of the control valve spool moves to a position where the pressure of chamber A (same as pressure at port P1) and the force of the return spring of the control valve spool are balanced.

PC160LC-7

10-113

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

3) Fine control (control lever returned) When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed up by metering spring (2), so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole f’ of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil.

4) At full stroke Lever (5) pushes down piston (4), and retainer (9) pushes down on spool (1). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P1 to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D.

10-114

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

Travel signal/Steering function • Travel signal If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5. • Steering signal If the operation quantities of both levers are different from each other as in the steering operation, the higher one of the PPC output pressures on both sides is output as the steering signal. Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neutral. Accordingly, if the machine is being steered is judged by the signal of port P6. OPERATION 1) While in NEUTRAL The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not output.

PC160LC-7

10-115

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

2) While travelling straight (The following drawing shows the circuit for traveling straight forward.) While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and right spring chamber ( l ) of steering signal valve ( j ) are set high. Accordingly, the steering signal valve is kept in neutral and the steering signal (Port P6) is not output.

10-116

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

3) When steered or pivot-turned (The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.) If the operation quantities of both levers are different from each other as in the steering operation (If the difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal. In the case of the following drawing, the pressure in left spring chamber ( k ) of steering signal valve ( j ) is P2. The pressure in right spring chamber ( l ) is P4. If (P4 – P2) x (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the steering signal to port P6.

PC160LC-7

10-117

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

TRAVEL PPC VALVE

4) When pivot-turned (The following drawing shows the circuit for left reverse and right forward operation.) While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber ( l ) of steering signal valve ( j ) is set high. Accordingly, the steering signal valve moves to the left and outputs the steering signal (port P6).

10-118

PC160LC-7

SERVICE PPC VALVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SERVICE PPC VALVE 1. Spool 2. Metering spring 3. Centering spring 4. Piston 5. Lever 6. Plate 7. Retainer 8. Body T : To tank P : From main pump P1 : Port P2 : Port

Unit: mm No.

Check item

Criteria

Remedy

Standard size 9

Centering spring

Metering spring

PC160LC-7

Free length x Outside diameter

Repair limit

Installed length

Installed load

33.9 × 15.3 22.7 × 8.1

Free length

Installed load

28.4

124.5 N {12.7 kg}



100 N {10.2 kg}

16.7 N {1.7 kg}



13.7 N {1.4 kg}

If damaged or deformed, replace spring

10-119

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SERVICE PPC VALVE

OPERATION At neutral • The pressurized oil from the main pump enters from port P and is blocked by spool (1). • Ports A and B of the control valve and ports a and b of the PPC valve are connected to drain port T through fine control hole X of spool (1).

WHEN OPERATED • When lever (5) is moved, metering spring (2) is pushed by piston (4) and retainer (7), and spool (1) is pushed down by this. • As a result, fine control portion Y is connected with port a, and the pressurized oil from port P flows from port a to port A of the control valve.

10-120

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

•

SERVICE PPC VALVE

When the pressure at port a becomes higher, spool (1) is pushed back by the force acting on the end of the spool, and fine control portion Y closes. As a result, spool (1) moves up and down to balance the force at port a and the force at metering spring (2). Therefore, metering spring (2) is compressed in proportion to the amount the control lever is moved. The spring force becomes larger, so the pressure at port a also increases in proportion to the amount the control lever is operated. In this way, the control valve spool moves to a position where the pressure of port A (the same as the pressure at port a) is balanced with the force of the return spring of the control valve spool.

PC160LC-7

10-121

SOLENOID VALVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SOLENOID VALVE PPC lock, 2-stage relief, travel speed, swing holding brake, merge-divider, travel junction solenoid valves

1. PPC lock solenoid valve 2. Travel junction solenoid valve 3. Merge-divider solenoid valve 4. Travel speed solenoid valve 5. Swing holding brake solenoid valve 6. 2-stage relief solenoid valve

10-122

T : To tank A1 : To PPC valve A2 : To main valve (Travel junction valve) A3 : To main valve (Merge-divider valve) A4 : To both travel motors A5 : To swing motor

: To main valve (2-stage relief valve) P1 : From main pump ACC : To accumulator

PC160LC-7

SOLENOID VALVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Connector 2. Moving core 3. Coil 4. Spool 5. Block 6. Spring

OPERATION WHEN SOLENOID IS TURNED OFF • Since the signal current does not flow from the controller, solenoid (3) is turned off. Accordingly, spool (4) is pressed by spring (6) against the left side. By this operation, the pass from P to A is closed and the hydraulic oil from the main pump does not flow into the actuator. At this time, the oil from the actuator is drained through ports A and T into the tank.

WHEN SOLENOID IS TURNED ON • The signal current flows from the controller to solenoid (3), and the latter is turned on. Accordingly, spool (4) is pressed against to the right side. By this operation, the hydraulic oil from the main pump flows through port P and spool (4) to port A, then flows into the actuator. At this time, port T is closed and the oil does not flow into the tank.

PC160LC-7

10-123

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ACCUMULATOR

ACCUMULATOR 1. Gas plug 2. Shell 3. Poppet 4. Holder 5. Bladder 6. Oil port

SPECIFICATIONS Gas capacity:300 cc (for PPC)

10-124

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

RETURN OIL FILTER

RETURN OIL FILTER FOR BREAKER

1. Drain plug 2. Filter 3. Case 4. Head cover 5. Relief valve

PC160LC-7

SPECIFICATIONS Rated pressure : 6.9 MPa {70 kg/cm2} Flow : 200 /min Relief valve cracking pressure: 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2} Filter mesh size : 6 µm Filtering area : 4,570 cm2

10-125

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ATTACHMENT CIRCUIT SELECTOR VALVE

1. Spool 2. Spring

V : To control valve T : To hydraulic tank ATT : To attachment ACC : To accumulator P1 : From attachment circuit selector solenoid valve TS : To hydraulic tank

Unit: mm No.

Check item

Criteria

Remedy

Standard size 3

Spool return spring

10-126

Repair limit

Free length x Outside diameter

Installed length

Installed load

Free length

Installed load

132.0 × 29

114.5

833 N {85.0 kg}



666 N {68.0 kg}

Replace spring if any damages or deformations are found

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ATTACHMENT CIRCUIT SELECTOR VALVE

Function When a breaker is installed, the return oil from the breaker does not pass through the main valve, but returns directly to the hydraulic tank. When other attachments (crusher, etc.) are installed, the attachment and the main valve are interconnected.

Operation 1. When attachment other than breaker is installed Spool (1) is pushed fully to the left by the force of spring (2), ATT port and port V are interconnected, and ATT port and port T are shut off, so the attachment and main valve are interconnected.

2. When breaker is installed When the pilot pressure from the attachment circuit selector solenoid valve overcomes the force of spring (2), the spool (1) moves fully to the right. ATT port and port V are shut off and ATT port and port T are interconnected, so the oil returning from the breaker does not pass through the main valve, but passes through port T and returns directly to the hydraulic tank.

PC160LC-7

10-127

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

HYDRAULIC CYLINDER

HYDRAULIC CYLINDER BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-128

PC160LC-7

HYDRAULIC CYLINDER

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm

No.

Check item

Criteria Tolerance

Cylinder

Clearance between piston rod and bushing

Clearance between piston rod support pin and bushing

Clearance between cylinder bottom support pin and bushing

PC160LC-7

Standard size Shaft

Hole

Remedy Standard clearance

Repair limit

Boom

– 0.030 – 0.076

+ 0.279 + 0.065

0.096 – 0.355

0.445

Arm

– 0.030 – 0.090

+ 0.222 + 0.047

0.083 – 0.312

0.445

Bucket

– 0.030 – 0.076

+ 0.259 + 0.063

0.093 – 0.335

0.445

Boom

– 0.030 – 0.060

+ 0.190 + 0.070

0.100 – 0.250

1.0

Arm

– 0.030 – 0.076

+ 0.175 + 0.075

0.105 – 0.251

1.0

Bucket

– 0.030 – 0.076

+ 0.170 + 0.070

0.100 – 0.246

1.0

Boom

– 0.030 – 0.060

+ 0.190 + 0.070

0.100 – 0.250

1.0

Arm

– 0.030 – 0.076

+ 0.175 + 0.075

0.105 – 0.251

1.0

Bucket

– 0.030 – 0.060

+ 0.170 + 0.070

0.100 – 0.230

1.0

Replace bushing

Replace pin or bushing

10-129

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

10-130

PC160LC-7

WORK EQUIPMENT

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm

No.

Check item

Clearance between connecting pin and bushing of revolving frame and boom

Criteria Tolerance

Remedy

Hole

Standard clearance

Repair limit

Shaft 80

– 0.030 – 0.060

+ 0.134 + 0.074

0.104 – 0.194

1.0

Standard size

Clearance between connecting pin and bushing of boom and arm

– 0.030 – 0.060

+ 0.136 + 0.076

0.106 – 0.196

1.0

Clearance between connecting pin and bushing of arm and link

– 0.030 – 0.076

+ 0.158 + 0.078

0.108 – 0.234

1.0

Clearance between connecting pin and bushing of arm and bucket

– 0.030 – 0.076

+ 0.135 + 0.074

0.104 – 0.211

1.0

Clearance between connecting pin and bushing of link and bucket

– 0.030 – 0.076

+ 0.157 + 0.078

0.108 – 0.233

1.0

Clearance between connecting pin and bushing of link and link

– 0.030 – 0.076

+ 0.154 + 0.074

0.104 – 0.230

1.0

PC160LC-7

Replace

10-131

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

1. DIMENSION OF ARM

10-132

PC160LC-7

WORK EQUIPMENT

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm Model No.

PC160LC-7 + 0.1 0

99.3 + 01.5

286– 0.5

90 – 0.071

– 0.036

414.7 ± 1.0

196.3 ± 0.5

747.4 ± 1.0

2,603

2,001.7 ± 1.0

330 ± 1.0

583 ± 0.5

524 ± 0.5

400.8

1,347

311.5 ± 1.0

70 0

Arm as individual part

276 – 0.5

When pressfitting bushing

310

Min.

1,501

Max.

2,528

PC160LC-7

10-133

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

2. DIMENSION OF BUCKET

10-134

PC160LC-7

WORK EQUIPMENT

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Unit: mm Model No.

PC160LC-7

400.5 ± 0.5

14.8 ± 0.5

97° 7’

400.8

1,334.7

180.7

–

311.5 ± 1

440.5

130

160

135

112

339.5 ± 1

+ 0.2 0

10-135

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AIR CONDITIONER

AIR CONDITIONER AIR CONDITIONER PIPING

1. Hot water pickup piping 2. Air conditioner compressor 3. Condenser 4. Refrigerant piping 5. Receiver tank 6. Hot water return piping 7. Air conditioner unit 8. Duct

10-136

A. Fresh air B. Recirculated air C. Hot air/cold air

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

1. Starting switch 2. Fuel control dial 3. Starting motor 4. Governor motor 5. Linkage 6. Battery relay 7. Battery 8. Engine throttle and pump controller 9. Fuel injection pump

PC160LC-7

OUTLINE • •

The engine can be started and stopped with only starting switch (1). The engine throttle and pump controller(8) reveives the signal of fuel control dial (2) and transmits the drive signal to governor motor (4) to control the governor lever angle of fuel injection pump (9) and control the engine speed.

10-137

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

1. OPERATION OF SYSTEM Starting engine • When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine throttle and pump controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.

Engine speed control • The fuel control dial sends a signal to the engine throttle and pump controller according to the position of the dial. The engine throttle and pump controller calculates the angle of the governor motor according to this signal, and sends a signal to drive the governor motor so that it is at that angle. When this happens, the operating angle of the governor motor is detected by the potentiometer, and feedback is sent to the engine throttle and pump controller, so that it can observe the operation of the governor motor.

Stopping engine • When the starting switch is turned to the STOP position, the engine throttle and pump controller drives the governor motor so that the governor lever is set to the NO INJECTION position. • When this happens, to maintain the electric power in the system until the engine stops completely, the engine throttle and pump controller itself drives the battery relay.

10-138

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

2. COMPONENT Fuel control dial 1. Knob 2. Dial 3. Spring 4. Ball 5. Potentiometer 6. Connector

FUNCTION •

•

The fuel control dial is installed under the monitor panel, and a potentiometer is installed under the knob. The potentiometer shaft is turned by turning the knob. As the potentiometer shaft is turned, the resistance of the variable resistor in the potentiometer changes and a throttle signal is sent to the engine throttle and pump controller. The hatched area in the graph shown at right is the abnormality detection area.

PC160LC-7

10-139

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

Governor motor

1. Potentiometer 2. Cover 3. Shaft 4. Dust seal 5. Bearing 6. Motor 7. Gear 8. Connector

OPERATION While motor is stopped • Electric power is applied to both phases A and B of the motor. While motor is running • The engine throttle and pump controller supplies a pulse current to phases A and B, and the motor revolves, synchronizing to the pulse.

FUNCTION •

• •

The motor is turned according to the drive signal from the engine throttle and pump controller to control the governor lever of the fuel injection pump. This motor used as the motive power source is a stepping motor. A potentiometer for feedback is installed to monitor the operation of the motor. Revolution of the motor is transmitted through the gear to the potentiometer.

10-140

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

Engine throttle and pump controller

10-142

PC160LC-7

ENGINE CONTROL

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Input and output signals CN-1

CN-2

Pin No.

Signal name

Input/ output

Pin No.

CN-3 Signal name

Input/ output

Pin No.

Input/ output

Signal name

CN1-1

Input

CN2-1

Output

CN3-1

VB (Controller PWR)

Input

CN1-2

R pump pressure sensor

Input

CN2-2

Swing prolix SW

Input

CN3-2

VIS (Solenoid PWR)

Input

CN1-3

Input

CN2-3

Input

CN3-3

CN1-4

Signal GND

CN2-4

232C-RxD

Input

CN1-5

Abnormal auto grease controller

Input

CN2-5

Input

CN1-6

Input

CN2-6

Overload alarm effective SW

Input

CN1-7

Overload sensor (Analog)

Input

CN2-7

Model selection 4

CN1-8

F pump pressure sensor

Input

CN2-8

CN1-9

Input CN2-9

CN1-10 Signal GND CN1-11

Knob SW

CN1-12 NC CN1-13

Governor motor FB potentiometer

ATT circuit selector SOL signal 1 Low-temperature start SOL relay

Output

Input

CN3-7

Travel junction SOL

Output

CN3-8

Output

CN3-9

Bucket CURL pressure SW

Input

CN3-10 Boom raise pressure SW

Input

Output Input

Input

Output

Input

CN1-15 NC

Input

CN1-16 SENS_PWR

Output

CN1-17 Key SW (Terminal C)

Output

Governor motor phase A (+) Output

CN2-11

CN1-14 NC

Battery relay drive

CN3-5

CN2-10 NC

Input

(Solenoid common GND)

CN3-4

CN3-6

Input

SOL_COM

CN3-11

VB (Controller PWR)

Input

CN3-12 VIS (Solenoid PWR)

Input

CN2-12 CAN shield CN2-13 Model selection 5

Input

CN2-14 232C_TxD

Output

CN2-15 NC

Input

CN3-13

SOL_COM

(Solenoid common GND)

CN3-14 KEY_SIG

Input

CN3-15 Governor motor phase A (–) Output CN3-16 PC-EPC

Output

Input

Travel steering signal CN2-16 pressure SW

Input

CN1-18 NC

Input

CN2-17 Model selection 3

Input

CN1-19 Throttle potentiometer

Input

CN2-18 NC

Output

CN3-18 Heater relay drive

Output

CN2-19 NC

Output

CN3-19 Bucket dump pressure SW

Input

CN2-20 NC

Input

CN3-20 Boom lower pressure SW

Input

Input/ output Input/ output Input/ output

CN3-21 GND (Controller GND)

Flash memory write CN2-24 permission signal

Input

CN3-25 Governor motor phase B (+) Output

CN2-25 NC

Input

CN3-26

CN2-26 NC

Input

CN3-27 Travel Hi/Lo selector SOL

Output

CN2-27 Model selection 2

Input

CN3-28 2-stage relief SOL

Output

CN2-28 NC

Input

CN3-29 Swing pressure SW

Input

CN3-30 Arm IN pressure SW

Input

CN1-20

Low water temperature sensor

Input

CN1-21 GND (Analog GND) CN1-22 POT_PWR

Output

CN1-23 Key SW (Terminal ACC)

Input

CN1-24 NC

Input

CN2-21 S_NET CN2-22 CAN0_L CN2-23 CAN1_L

CN2-29 GND (Pulse GND) CN2-30 NC

Input

CN2-31 GND (S_NET GND) CN2-32 CANO_H CN2-33 CAN1_H

CN3-17

Pump merge-divider solenoid

CN3-22 VIS (Solenoid PWR) CN3-23

Output

Input

SOL_COM

(Solenoid common GND)

CN3-24 KEY_SIG

Input

Service flow adjustment EPC (1) *1

Output

CN3-31 GND (Controller GND) CN3-32 GND (Controller GND)

Input/ output Input/ output

CN2-34 GND (232C GND)

CN3-33 GND (Controller GND) CN3-34 NC CN3-35 Governor motor phase B (–) Output CN3-36 NC

Output

CN3-37 Swing holding brake SOL

Output

Input

CN3-38 NC

Output

CN2-37 Model selection 1

Input

CN3-39 Travel pressure SW

Input

CN2-38 Swing lock SW

Input

CN3-40 Arm OUT pressure SW

Input

CN2-39 GND (Pulse GND)

Input

*1. Only ATT specification

CN2-40 Engine speed sensor

Input

Service valve pressure CN2-35 SW *1

Input

CN2-36 NC

*1. Only ATT specification

PC160LC-7

10-143

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

ELECTRONIC CONTROL SYSTEM Control function 1 Engine/Pump composite control function

2 Pump/Valve control function

3 One-touch power maximizing function

4 Auto-deceleration function

5 Auto-warm-up/Overheat prevention function Electronic control system

6 Low-temperature engine startability improving function

7 Swing control function

8 Travel control function

9 ATT flow control, circuit selector function (if equipped)

Self-diagnosis function

★ For the self-diagnosis function, see "TROUBLE SHOOTING".

PC160LC-7

10-145

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

MACHINE CONTROL SYSTEM DIAGRAM

10-146

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PC160LC-7

ELECTRONIC CONTROL SYSTEM

10-147

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1. Engine and Pump control function

10-148

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

FUNCTION •

•

The operator can set the work mode switch on the monitor panel to mode A, E, B and L and select proper engine torque and pump absorption torque according to the type of work. The engine throttle and pump controller detects the speed of the engine governor set with the fuel control dial and the actual engine speed and controls them so that the pump will absorb all the torque at each output point of the engine, according to the pump absorption torque set in each mode.

PC160LC-7

10-149

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1) Control method in each mode Mode A • Matching point in mode A: Rated speed Model Mode

PC160LC-7

Travel A

82 kW/2,150 rpm {110 HP/2,150 rpm}

Work A

81 kW/2,036 rpm {108 HP/2,036 rpm}

•

If the pump load increases and the pressure rises, the engine speed lowers. At this time, the pump discharge is reduced and controlled so that the engine speed will be near the rated output point. If the pressure lowers in reverse, the pump discharge is increased and control so that the engine speed will be near the rated output point. These operations are repeated to keep the engine speed near the rated output point.

10-150

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

Mode E / Mode B / Mode L Mode Partial output point

Model

91%

75%

65%

PC160LC-7

Mode E

73.5 kW/1,870 rpm {99 HP/1,870 rpm}

Mode B

60.3 kW/1,860 rpm {81 HP/1,860 rpm}

Mode L

52.2 kW/1,573 rpm {70 HP/1,573 rtpm}

•

At this time, the controller keeps the pump absorption torque along the constant horsepower curve and lower the engine speed by the composite control of the engine and pump. By this method, the engine is used in the low fuel consumption area.

PC160LC-7

10-151

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

2) Function to control pump during travel • If the machine travels in mode work A, B, E, or L, the working mode does not change, but the pump absorption torque and engine speed rise to travel A mode.

3) Function to control when emergency pump drive switch is turned ON • Even if the controller or a sensor has a trouble, the functions of the machine can be secured with pump absorption torque almost equivalent to mode E by turning on emergency pump drive switch (10). In this case, a constant current flows from the battery to the PC-EPC valve and the oil pressure is sensed by only the PC-EPC valve.

10-152

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

2. Pump/Valve control function

FUNCTION •

The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.

PC160LC-7

10-153

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1) Cut-off function • When the cut-off function is turned on, the PC-EPC current is increased to near the maximum value. By this operation, the flow rate in the relief state is lowered to reduce fuel consumption. • Operating condition for turning on cut-off function. •

Condition The average value of the front and rear pressure sensors is above 27.9 MPa {285 kg/cm2} and the one-touch power maximizing function is not turned on

The cut-off function does not work, however, while the machine is traveling in mode A, the lock switch is turned on, or the arm IN switch is turned on. 2) 2-stage relief function • The relief pressure in the normal work is 34.8 MPa {355 kg/cm2}. If the 2-stage relief function is turned on, however, the relief pressure rises to about 37.2 MPa {380 kg/cm2}. By this operation, the hydraulic force is increased further. • Operating condition for turning on 2-stage relief function • • • • •

Condition Relief pressure During travel When swing lock switch is 34.8 MPa turned on {355 kg/cm2} When boom is lowered ⇓ When one-touch power maxi37.2 MPa mizing function is turned on {380 kg/cm2} When L mode is operated

10-154

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

3. One-touch power maximizing function

FUNCTION •

Power can be increased for a certain time by operating the left knob switch.

PC160LC-7

10-155

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1) One-touch power maximizing function • When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydraulic force is increased about 7% to increase the digging force. • If the left knob switch is turned on in working mode "A" or "E", each function is set automatically as shown below.

⇓ Software cut-off function Working mode

Engine/Pump control

A, E

Matching at rated output point

10-156

2-stage relief function 34.8 MPa {355 kg/cm2} ⇓

37.2 MPa {380 kg/cm2}

Operation time Automatically Cancel reset at 8.5 sec

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

4. Auto-deceleration function

FUNCTION •

•

If the all control levers are set in NEUTRAL while waiting for a dump truck or work, the engine speed is lowered to the medium level automatically to reduce the fuel consumption and noise. If any lever is operated, the engine speed rises to the set level instantly.

PC160LC-7

10-157

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

OPERATION When control levers are set in neutral • If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,400 rpm), the engine speed lowers instantly to the first deceleration level about 100 rpm lower than the set speed. • If 4 more seconds pass, the engine speed lowers to the second deceleration level (about 1,400 rpm) and keeps at that level until any lever is operated again. When any control lever is operated • If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly to the level set with the fuel control dial.

10-158

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

5. Auto-warm-up/Overheat prevention function

FUNCTION •

After the engine is started, if the engine cooling water temperature is low, the engine speed is raised automatically to warm up the engine. If the engine cooling water temperature rises too high during work, the pump load is reduced to prevent overheating.

PC160LC-7

10-159

ELECTRONIC CONTROL SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1) Auto-warm-up function • After the engine is started, if the engine cooling water temperature is low, the engine speed is raised automatically to warm up the engine. Operating condition (All)

Operated

⇒

Water temperature: Below 30°C. Engine speed: Max. 1,200 rpm

Engine speed: Max. 1,200 rpm

⇓ Resetting condition (Any one) Auto Manual

Reset

⇒

Water temperature: Above 30°C Auto-warm-up operation time: Min. 10 minutes

Engine speed: Any level

Fuel control dial: Kept at 70% of full level for 3 sec. or longer

2) Overheat prevention function • If the engine cooling water temperature or the hydraulic oil temperature rises too high, th e p u m p l o a d an d e n g i n e s p e e d a r e reduced to prevent overheating and protect the engine and hydraulic equipment. Operating condition

•

This function is turned on when the water temperature rises above 95°C.

Operation/Remedy

Resetting condition Water and oil temperature: Below 105?C

Water and oil temperature: Above 105°C

⇒

Operating condition

Water and oil temperature: Above 102°C

⇒

Operating condition

Water and oil temperature: Above 100°C

10-160

⇒

• Under above condition, controller is set to condition before operation of function. (Manual reset) Resetting condition

Work mode: Mode A, E, OR B Engine speed: Keep as is. Monitor alarm lamp: Lights up. Lower pump discharge.

Water and oil temperature: Below 102°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)

⇒

Work mode: Mode A Engine speed: Keep as is. Lower pump discharge.

Resetting condition

⇒

Operation/Remedy

⇒

Fuel control dial: Return to low idle position once.

Operation/Remedy

Operating condition

Water and oil temperature: Above 97°C

Work mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds

Work mode: Travel Engine speed: Keep as is. Lower travel speed.

Water and oil temperature: Below 100°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition

⇒

Water and oil temperature: Below 97°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

6. Low-temperature engine startability improving function

FUNCTION •

When the engine is started, if the engine cooling water temperature is low (below 0°C), the lowtemperature starting solenoid is turned on to increase the fuel injection ratio temporarily so that the engine will start easily. (The condition for turning on this function is different from that for turning on the auto-warm-up function. A special water temperature sensor is used for this function.)

PC160LC-7

10-161

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

7. Swing control function

FUNCTION The swing lock and swing holding brake functions are installed.

10-162

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1) Swing lock and swing holding brake functions • The swing lock function (manual) is used to lock the machine from swinging at any position. The swing holding brake function (automatic) is interlocked with the swing operation and used to prevent hydraulic drift while the machine is not swinging. • Swing lock switch and swing lock/holding brake Lock Lock switch lamp

OFF

•

Function

Operation

Swing holding brake

If swing lever is set in neutral, swing brake operates in about 5 sec. If swing lever is operated, brake is released and machine can swing freely.

Swing lock

Swing lock operates and machine is locked from swinging. Even if swing lever is operated, swing lock is not reset and machine does not swing.

ELECTRONIC CONTROL SYSTEM

2) Quick hydraulic oil warm-up function when swing lock switch is turned on • If swing lock switch (4) is turned on, the pump-cut function is cancelled and the relief pressure rises from 34.8 MPa {355 kg/cmð} to 37.2 MPa {380 kg/cmð}. If the work equipment is relieved under this condition, the hydraulic oil temperature rises quickly and the warm-up time can be shortened.

Operation of swing holding brake release switch If the controller, etc. has a problem, the swing holding brake does not work normally, and the machine cannot swing, the swing lock can be reset with the swing holding brake release switch.

Swing holding brake release switch Swing lock switch

Swing brake

ON (When control has trouble) ON Swing lock is turned on.

OFF

OFF (When controller is normal) ON

OFF

Swing Swing lock is lock is canceled. turned on.

Swing holding brake is turned on.

★ If the swing lock is reset, swinging is stopped by only the hydraulic brake of the safety valve. Accordingly, if swinging is stopped on a slope, the upper structure may drift hydraulically.

PC160LC-7

10-163

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

8. Travel control function

FUNCTION •

The pumps are controlled and the travel speed is changed manually or automatically, to secure proper travel performance matched to the type of work and jobsite during travel.

10-164

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

1) Pump control function during travel • If the machine travels in a work mode other than mode A, the work mode and the engine speed are kept as they are and the pump absorption torque is increased. ★ For details, see ENGINE/PUMP COMPOSITE CONTROL FUNCTION. 2) Travel speed change function i) Manual change with travel speed switch If the travel speed switch is changed between Lo, and Hi, the governor/pump controller controls the pump capacity and motor capacity at each gear speed as shown at right to change the travel speed. Travel speed switch

Lo Hi (Low speed) (High speed)

Pump capacity (%) Motor capacity

100 Max.

100 Min.

Travel speed (km/h)

3.4

5.5

ii) Automatic change by engine speed If the engine speed is lowered to 1,500 rpm or less with the fuel control dial during travel; • The travel speed does not change even if the travel speed switch is changed from Lo to Hi. • The travel speed changes to Lo automatically if the travel speed has been Hi. iii) Automatic change by pump discharge pressure While the machine is traveling with the travel speed switch at Hi, if the load is increased because of an upslope ground, etc. and the travel pressure keeps above 29.4 MPa {300 kg/cm2} for 0.5 seconds, the travel motor capacity is changed automatically and the travel speed is lowered (to the Lo level). While the machine is traveling at the Lo speed on an upslope ground with the travel speed switch at Hi, if the load is reduced on a flat or downslope ground and the travel pressure keeps below 15.3 MPa {156 kg/cm2} for 0.5 seconds, the travel motor capacity is changed automatically and the travel speed is set to the Hi level again.

PC160LC-7

10-165

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

9. ATT flow control, circuit selector function (if equipped)

FUNCTION This function is available only with the ATT specification. The function acts as follows according to the flow command and working mode from the monitor. 1) It throttles the ATT PPC pressure and controls the flow when the pedal is depressed fully. 2) In mode B and the other modes, it switches to ATT single acting (B) or double acting (other modes).

10-166

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

10. System component parts 1) Engine revolution sensor

1. Sensor 2. Locknut 3. Wiring harness 4. Connector

FUNCTION •

•

The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine throttle and pump controller. A magnet is used to sense the gear teeth. Each time a gear tooth passes in front of the magnet, a current is generated.

PC160LC-7

10-167

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

2) PPC oil pressure switch

1. Plug 2. Switch 3. Connector

SPECIFICATIONS Type of contacts: Normally open contacts Operating (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2} Resetting (OFF) Pressure:0.3 ± 0.5 MPa {3.0 ± 0.5 kg/cm2} FUNCTION •

The junction block has 9 pressure switches, which check the operating condition of each actuator by the PPC pressure and transmit it to the engine throttle and pump controller.

10-168

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ELECTRONIC CONTROL SYSTEM

3) Pump pressure sensor

1. Sensor 2. Connector FUNCTION •

The pump pressure sensor is installed to the inlet circuit of the control valve. It converts the pump discharge pressure into a voltage and transmits it to the engine thtottle and pump controller.

OPERATION •

•

The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed. The gauge layer facing the diaphragm measures the deformation of the diaphragm by the change of its resistance, then converts the change of the resistance into a voltage and transmits it to the amplifier (voltage amplifier). The amplifier amplifies the received voltage and transmits it to the engine throttle and pump controller. Relationship between pressure P (MPa {kg/ cm2}) and output voltage (V) is as follows. V = 0.08 {0.008} x P + 0.5

PC160LC-7

10-169

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

•

The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)

10-170

•

The monitor panel also has various mode selector switches and functions to operate the machine control system.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

Monitor panel

OUTLINE •

The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.

PC160LC-7

10-171

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Input and output signals CN-1

CN-2

Pin No.

Signal name

CN-3

Input/ output

Pin No.

Signal name

Input/ output

Pin No.

Signal name

Input/ output

Key ON

Input

Engine coolant temperature

Input

Key ON

Input

Fuel level

Input

Washer motor output

Output

Radiator coolant level

Input

Starting signal

Input

(Hydraulic oil level)

Input

Limit switch (W)

Input

Air cleaner clogging

Input

GND

Input

GND

VB +

Input

Wiper motor (+)

Output

Wiper motor (–)

Output

Buzzer ON signal

Input

Limit switch (P)

Input

10-172 (5)

Engine oil pressure

Input

RS230C CTS

Input

Engine oil level

Input

RS230C RXD

Input

N/W signal

Input/ Output

RS230C RXD

Input/ Output

N/W signal

Input/ Output

RS230C RXD

Input/ Output

Battery charge

Input

Hydraulic oil temperature (analog)

GND (for analog signal)

Personal code relay

15 16 17

Swing lock

Input

Preheat

Input

Light switch

Input

N/W GND

Input

BOOTSW

Input

GND

CAN (SHIELD)

Input

Output

CAN (+)

Input

Limit SW (window)

Input

CAN (–)

Input

Buzzer cancel

Input

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION

1. Wiper motor 2. Preheating monitor 3. Swing lock monitor 4. Engine coolant temperature monitor 5. Hydraulic oil temperature gauge 6. Engine coolant temperature gauge 7. Working mode monitor 8. Service monitor 9. Travel speed monitor

PC160LC-7

10. Fuel gauge 11. Fuel level monitor 12. Hydraulic oil temperature monitor 13. Power max. monitor 14. Auto-deceleration monitor 15. Engine oil pressure caution 16. Battery charge caution 17. Radiator coolant level caution 18. Engine oil level caution 19. Air cleaner clogging 20. Maintenance time warning caution

10-173 (5)

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MONITOR ITEMS AND DISPLAY Symbol

Display item

Swing lock

Display method

Swing lock switch

Swing holding brake release switch

Swing lock monitor

OFF

Flashes

Continuous set time

Preheating monitor status

Up to 30 sec.

From 30 sec. to 40 sec.

Flashes

More than 40 sec.

OFF

Power Max. switch status

Power max. monitor status

Being pressed

Lights up but goes out after approx. 9 sec. when kept pressed

Not being pressed

Flashes

Preheating

Power Max.

Engine coolant temperature Hydraulic oil temperature

See gauge display on the next page

Fuel level

10-174

PC160LC-7

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Gauge

Engine coolant temperature (°C)

Hydraulic oil temperature (°C)

Fuel level ( )

PC160LC-7

Range

Temperature, volume

Indicator

105

Red

102

Red

100

Green

White

105

Red

102

Red

100

Green

White

289

Green

244.5

Green

200

Green

100

Green

Red

Buzzer sound

10-175

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Checks before starting (caution lamps all light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed. Symbol

Display item

Check before starting item

Engine oil pressure

—

When abnormal, lights up and buzzer sounds

Battery charge

—

Lights up when abnormal

Radiator coolant level

Lights up when abnormal

When abnormal, lights up and buzzer sounds

Engine oil level

Lights up when abnormal

—

Air cleaner clogging

Maintenance

When engine is stopped When engine is running

Lights up when abnormal

—

Lights up when there is a warning. Lights up for only 30 sec. after key is turned ON, then goes out.

The problems that have occurred are displayed in order from the left. When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed. Condition of hydraulic oil

Color of symbol

Low temperature (below B6 or equivalent)

Black on white background

Normal (B6 – B2)

No display

High temperature (below B2)

White on red letters

10-176 (5)

PC160LC-7

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Display category

Symbol

Display item

Wiper

Display range

INT

Display method

OFF

Displays set condition

Working mode

Displays set mode

Travel speed

Displays set speed

Monitor

Autodeceleration

Service meter

PC160LC-7

Service meter indicator

OFF

When service meter is working

Displays actuation status

Lights up when service meter is working

10-177 (5)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

SWITCHES

1. Working mode selector switch 2. Selector switch 3. LC monitor adjustment switch 4. Control switch 5. Window washer switch 6. Wiper switch 7. Maintenance switch 8. Travel speed selector switch 9. Auto-deceleration switch

10-178

PC160LC-7

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

•

Working mode selector switch The condition of the machine changes according to the switch that is pressed (A, E, L, B). It is possible to check the condition on the working mode monitor display. The relationship between each working mode and the monitor display is shown in the table on the right.

•

Selector switch This is used when making detailed settings in each working mode. (For details, see ATTACHMENT FLOW CONTROL FUNCTION for modes A and E.)

•

Maintenance switch Check the condition of the maintenance items. (For details, see MAINTENANCE FUNCTION.)

•

Auto-deceleration switch Each time the auto-deceleration switch is pressed, the auto-deceleration function is switched ON → OFF → ON → • • •. Use the auto-deceleration monitor display to check the present condition. When the working mode switch is operated to switch the working mode, it is automatically set to ON.

•

Travel speed selector switch Each time the travel speed selector switch is pressed, the travel speed changes. Lo → Hi → Lo → • • • Use the travel speed monitor display to check the present condition. The relationship between the set speed and the monitor display in the table on the right.

•

Wiper switch Each time the wiper switch is pressed, the wiper setting changes OFF → INT → ON → OFF → • • • Use the wiper monitor display to check the present condition. The relationship between the wiper setting and the monitor display is as shown in the table on the right.

PC160LC-7

Switch that is pressed

Display

Working mode status after setting

[A]

A mode (default)

[E]

E mode

[L]

L mode

[B]

B mode

Display

Setting

Crawler symbol + Lo

Low speed (default)

Crawler symbol + Hi

High speed

Display

Setting

None

OFF

Wiper symbol + INT

INT

Wiper symbol + ON

Wiper actuation status Stowing stopped or now stowing Intermittent actuation Continuous actuation

10-179

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

•

Window washer switch While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.

•

Control switch This is used for control when using the maintenance function or select function. (For details, see each function.)

•

LC monitor adjustment switch Use this switch when adjusting the display brightness and contrast. (For details, see each function.)

10-180

MULTI MONITOR SYSTEM

PC160LC-7

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SELECT MODE FUNCTION •

•

This is used when setting the flow in each working mode. It is possible to make the setting when genuine attachment piping is installed and the initial value setting function on the service menu h a s b e e n u s e d t o s e t t o AT TA C H M E N T INSTALLED. It is possible to check on the working mode monitor if this function can be set. Working mode

Monitor display

A mode

[A] + crusher symbol

E mode

[E] + crusher symbol

B mode

[B] + flow symbol

METHOD OF USE ★ Carry out the setting on the normal screen 1. A mode, E mode 1) Press select switch (1) on the monitor to move to the adjustment screen. 2) Press control switch (2) to select the flow level. Control switch

Actuation Flow level bar graph extends to the right

Flow level bar graph retracts to the left

3) After completing the level selection, press input confirmation switch (3). The selection flow level is confirmed and the screen moves to the normal screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. ★ Before the input confirmation switch is pressed, the flow levelis not confirmed, so press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right.

PC160LC-7

Flow level

Flow ( /min.)

Remarks

290

★ Default

240

170

120

100

10-181

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

2. B mode 1) Press select switch (1) on the monitor to move to the screen for selecting the 3-stage flow level. 2) Press control switch (2), or input [01] - [03] with the numeral 10-key pad to choose one on the three flow levels. No.

10-key pad operation

→

3) After completing the level selection, press input confirmation switch (3). The selected flow level is selected. ★ Before the input confirmation switch is pressed, the flow level is not confirmed, so press return switch (4) to return to the operator screen. This function can be used to return to the previously set flow. 4) After the flow level is confirmed, the screen changes to the screen shown in the diagram on the right. With this screen, it is possible to make fine adjustment to the flow. 5) Press control switch (2) and select the flow level. Control switch

No.

Flow level (L/min.)

Remarks

140

★ Default

100

600

Actuation Flow level bar graph extends to the right

Flow level bar graph retracts to the left

10-182

PC160LC-7

MULTI MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

6) After completing the level selection, press input confirmation switch (3). The selected flow level is confirmed and the screen moves to the operator screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. ★ Before the input confirmation switch is pressed, the flow level is not confirmed, se press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right. 7) Check the set value with the working mode monitor. The relationship between the display level and the set value is as shown in the table on the right, and it is possible to check the level of the flow that can be set.

PC160LC-7

Flow level

When flow When flow When flow is 60 / is 100 / is 140 / min. min. min.

130

170

120

160

110

150

100

140

130

120

110

Remarks Default

Display level

Set value ( /min.)

160 or 170

140 or 150

120 or 130

100 or 110

80 or 90

60 or 70

40 or 50

10-183

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

MAINTENANCE FUNCTION When the maintenance time for replacement, inspection, or filling has approached for the 10 maintenance items, press maintenance switch (1) and the caution display (yellow or red) appears on the monitor display for 30 seconds after the key is turned ON to remind the operator to carry out lubrication maintenance. ★ Maintenance items No.

Replacement interval (hours)

Item

Engine oil

500

Engine oil filter

500

Fuel filter

500

Hydraulic filter

1000

Hydraulic tank breather

500

Corrosion resistor

(1000)

Damper case oil

1000

Final case oil

2000

Machinery case oil

1000

Hydraulic oil

5000

Option, so not set

★ The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is operated. The content of the caution display differs according to the ramaining time. The relationship is as shown in the table below.

Display

Condition

None

Remaining time for maintenance for all items is more than 30 hours

Notice display (black symbol displayed on yellow background) Warning display (wiper symbol displayed on red background)

10-184

There is one or more items with less than 30 hours remaining time for maintenance There is one or more items with less than 0 hours remaining time for maintenance

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

METHOD OF CHECKING STATUS MAINTENANCE ITEMS ★ Operate as follows when on the operator screen. 1. Press maintenance switch (1) and switch to the maintenance list display screen. ★ The maintencance items are displayed as symbols on the screen. 2. Press control switch (2), or use the 10-key pad to input the number (01 – 10) of the maintenance item to select the item. ★ The cursor moves and the item is highlighted. ★ The display method is the same as described on the previous page (relationship between remaining time and caution display). If the remaining time is less than 30 hours, the item is displayed in yellow, and if it is less than 0 hours, it is displayed in red.

MAINTENANCE OPERATION 1. After completing the selection, press input confirmation switch (3). The screen will change to the maintenance reset screen. 2. Use the maintenance reset screen to check the content, and if there is any problem, press input confirmation switch (3) to move to the check screen. If the wrong item is selected, press return switch (4) to return to the maintenance list screen. 3. Check the content on the check screen, and if there is no problem, press input confirmation switch (3) to reset the maintenance time. After the reset is completed, the screen returns to the maintenance list display screen. To check the remaining time, or if the wrong item is selected, press return switch (4) to return to the maintenance list screen. ★ The check screen shows the symbol for the maintenance item and the set time in large letters. ★ The background color of the symbol for the item where the maintenance tiem was reset is the same as the background of the screen, so it is possible to check that it has been reset.

PC160LC-7

10-185

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION This function is used to adjust the brightness and contrast of the LC monitor.

ADJUSTMENT METHOD ★ Operate as follows when on the operator screen. 1. Press LC monitor adjustment switch (1) and switch to the adjustment screen. ★ Relationship between menu symbol and content. No.

Symbol

Content

Return mark

Return

Contrast

Brightness

2. Press control switch (2), or use the 10-key pad to input the number (00 - 02) to select either contrast or brightness. After completing the selection, press input confirmation switch (3) and return to the adjustment screen. Then press return switch (4) or use the 10-key pas to set to [00] and press input confirmation switch (3) to return to the normal screen. 3. Press control switch (2) and adjust the brightness and contrast as desired. Control switch

Actuation Flow level bar graph extends to the right Flow level bar graph retracts to the left

10-186

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

SERVICE METER CHECK FUNCTION •

•

When the starting switch is at the OFF position, keep return switch (1) and control switch (2) of the monitor pressed at the same time, and the service meter is shown on the display. This display is shown only while the two switches are being pressed. When the switches are released, the display goes out. Note that it takes 3 – 5 seconds after the switches are pressed for the service meter display to appear.

DISPLAY LCD CHECK FUNCTION •

•

On the password input screen or on the normal screen, if monitor return switch (1) and working mode (A) switch are kept pressed at the same time, all the LCD display will light up and the whole screen will become white, so the display can be checked. If any part of the display is black, the LCD is broken.

PC160LC-7

10-187

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

MULTI MONITOR SYSTEM

USER CODE DISPLAY FUNCTION •

•

If there is any problem in operating the machine, the user code is displayed on the monitor to advise the operator of the steps to take. This code display appears on the operator screen. On the operator screen, the user code is displayed on the portion for the hydraulic oil temperature gauge.

If more than one user code is generated at the same time, the user codes are displayed in turn for 2 seconds each to display all the user codes.

10-188

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

•

While the user code is being displayed, if the input confirmation switch is pressed, the service code and failure code can be displayed.

•

If there is more than one service code or failure code, the display switches every 2 seconds and displays all the service codes/failure codes that caused the user code to be displayed. Even if service codes/failure codes have occurred, if they did not cause the user code to be displayed, this function does not display them.

•

If the telephone number has been set using the telephone number input on the service menu, it is possible to switch on the service code/failure code and display the telephone symbol and telephone number. For details of inputting and setting the telephone number, see SPECIAL FUNCTIONS OF MONITOR PANEL in the TESTING AND ADJUSTING section.

PC160LC-7

MULTI MONITOR SYSTEM

10-189

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

•

PC160LC-7

•

The monitor panel also has various mode selector switches and functions to operate the machine control system.

10-191 (3)

7-SEGMENT MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

1. Monitor panel

OUTLINE • The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode). The switches are flat sheet switches.

10-192 (3)

INPUT AND OUTPUT SIGNALS CN-P01

CN-P02 Pin No.

Pin No.

Signal neme

Key switch (Battery)

Engine water temperature

Key switch (Battery)

Fuel

Signal Name

Washer motor output

Radiator water level

Key switch (Terminal C)

Wiper contact W

Air cleaner clogging sensor

GND

Engine oil pressure sensor

VB + (24 V)

Engine oil level sensor

Wiper motor (+)

Network signal

Wiper motor (–)

Network signal

(Buzzer ON signal input)

Charge level

Wiper contact P

GND (For analog signal)

Wind limit switch

Buzzer cancel

Swing lock

Preheating

Limit switch

Network (GND)

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Display section of monitor

1. Service meter display 2. Coolant temperature gauge 3. Coolant temperature caution 4. Digital meter display (Service code and user code are displayed when trouble occurs) 5. Fuel level caution 6. Fuel level gauge 7. Engine oil level caution lamp 8. Preheating pilot lamp 9. Swing holding brake pilot lamp 10. Oil maintenance pilot lamp 11. Battery charge caution lamp 12. Air cleaner clogging caution lamp 13. Engine oil pressure caution lamp

PC160LC-7

10-193 (3)

7-SEGMENT MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Monitored items and display Symbol

Displayed item

Display range

When engine is stopped

While engine is running

Engine oil pressure

Max. 1,500 rpm Max. 0.05 MPa {0.5 kg/cm²} Min. 1,500 rpm Max. 0.15 MPa {1.5 kg/cm²}

Lights when normal. (Goes off when engine is started.)

Air cleaner clogging

When clogged

Goes off.

Flashes when abnormal.

Charge level

When charge is abnormal

Lights when normal. (Goes off when engine is started.)

Flashes when abnormal.

Engine oil level

Below low level

Flashes when abnormal.

Packing (Swing lock)

When swing is locked

Lights up when swing is locked. Flashes when swing holding brake release switch is turned on.

Oil maintenance

See "OIL MAINTENANCE FUNCTION" on next page.

Preheating

When preheated

Coolant temperature

Flashes at 102°C or higher. Flashes and buzzer sounds at 105°C or higher.

Fuel level

Flashes when below low level.

Flashes and buzzer sounds when abnormal.

SAP00521

Goes off.

SAP00523

SAT00098

SAP00526

10-194 (3)

Lights up for 30 sec. when starting switch is set to HEAT. Then, flashes for 10 sec. to indicated completion of preheating.

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

Oil maintenance function 1. Function and operation At a set time after the engine oil is replaced, the oil maintenance function is turned on to notify the operator by the LED lamp on the monitor panel that it is time to replace the oil. The function to indicate the phone number of the place to make contact for service on the LCD unit is installed, too. 1) Check of elapsed time Nothing is displayed normally until point B shown in the figure at right after this function is reset. If the key is turned on with the buzzer cancel switch processed (for 2.5 seconds), however, the elapsed time is displayed on the service meter section. 2) Display of replacement of oil If time passes point B after this function is reset, the elapsed time is displayed on the service meter section and the LED flashes when the key is turned on. 2. Setting of time interval 1) The time interval is set in the interval setting mode. It can be set to "125h", "250h", "500h", "Not set", or "Demo-mode". The default is "Not set". 2) To enter the interval setting mode, press and hold the clock switch for 2.5 seconds. 3) If the buzzer cancel switch is pressed in the interval setting mode, the clock display section changes to "—" o "125" o "250" o "500" o "d" in order. ("—" corresponds to "Not set" and "d" corresponds to "Demomode".) 4) To save the time interval, set a desired time (mode) on the monitor panel and press and hold the clock switch for 2.5 seconds.

PC160LC-7

10-195 (3)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

7-SEGMENT MONITOR SYSTEM

3. Timing and contents of display 1) When replacement of oil is displayed The elapsed time is displayed for 10 seconds after all segments are turned on. Phone number is displayed for the next 10 seconds. If the phone number has not been input, however, the elapsed time is displayed for 20 seconds after all segments are turned on. 2) When elapsed time is checked The elapsed time is displayed for 10 seconds after all segments are turned on. 4. Resetting elapsed time 1) When the replacement of oil and elapsed time are displayed, press the buzzer cancel switch 10 seconds after all segments are turned on (while the elapsed time is displayed) and hold for 3 seconds. The elapsed time is reset. After this operation, "0h" is displayed for 1 second. 2) When the set time is changed, the elapsed time is reset to "0h". 5. Demo-mode 1) In the demo-mode, the time is set to 250h, the elapsed time is set to 240h, and replacement of oil is displayed when the key is turned on. The elapsed time does not increase, however. The time can be reset in this mode. Turn on the key 3 times in this mode, and the time interval is automatically set to "Not set" at the 4th time and after. The elapsed time is set to "0h" and counting of elapsed time is started.

10-196 (3)

PC160LC-7

7-SEGMENT MONITOR SYSTEM

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

Mode selector switches

1. 2. 3. 4.

•

There are 4 sets of the mode selector switches on the switch section. Each time one switch is pressed, the machine condition changes. The current condition is indicated by the lighting of the LED above the switch.

The initial setting of only the work mode after the starting switch is turned on can be changed. a For how to change the setting, see "Work mode default setting mode" in TROUBLESHOOTINGDisplay and special functions of monitor panel.

Operations table of switch section a The bold letters are the positions of the switches reset when the starting switch is turned on. Item

•

Operation

Work mode

Ai oEi oB

Auto-deceleration

ON i o OFF

Wiper Travel speed

PC160LC-7

Travel speed switch Auto-deceleration switch Wiper switch Work mode selector switch (Including setting switch)

OFF i o Intermittent i o ON Hi i o Lo

10-197 (3)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SENSOR

SENSOR •

The signals from the sensors are input to the panel directly. Either side of a sensor of contact type is always connected to the chassis ground. Sensor name

When normal

When abnormal

Contact

ON (Closed) OFF (Open)

OFF (Open) ON (Closed)

Resistance

—

Resistance

—

Fuel level

Resistance

—

Air cleaner clogging

Contact

ON (Closed)

OFF (Open)

Engine oil level Engine oil pressure Hydraulic oil temperature Coolant temperature

Type of sensor Contact

Engine oil level sensor 1. Connector 2. Bracket 3. Float 4. Switch

Engine oil pressure sensor (For low pressure) 1. Plug 2. Contact ring 3. Contact 4. Diaphragm 5. Spring 6. Terminal

10-198 (5)

PC160LC-7

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SENSOR

Hydraulic oil temperature sensor (for normal temperature)

1. Thermistor 2. Body 3. Tube

4. Tube 5. Wire 6. Connector

1. Thermistor 2. Body 3. Tube

4. Tube 5. Wire 6. Connector

Coolant temperature sensor

1. Thermistor 2. Body 3. Tube

PC160LC-7

4. Tube 5. Wire 6. Connector

10-199 (3)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

SENSOR

Fuel level sensor

1. Float 2. Connector 3. Cover 4. Variable resistor

Air cleaner clogging sensor

10-200 (3)

PC160LC-7

20 TESTING AND ADJUSTING STANDARD VALUE TABLE Standard value table for engine related parts ........ 20- 2 Standard value table for chassis related parts......... 20- 3 TESTING AND ADJUSTING.................................. 20-101 TROUBLESHOOTING ........................................... 20-201

Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims. When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts.

PC160LC-7

20-1 (1)

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Item

Applicable model

PC160LC-7

Engine

SAA4D102E-2

Measurement condition

Unit

High idling Engine speed

Low idling

rpm

Rated speed At sudden acceleration Exhaust gas color At high idling Valve clearance (Normal temperature)

Bosch index

Intake valve

Standard value for new machine

Service limit value

2,350 ± 70

1,030 ± 50

2,200

Max. 1.0

Max. 2.0

Max. 0.5

Max. 1.5

0.25

—

0.51

—

mm Exhaust valve

Compression pressure

Oil temperature: 40 – 60ºC Engine speed: 250rpm

MPa {kg/cm2}

Min. 2.4 {Min. 24.6}

Difference between cyinders Min. 1.0 {Min. 10.3}

Blow-by pressure

(Water temperature: operating range) At rated output

kPa {mmH2O}

Max. 1.2 {Max. 123}

5.1 {520}

MPa {kg/cm2}

0.39 – 0.64 {4.0 – 6.5} Min. 0.15 {Min. 1.5}

0.25 {2.6} 0.09 {0.9}

ºC

80 – 110

120

°(degree)

11 ± 1

Min. 6, Max. 10

5–8

Oil pressure (SAE15W-40)

(Water temperature: operating range) At high idling At low idling

Oil temperature

Whole speed range (inside oil pan)

Fuel injection timing

Before Top Dead Center

Fan belt tension Air conditioner compressor belt tension

20-2 (1)

Deflection when pressed with finger force of approx. 58.8 N{6 kg}

PC160LC-7

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model

Engine speed

Category

Item

Measurement Condition

Pump at relief

• Engine water temperature: Within operation range • Hydraulic oil temperature: Within operation range • Engine at high idling • Arm OUT relief condition

At pump relief + one touch power up

• Engine water temperature: Within operation range • Hydraulic oil temperature: Within operation range • Engine at high idling • Arm OUT relief + One-touch power max. switch in ON condition

Speed when autodeceleration is operated

• Engine at high idling • Auto-deceleration switch in ON condition • All control levers in NEUTRAL condition

Unit

rpm

RAISE

Boom control valve Control valve Spool stroke

PC160LC-7

• Engine stopped Arm control valve

Travel of control levers Operating force of control levers

2,055 ± 100

1,400 ± 100

8.0 ± 0.5

8.0 ± 0.5 9.5 ± 0.5 9.5 ± 0.5

Boom control lever • Engine stopped • At center of control lever grip • Max. reading up to stroke end (excepting lever play in NEUTRAL position)

Travel control lever

2,055 ± 100

9.5 ± 0.5

• Engine stopped

Swing control lever

2,145 ±1 00

9.5 ± 0.5

Travel control valve

Bucket control lever

2,145 ± 100

IN OUT

Arm control lever

Permissible value

LOWER

Bucket control valve Swing control valve

Standard value

8.0 ± 0.5

7.5 ± 0.5

85 ± 10

115 ± 12

Play of control lever

Max. 10

Max. 15

Boom control lever

15.7 ± 3.9 {1.6 ± 0.4}

Max. 24.5 {Max. 2.5}

Arm control lever

15.7 ± 3.9 {1.6 ± 0.4}

Max. 24.5 {Max. 2.5}

12.7 ± 2.9 {1.3 ± 0.3}

Max. 21.6 {Max. 2.2}

12.7 ± 2.9 {1.3 ± 0.3}

Max. 21.6 {Max. 2.2}

Lever

26.5 ± 6.6 {2.7 ± 0.7}

Min. 43.1 {Min. 4.4}

Papel

80.4 ± 20.1 {8.2 ± 2.0}

Max. 117.6 {Max. 12}

• Hydraulic oil temperature: Within operation range • Engine at high idling • At center of control lever grip • At tip in case of pedal • Max. reading up to stroke end

Bucket control lever Swing control lever

Travel control lever

PC160LC-7

N{kg}

20-3 (1)

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

Applicable model Category

Item

Standard value

Permissible value

When hydraulic oil temperature is about 50°C

Max. 5.9 {Max. 60}

When hydraulic oil temperature is about 80°C

Max. 7.4 {Max. 75}

At normal relief

34.8 ± 1.0 {355 ± 10}

33.3 – 36.8 {340 – 375}

At power-up relief

37.3 ± 1.0 {380 ± 10}

36.3 – 39.2 {370 – 400}

At normal relief

35.1 ± 1.0 {358 ± 10}

33.6 – 37.0 {343 – 378}

At power-up relief

37.3 ± 1.0 {380 ± 10}

36.3 – 39.2 {370 – 400}

At normal relief

34.8 ± 1.0 {355 ± 10}

33.3 – 36.8 {340 – 375}

MPa At power-up 2} {kg/cm relief

37.3 ± 1.0 {380 ± 10}

36.3 – 39.2 {370 – 400}

30.9 ± 1.5 {315 ± 15}

28.9 – 32.9 {295 – 335}

37.3 ± 1.0 {380 ± 10}

36.3 – 39.2 {370 – 400}

Control circuit basic pressure

• Hydraulic oil temperature: Within operating range • Engine: High idling • Measure outlet pressure of self-pressure reducing valve when all control levers are in neutral.

3.23 ± 0.2 {33 ± 2}

2.84 – 3.43 {29 – 35}

When all levers are in neutral

4.5 ± 1.0 {46 ± 10}

LS differential pressure

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure difference between pump pressure and LS pressure.

While bucket is digging (Full)

2.2 ± 0.1 {22.5 ± 1}

Overrun of swing

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure deviation of swing circle when upper structure stops swinging after one turn. • For measuring posture, see SWING 1.

Max. 100 (–)

Max. 130 (–)

3.0 ± 0.3

Max. 3.7

Time taken to start swinging

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure time taken to pass 90 degrees and 180 degrees after starting point. • For measuring posture, see SWING 1.

4.2 ± 0.4

Max. 5.5

25 ± 2.5

Max. 30

Unload pressure

Measurement Condition • Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure pump outlet pressure when all control levers are in neutral.

Oil pressure

Boom relief pressure • Hydraulic oil temperature: Within operating range • Engine: High idling Arm relief pressure • Working mode: A • Measure pump outlet pressure when circuit to be measured is relieved. Bucket relief pressure Swing relief pressure

Swing

Travel relief pressure

Time taken to swing

20-4 (1)

PC160LC-7 Unit

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure pump outlet pressure when circuit to be measured is relieved.

deg (mm)

90 deg

180 deg

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure time taken to swing 5 turns after swinging 1 turn. • For measuring posture, see SWING 1.

sec

PC160LC-7

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

Applicable model Category

PC160LC-7

Measurement Condition

Unit

Standard value

Permissible value

Hydraulic drift of swing

• Hydraulic oil temperature: Within operating range • Set upper structure at 90 degrees to machine body on slope of 15 degrees. • Engine: Stopped • Make match marks on inner race and outer race of swing circle. • Measure deviation of match marks in 5 minutes. • For measuring posture, see SWING 2.

Leakage from swing motor

• Hydraulic oil temperature: Within operating range • Engine: High idling • Swing lock switch: ON • Measure leakage for 1 minutes while swing circuit is relieved.

/min

Max. 5

Max. 10

44.3 ± 4.4

39.9 – 50.7

Travel speed (Free rotation)

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Measure time taken to rotate track shoes 5 turns after 1 turn. • For measuring posture, see TRAVEL 1.

27.4 ± 1.4

26.0 – 30.8

21 ± 2.5

21.5 – 27.5

13 ± 1.0

12.0 – 15.0

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Travel speed: Lo • Ground: Hard and level • Measure travel deviation in travel of 20 m after running up 10 m. • For measuring posture, see TRAVEL 2 and 3.

Max. 150

Max. 250

13.6

27.2

Swing

Item

Travel

Travel speed (Actual travel)

Travel deviation

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Ground: Hard and level • Measure time taken to travel 20 m after running up 10 m. • For measuring posture, see TRAVEL 2.

sec

Hydraulic drift of travel

• Hydraulic oil temperature: Within operating range • Stop machine on slope of 12 degrees with sprocket directed up bias. • Engine: Stopped • Measure hydraulic drift of travel in 5 minutes. • For measuring posture, see TRAVEL 4.

Leakage from travel motor

• Hydraulic oil temperature: Within operating range • Engine: High idling • Lock sprocket. • Measure leakage for 1 minutes while travel circuit is relieved.

PC160LC-7

/min

20-5 (1)

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

Work equipment

Bucket cylinder

Work equipment speed

Boom speed

Arm speed

Bucket speed

20-6 (1)

Max. 900

Max. 18

Max. 27

Max. 160

Max. 240

Max. 40

Max. 58

RAISE

Arm cylinder

Max. 600

3.5 ± 0.4

Max. 4.9

LOWER

Boom cylinder

Permissible value

2.4 ± 0.3

Max. 3.7

Hydraulic drift of work equipment

Whole work equipment

Standard value

3.3 - 0.2

+0.4

Max. 4.5

OUT

Item

2.8 ± 0.3

Max. 3.5

CURL

Category

PC160LC-7

2.8 ± 0.3

Max. 3.5

DUMP

Applicable model Measurement Condition

Unit

2.2 ± 0.2

3.0

• Hydraulic oil temperature: Within operating range • Ground Level and flat • Bucket: Full of dirt and sand or filled with rated load (1,080 kg) • Level boom top, retract arm cylinder fully, and extract bucket cylinder fully. • Engine: Stopped • Work equipment control lever: Neutral • Start measuring just after setting machine and measure every 5 minutes for 15 minutes. • Whole work equipment: Hydraulic drift of tooth tip • Boom cylinder: Retraction of cylinder • Arm cylinder: Extraction of cylinder • Bucket cylinder: Retraction of cylinder • For measuring posture, see WORK EQUIPMENT 1. • Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Time required from raise stroke end till bucket touches ground (Raise until cushion starts operates for raising stroke). • For measuring posture, see WORK EQUIPMENT 2. • Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Time required from dumping stroke end to digging stroke end (between starting points of cushion). • For measuring posture, see WORK EQUIPMENT 3.

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Time required from dumping stroke end to digging stroke end. • For measuring posture, see WORK EQUIPMENT 4.

sec

PC160LC-7

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

Applicable model

Time lag

Item

Measurement Condition

Boom time lag

• Hydraulic oil temperature: Within operating range • Engine: Low idling • Working mode: A • Lower boom from RAISE stroke end and measure time taken to lift up front side of machine after bucket touches ground. • For measuring posture, see WORK EQUIPMENT 5.

Arm time lag

• Hydraulic oil temperature: Within operating range • Engine: Low idling • Working mode: A • Move in arm from OUT stroke end and measure time taken to start moving arm again after it is stopped. • For measuring posture, see WORK EQUIPMENT 6.

Bucket time lag

• Hydraulic oil temperature: Within operating range • Engine: Low idling • Working mode: A • Curl bucket from DUMP stroke end and measure time taken to start moving bucket again after it is stopped. • For measuring posture, see WORK EQUIPMENT 7.

Unit

sec

cc/min

• Hydraulic oil temperature: Within operating range Travel deviation in • Engine: High idling compound opera- • Working mode: A tion of work equip- • Travel speed: Lo ment and travel • Ground: Hard and level • Measure travel deviation in travel of 20 m after running up 10 m.

—

Hydraulic pump performance

PC flow control characteristics

Oil leakage

• Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Relieve cylinder to be measured or travel circuit and measure leakage in 1 minute.

Compound operation performance

Work equipment

Category

PC160LC-7

Leakage from cylinder Leakage from center swivel joint

Time taken to swing 90 degrees in compound operation of raising boom and starting swinging

PC160LC-7

Standard value

Permissible value

Max. 1.0

Max. 1.2

Max. 3.0

Max. 4.2

Max. 1.0

Max. 3.6

4.5

Max. 200

Max. 220

See HYDRAULIC PUMP PERFORMANCE. • Hydraulic oil temperature: Within operating range • Engine: High idling • Working mode: A • Bucket: Filled with rated load • Ground: Hard and level • Set arm vertically and lower back of bucket to ground. • Raise boom and start swinging simultaneously from above posture and measure time taken to pass 90 degrees.

sec

4.0 ± 0.4 (Reference)

20-7 (1)

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

HYDRAULIC PUMP PERFORMANCE Applicable model Category

Item

PC160LC-7

Measurement Condition

Unit

Standard value

Permissible value

Standard value for discharge amount Q ( /min)

Judgement standard lower limit Q ( /min)

See graph

Performance of hydraulic pump

Discharge amount of hydraulic pump (A mode)

• Pump speed: At 2,200 rpm, PC-EPC current 350 mA

Check point

As desired

Test pump discharge pressure (MPa {kg/cm2})

Discharge pressure of other pump (MPa {kg/cm2})

Average pressure (MPa {kg/cm2}) PP =

P1+P2 2

As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point. When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.

20-8 (1)

PC160LC-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Posture of machine for measuring performance and measuring method

Travel 2: Travel speed (Actual travel), travel deviation

Swing 1: Overrun of swing, time taken to start swing, time taken to swing

Travel 3: Travel deviation

Swing 2: Hydraulic drift of swing

Travel 4: Hydraulic drift of travel

Travel 1: Travel speed (Free rotation)

PC160LC-7

20-9 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Work equipment 1: Hydraulic drift of work equipment

Work equipment 4: Bucket speed

Work equipment 2: Boom speed

Work equipment 5: Boom time lag

Work equipment 3: Arm speed

Work equipment 6: Arm time lag

20-10 (1)

PC160LC-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Work equipment 7: Bucket time lag

PC160LC-7

20-11 (1)

TESTING AND ADJUSTING Tools for testing, adjusting and troubleshooting .......................................................................................... 20-102 Inspection and adjustment of engine rpm ................................................................................................... 20-104 Measurement of exhaust gas color ............................................................................................................. 20-106 Adjustment of valve clearance .................................................................................................................... 20-107 Measurement of compression pressure...................................................................................................... 20-109 Measurement of blow-by pressure...............................................................................................................20-110 Inspection and adjustment of fuel injection timing .......................................................................................20-111 Measurement of engine oil pressure............................................................................................................20-113 Adjustment of engine speed sensor.............................................................................................................20-114 Inspection and adjustment of air compressor belt tension ...........................................................................20-115 Measurement of clearance in swing circle bearings ....................................................................................20-116 Inspection and adjustment of track shoe tension .........................................................................................20-117 Inspection and adjustment oil pressure in work equipment, swing, and travel circuits ................................20-118 Inspection and adjustment of control circuit oil pressure ............................................................................ 20-121 Inspection and adjustment of pump PC control circuit oil pressure ............................................................ 20-122 Inspection and adjustment pump LS control circuit oil pressure ................................................................. 20-125 Measurement of solenoid valve output pressure ........................................................................................ 20-128 Measurement of PPC valve output pressure .............................................................................................. 20-131 Adjustment of work equipment and swing PPC valve................................................................................. 20-132 Inspection of locations of hydraulic drift of work equipment........................................................................ 20-133 Testing and adjusting travel deviation ......................................................................................................... 20-135 Release of residual pressure from hydraulic circuit .................................................................................... 20-137 Measurement of oil leakage ........................................................................................................................ 20-138 Bleeding air from each part ......................................................................................................................... 20-140 Inspection procedures for diode.................................................................................................................. 20-142 Special function of monitor panel ................................................................................................................ 20-143 Special functions of 7-segments monitor panel........................................................................................... 20-169 Preparations for troubleshooting electrical system ..................................................................................... 20-186 Pm-Tune up Service ................................................................................................................................... 20-187

PC160LC-7

20-101 (3)

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

TESTING AND ADJUSTING

Engine speed

Exhaust gas color

Engine valve clearance

Compression pressure

Blow-by pressure

Fuel injection timing

Part Name

Q’ty

Test, measurement item

Symbol

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

1 799-205-1100

Tachometer KIT

Digital display: 6 – 99,999.9 rpm

2 795-790-2500

adapter

For 102-Series engine

1 799-201-9001

Handy smoke checker

Commercially 2 available

Smoke meter

1 795-799-1131

Gear

For 102-Series engine

Commercially 2 available

Thickness gauge

Intake : 0.25 mm Exhaust: 0.51 mm

1 795-502-1205 Compression gauge

0 – 6.9 MPa {0 – 70 kg/cm2}

2 795-502-1700 Adapter

For 102-Series engine

1 799-201-1504 Blow-by KIT

0 – 4.9 kPa {0 – 500 mmH2O}

2 795-790-1950 Tool (Nozzle)

1 795-799-1131

Part No.

F 2 795-799-1900 Pin assembly 3 795-799-1950

Engine oil pressure

Swing circle bearing clearance

Hydraulic oil pressure of work equipment, swing and travel circuit

799-101-5002

Oil pressure gauge KIT (analog type)

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Oil pressure gauge KIT (digital type)

Pressure gauge: 58.8 MPa {600kg/cm2}

2 799-401-2320

Oil pressure gauge

Pressure gauge: 0.98 MPa {10kg/cm2}

Commercially available

Dial gauge

799-101-5002

Oil pressure gauge KIT (analog type)

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Oil pressure gauge KIT (digital type)

Pressure gauge: 58.8 MPa {600kg/cm2}

799-101-5220

Nipple

10 x 1.25 mm

07002-11023

O-ring

799-101-5002

Oil pressure gauge KIT (analog type)

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Oil pressure gauge KIT (digital type)

Pressure gauge: 58.8 MPa {600kg/cm2}

799-101-5220

Nipple

10 x 1.25 mm

07002-11023

O-ring

799-101-5002

Oil pressure gauge (analog type)

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Oil pressure gauge (digital type)

Pressure gauge: 58.8 MPa {600kg/cm2}

799-101-5220

Nipple

10 x 1.25 mm

07002-11023

O-ring

1 J

K 2

1 L 2

20-102 (4)

1 1

Pump PC control circuit oil pressure

Bosch index = 0 – 9

Lock pin

Control circuit basic pressure

Gear

Remarks

PC160LC-7

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Part No.

Part Name

Q’ty

Test, measurement item

Symbol

TESTING AND ADJUSTING

Remarks

799-101-5002

Oil pressure gauge KIT (analog type)

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Oil pressure gauge KIT (digital type)

Pressure gauge: 58.8 MPa {600kg/cm2}

799-101-5220

Nipple

10 x 1.25 mm

07002-11023

O-ring

3 799-401-2701

Differential pressure gauge

799-101-5002

Oil pressure gauge KIT (analog type)

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Oil pressure gauge KIT (digital type)

Pressure gauge: 58.8 MPa {600kg/cm2}

799-401-3100

Adapter

02 size

799-401-3200

Adapter

03 size

799-101-5002

Oil pressure gauge KIT (analog type)

Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

790-261-1204

Oil pressure gauge KIT (digital type)

Pressure gauge: 58.8 MPa {600kg/cm2}

1 Pump LS control circuit oil pressure

M 2

1 Solenoid vallve output pressure

N 2

PPC vallve output pressure P 1

Oil leakage

Commercially available

Measuring cylinder

Water temperature, oil temperature

–

799-101-1502

Digital thermometer gauge

– 99.9 – 1,299°C

Operating force

–

0 – 294 N {0 – 30 kg}

0 – 490 N {0 – 50 kg}

Stroke, hydraulic drift

–

Commercially available

Scale

Work equipment Speed

–

Commercially available

Stopwatch

Voltage, resistance

–

Commercially available

Tester

79A-264-0021 79A-264-0091

Push-pull scale

For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Connector arrangement drawing and electric circuit diagram of each system.

PC160LC-7

20-103 (4)

INSPECTION AND ADJUSTMENT OF ENGINE RPM

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF ENGINE RPM Engine inspection and maintenance tools Mark 1 A 2

Part No. 799-205-1100 795-790-2500

Part Name Tachometer KIT Adapter

3. Fit adapter A2, and connect pickup set [1] and meter [2] of multi-tachometer A1.

Engine RPM may be detected using a monitoring function in the monitor panel (special function furnished to the monitor panel).

Be careful not to touch the strongly heated portion of the engine by accident while installing a measurement equipment. Inspection 1. Open the engine hood and remove the guard of the air conditioner compressor belt. 2. Remove cover (1). Use a filter wrench to take off the cover.

20-104 (4)

4. Measure the engine RPM after setting each measurement condition. 1) RPM at low idling: i) Set the fuel dial at low idling (MIN). ii) Move all the control levers of work equipment, swing and travel to the NEUTRAL position. 2) RPM at high idling: i) Turn the auto-decelerator OFF. ii) Set the fuel dial at high idling (MAX). iii) Move all the control levers of work equipment, swing and travel to the NEUTRAL position. 3) RPM at fuel pump relief i) Set the fuel dial at high idling (MAX) ii) Put the arm in the OUT relief position. 4) RPM when pump relief and one-touch power max. switch are set (near rated RPM) i) Set the fuel dial at high idling (MAX). ii) Put the arm in OUT relief position and keep the one-touch max. power switch depressed. The one-touch power max. function is automatically released in 8.5 seconds, even if the knob switch is kept depressed. Take measurement during the period. 5) RPM when auto-decelerator is set i) Turn the auto-decelerator ON. ii) Set the fuel dial at high idling (MAX). iii) Move all the control levers of work equipment, swing and travel to the NEUTRAL position. Approx. 5 seconds after all the control levers are moved to the NEUTRAL position, the rpm falls automatically. That is when the rpm with the auto-decelerator in motion should be measured.

PC160LC-7

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF ENGINE RPM

5. Detach all the measurement tools after the inspection, and make sure that the machine is back to normal condition. Adjustment 1. Adjustment of RPM at low idling If the rpm at low idling deviates from the standard value, make adjustment using the adjustment function provided in the monitor panel. For the adjustment procedures, refer to the section, "Special Function of Monitor Panel" 2. Adjustment of high idling deviates If the rpm at high idling deviates from the standard value, or it is unsteady (hunting), adjust the governor spring securing dimensions, using the adjustment function in the monitor panel. For the adjustment procedures, refer to the section, "Special Function of Monitor Panel"

PC160LC-7

20-105 (1)

MEASUREMENT OF EXHAUST GAS COLOR

TESTING AND ADJUSTING

MEASUREMENT OF EXHAUST GAS COLOR Exhaust gas color measurement tool Mark 1 B 2

Part No. 799-201-9001 Commercial product

Part Name Handy Smoke Checker Smoke Meter

Be careful not to touch the highly heated parts, while fitting and detaching a measurement tool. If no compressed air or power is not available in the field, use Handy Smoke Checker B1. For recording official data, use Smoke Meter B2. 1. Measurement with Handy Smoke Checker B1 1) Fit a filtering paper to Handy Smoke Checker B1. 2) Insert the exhaust gas intake pipe into the exhaust pipe (1). 3) Start the engine and keep it running until the engine cooling water temperature comes within the operating range. 4) Let the exhaust gas stay on the filtering paper by operating a handle of Handy Smoke Checker B1, when the engine speed is suddenly accelerated or kept at high idling.

5) Take out the filtering paper and compare it with the attached scale for judgement. 6) Detach the measurement tool after the measurement, and make sure the machine is back to normal condition. 2. Measurement with Smoke Meter B2 1) Insert probe [1] of the Smoke Meter B2 into the exhaust gas pipe outlet, and fasten it to the outlet with a clip.

20-106 (4)

2) Connect the probe hose, accelerator switch outlet and air hose to the Smoke Meter B2. Keep the pressure of the supplied compressed air below 1.5 MPa {15 kg/cm2}. 3) Connect the power cable to an outlet of AC100V. Confirm that the Smoke Meter power switch is in the OFF position, before connecting the power cable to an outlet. 4) Fit a filtering paper by loosening the suction pump cap nut. Fit the filtering paper securely so that air may not leak. 5) Move the Smoke Meter B2 power switch to the ON position.

6) Start the engine and keep it running until the engine water temperature rises to the operating range. 7) Let the exhaust gas stay on the filtering paper by depressing the accelerator pedal of Smoke Meter B2, when the engine speed is suddenly accelerated or kept at high idling. 8) Put the polluted filtering paper on non-polluted filtering paper (more than 10 sheets) in the filtering paper holder, and read the indicated value. 9) Detach the measurement tool after the measurement, and make sure that the machine is back to normal condition.

PC160LC-7

ADJUSTMENT OF VALVE CLEARANCE

TESTING AND ADJUSTING

ADJUSTMENT OF VALVE CLEARANCE Valve clearance adjustment tools Mark 1 C 2

Part No. 795-799-1131 Commercial product

Part Name Gear Thickness Gauge

1. Open the engine hood and remove the guard of the air conditioner compressor belt. 2. Remove all cylinder head covers (1).

5. While No. 1 cylinder is at the compression top dead center, adjust the valve clearances marked with q in the valve arrangement diagram according to the following procedure. Valve arrangement diagram

3. Take off cap (2) and fit gear C1.

4. Rotate the crankshaft forward with gear C1 and match yellow paint (a) of the crank pulley to the tip of pointer (3) to set No. 1 cylinder to the compression top dead center. When No. 1 cylinder is at the top dead center, its rocker arm can be manually moved as much as the valve clearance. If it cannot be moved, that means that No. 1 cylinder is not yet at the top dead center. In that case, rotate it by one more turn.

PC160LC-7

1) Insert thickness gauge C2 in clearance (b) between rocker arm (4) and valve stem (5) and adjust the valve clearance with adjusting screw (6). For the adjustment, turn the adjusting screw with filler gauge C2 inserted to the extent that filler gauge C2 can be lightly moved. 2) Fix adjusting screw (6) and then tighten lock nut (7). Lock nut: 24±4 Nm{2.45±0.41kgm} Check the valve clearance again after tightening lock nut (7). Proceed to the next step once all the adjustments of valve clearance indicated with a black bullet mark (q) have been completed.

20-107 (1)

TESTING AND ADJUSTING

ADJUSTMENT OF VALVE CLEARANCE

6. Rotate the crankshaft forward with gear C1 and match red paint (a) of the crank pulley to the tip of pointer (3) to set No. 4 cylinder to the compression top dead center. 7. When No. 4 cylinder is at the top dead center, adjust valve clearances indicated with a white bullet mark (Q) in the chart. The adjustment procedures are the same as introduced in Item 5 above. 8. After the adjustment, make sure that the machine is back to normal condition. Cylinder head cover securing bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

20-108 (1)

PC160LC-7

MEASUREMENT OF COMPRESSION PRESSURE

TESTING AND ADJUSTING

MEASUREMENT OF COMPRESSION PRESSURE Compression pressure measurement tools Mark 1 D 2

Part No. 795-502-1205 795-502-1700

Part Name Compression Gauge Adapter

Be careful not to get burnt by touching the exhaust manifold or muffler, or get caught with a rotating parts, while taking measurement of compression pressure.

6. Remove governor spring (2). Fix governor lever (3) of the fuel injection pump to the stopper on the STOP side. If the governor lever is not fixed, the engine may start when it is cranked. Accordingly, be sure to fix the governor lever to the STOP side.

1. Adjust the valve clearances. For the adjustment, refer to the section, "Adjustment of Valve Clearance". 2. Make preparations for measuring the engine rpm. For the preparations, refer to the section, "Inspection and adjustment of Engine RPM". 3. Warm up the engine until the engine oil temperature rises up to 40 – 60°C. 4. Open the engine hood and remove nozzle holder (1) of the cylinder to be measured.

7. Crank up the engine with the engine starting motor, and measure the compression pressure. Read off the value, when the needle of the compression gauge steadies itself. When taking measurement of the compression pressure, be sure to measure the engine rpm, too, so that it stays within the range of designated measurement conditions. 8. Detach the measurement tools after the measurement, and make sure that the machine is back to normal condition. Nozzle holder: Seizure preventive (Molycoat 100) Nozzle holder: 60 ± 9 Nm {6.12 ± 0.92 kgm}

5. Fit Adapter D2 to the nozzle holder mounting, and connect with gauge ass'y [1] of compression gauge D1. Adapter: 60 ± 9 Nm {6.12 ± 0.92 kgm}

PC160LC-7

20-109 (1)

MEASUREMENT OF BLOW-BY PRESSURE

TESTING AND ADJUSTING

MEASUREMENT OF BLOW-BY PRESSURE Blow-by pressure measurement tools Mark 1 E 2

Part No. 799-201-1504 795-790-1950

Part Name Blow-by Kit Tool (Nozzle)

Read off the blow-by pressure value, when the needle of the gauge steadies itself.

1. Fit tool E2 to blow-by hose (1) and connect it with gauge [1] of blow-by kit E1.

5. Detach the measurement tools after the measurement, and make sure that the machine is back to normal condition.

2. Start the engine, and lock (left and right) the travel. Insert pin [2] in between the sprocket and the track frame to make sure to block the travel.

3. Start the engine and keep it running until the engine cooling water temperature rises to the operating range. 4. Measure the blow-by pressure at high idling and under the following conditions. • Working mode: A mode • Work equipment, swing and travel: Left and right travel relief

20-110 (1)

PC160LC-7

INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING Fuel injection timing inspection and adjustment tools Mark 1 F 2 3

Part No. 795-799-1131 795-799-1900 795-799-1950

Part Name Gear Pin Ass'y Lock Pin

Inspection 1. Open the engine hood and remove the guard of the air conditioner compressor belt. 2. Take off cover (1) and fit gear F1.

3. Rotate the crankshaft forward with gear F1 and match yellow paint (a) of the crank pulley to the tip of pointer (2) to set No. 1 cylinder to the compression top dead center. Take off the cylinder head cover for No.1 cylinder, and confirm that its rocker arm can be manually moved as much as the valve clearance. If it cannot be moved, that means that No.1 cylinder is not yet at the top dead center. In that case, rotate it by one more turn.

PC160LC-7

4. Fix the fuel injection pump drive gear to match injection timing by pushing drive gear timing pin (3) in the direction of the front cover. Injection timing requires adjustment of high precision. Be sure to fix the drive gear with timing pin (3) so as to match injection timing. Push-in depth: 8 mm If timing pin (3) cannot be pushed in, turn the crankshaft a bit fore or aft with gear F1. If it is found difficult to confirm the push-in depth with timing pin (3) as installed in the flywheel housing, metallic pin ass'y F2 may well be used instead.

5. Disconnect plug (4) of the fuel injection pump. 6. Reverse and push in timing pin (5) of the fuel injection pump, and confirm its cut-out portion matches with protruding portion b inside the pump. If timing pin (5) can be pushed in smoothly, then injection timing is correct. If timing pin (5) cannot be pushed in smoothly, injection timing is incorrect and requires adjustment. If it is found difficult to confirm the push-in depth with timing pin (5) as installed in the engine, metallic pin ass'y F3 may well be used instead.

20-111 (1)

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

7. Detach the measurement tools after the measurement, and make sure that the machine is back to normal condition. Cylinder head cover securing bolt: 24 ± 4 Nm {2.45 ± 0.45 kgm} Do not forget to bring driving gear timing pin (3) and injection pump timing pin (5) back to the pre-inspection condition. In case the adjustment follows, leave gear F1 and timing pin (3) as they are.

2. Dismantle the fuel injection pump. For dismantling the fuel injection pump, refer to the section, "FUEL INJECTION PUMP ASSEMBLY" in the chapter of "DISASSEMBLY AND ASSEMBLY". 3. Reverse and push in timing pin (5) of the fuel injection pump, then match the pin cut-out portion and protruding portion "b" inside the fuel injection pump by turning the shaft. After fuel timing has been set, fix it by fitting plug (4).

Adjustment ! If fuel injection timing is found incorrect, adjust it in the following manner. 1. Confirm that drive gear injection timing is fixed with driving gear timing pin (3). If timing pin (3) was pulled back after the inspection had been completed, push it in again following the foregoing inspection procedures.

4. Mount the fuel injection pump. For dismantling the fuel injection pump, refer to the section, "FUEL INJECTION PUMP ASSEMBLY" in the chapter of "DISASSEMBLY AND ASSEMBLY". 5. Detach the measurement tools after the adjustment, and make sure that the machine is back to normal condition. Before starting the engine again, check that driving gear timing pin (3) and fuel injection pump timing pin (5) have been brought back to the pre-adjustment condition.

20-112 (1)

PC160LC-7

MEASUREMENT OF ENGINE OIL PRESSURE

TESTING AND ADJUSTING

MEASUREMENT OF ENGINE OIL PRESSURE Engine oil pressure measurement tools Mark G

1 2

Part No. 799-101-5002 790-261-1204 799-401-2320

Part Name Hydraulic Tester Digital type hydraulic tester Hydraulic Tester

4. Measure engine oil pressure at low idling as well as at high idling.

A nipple (quick coupler) is installed to the engine oil pressure pickup port of the Pm clinic specification machine. 1. Take off engine oil pressure measurement plug (1) on top of the engine filter.

5. Detach the measurement tools after the measurement, and make sure that the machine is back to normal condition.

2. Install fitting [1] of the hydraulic tester G1, and connect it to hydraulic tester G2.

3. Start the engine and keep it running until the engine cooling water temperature rises to the operating range.

PC160LC-7

20-113 (4)

TESTING AND ADJUSTING

ADJUSTMENT OF ENGINE SPEED SENSOR

ADJUSTMENT OF ENGINE SPEED SENSOR Detach engine speed sensor (1) before the adjustment, then check that there is no metal dust stuck or damage at the tip and fit it again.

1. Screw in sensor (1) until its tip comes to contact with the tip of flywheel ring gear teeth (2). Threaded portion: Gasket sealant (LG-6) 2. Screw back sensor (1) from that position by the prescribed angle. Screw-back angle: 1±1/6 turn Adjust clearance "a" between the sensor tip and gear tooth tip to be 1.25 – 1.75 mm. 3. Fix sensor (1) and tighten nut (3). Nut: 49.0 – 68.6 Nm{5 – 7 kgm}

4. After the adjustment, confirm that correct engine speed is displayed in the monitor panel, using the special monitoring function. For monitoring engine speed, refer to the section, "Special Function of Monitor Panel".

20-114 (1)

PC160LC-7

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION

INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION Inspection 1. Open the engine hood and remove the guard of the air conditioner compressor belt. 2. Check belt deflection amount a when depressing the mid point between the fan pulley and the compressor with a thumb. • Belt depressing force: Equivalent to 58.8 N {6 kg}

Adjustment If the belt deflection amount is not proper, adjust it in the following manner. 1. Loosen two compressor bracket (1) securing bolts (upper and lower). 2. Loosen lock nut (2), and adjust the belt (3) tension by shifting the position of compressor bracket (1). 3. Fix adjusting bolt (3) and tighten locknut (2). 4. Tighten two compressor bracket (1) securing bolts (upper and lower).

5. Check the belt tension again after the adjustment.

PC160LC-7

20-115 (1)

TESTING AND ADJUSTING

MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS

MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS Swing circle bearing clearance measurement tools Mark H

Part No. Commercial Product

Part Name Dial Gauge

Follow the steps explained below, when measuring clearance in the swing circle bearing in the actual machine. Be careful not to put a hand or foot under the undercarriage, while taking measurement.

4. Hold the arm nearly perpendicular to the ground, and lower the boom until the track shoes will be lifted at the machine front. The upper structure is raised at the front and lowered at the rear at that time. 5. Read off the value in dial gauge H in this condition. The value indicated in dial gauge H expresses clearance in the bearings.

1. Fasten dial gauge H to swing circle outer race (1) or inner race (2), and contact the probe with the end surface of inner race (2) or outer race (1) on the opposite side. Set dial gauge H at the machine front or rear.

6. Return the machine to the posture in Item 2 above, and confirm reading of dial gauge H is zero. If zero value is not indicated, repeat the steps in Items 3 through 5.

2. Keep the work equipment in the max. reach posture and keep the height of the bucket teeth tip level with the lower height of the revolving frame. 3. Set dial gauge H at zero point.

20-116 (1)

PC160LC-7

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION

INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION Inspection 1. Travel the machine forward by the length of track on ground, keeping the engine at low idling, and stop the machine slowly. 2. Place straight bar [1] on the track shoe between the idler and the 1st carrier roller. L beam is recommended for bar [1], because of its deflection-free nature. 3. Measure max. clearance a between bar [1] and the track shoe. • Max. standard clearance a: 10 – 30 mm

Adjustment If the track shoe tension is not proper, adjust it in the following manner. 1. When the tension is too strong Discharge grease by loosening valve (1). Do not loosen valve (1) by more than one turn, because grease will spurt out due to its internal high pressure. 2. When the tension is too weak Add grease through valve (1). If the normal track shoe tension is not restored even after greasing, move the machine slowly back and forth.

PC160LC-7

20-117 (1)

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS Instruments for inspecting and adjusting oil pressure in work equipment, swing, and travel circuits Mark 1 J 2

Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023

•

(2): Rear pump discharge pressure pickup plug

Part Name Hydraulic tester Digital hydraulic tester Nipple (10 x 1.25 mm) O-ring

A nipple (quick coupler) is installed to the pump discharge pressure pickup port of the Pm clinic specification machine. The oil pressure (pump discharge pressure) in the work equipment, swing, and travel circuits can be checked with the monitoring function of the monitor panel (special function of the monitor panel).

2) Install nipple J2 and connect it to oil pressure gauge [1] of hydraulic tester J1. Use the oil pressure gauge of 58.8 MPa {500 kg/cm2}. The measuring instruments installed to the front pump discharge pressure pickup port are shown in the figure.

Measurement 1. Preparation work Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the residual pressure from the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank. 1) Remove oil pressure pickup plugs (1) and (2). • (1): Front pump discharge pressure pickup plug

20-118 (4)

3) Run the engine and heighten the hydraulic oil temperature to the operating range.

PC160LC-7

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

2. Combination of pump, actuator, and valve When the pump is separated, the front pump and rear pump act independently on each actuator as shown in the table. Note that different actuators relieve different valves. When the work equipment circuit or swing circuit are relieved singly, the oils of the pumps are merged. When the travel circuit is relieved singly, the oils of the pump are divided. The actuators in the table are arranged in the order when the control valve is seen from the front of the machine (and 1 attachment is installed to the service valve). Pump

Rear

Actuator Valve relieved (Centralized safety valve) Service Safety-suction valve Bucket Main relief valve Arm Main relief valve

5. Measurement of swing circuit relief pressure 1) Start the engine and turn the swing lock switch ON. 2) Run the engine at high idling and swing to the right and left to relieve the swing circuit and measure the oil pressure at this time. The pressure measured when the swing motor safety valve is relieved is indicated. The swing motor relief pressure is lower than the main relief valve. 6. Measurement of travel circuit relief pressure 1) Start the engine and lock the travel mechanism. Set pin [2] between the sprocket and track frame to lock the travel mechanism securely.

RAISE: Main relief valve LOWER: Safety-suction valve (Front unload valve) (Rear unload valve) (Main relief valve) (Pump merge-divider valve) (Self-pressure reducing valve)

Boom

Front Rear

Left travel Main relief valve Right travel Main relief valve Swing Swing motor safety valve (LS separate valve)

3. Measurement of unload pressure 1) Start the engine. 2) Run the engine at high idling and set the all control levers in neutral and measure the oil pressure at this time. The pressure measured when the front and rear unload valves are unloaded is indicated. 4. Measurement of work equipment circuit relief pressure 1) Start the engine and move the cylinder to be measured to the stroke end. 2) Run the engine at high idling and relieve the cylinder and measure the oil pressure at this time. The pressure measured when the main relief valve is relieved is indicated. If the one-touch power maximizing switch is released, the valve is relieved at low pressure. If the former is pressed, the lower is relieved at high pressure. If the swing lock switch is turned ON, the constant 2-stage relief valve is turned ON and the valve is relieved at high pressure. Accordingly, keep the swing lock switch turned OFF.

PC160LC-7

2) Run the engine at high idling and relieve the travel circuit and measure the oil pressure at this time. The pressure measured when the main relief valve is relieved is indicated. The travel circuit is always relieved at high pressure. Adjusting The unload valve and the boom lowering safetysuction valve cannot be adjusted. 1. Adjusting main relief pressure If the relief pressure of the work equipment circuit and/or travel circuit is abnormal, adjust main relief valve (3) according to the following procedure. Adjust only the low relief pressure of the main relief valve. (If the low relief pressure is adjusted, the high relief pressure is adjusted automatically.) The low relief pressure is the pressure applied when the 2-stage relief solenoid valve is turned OFF and the pilot pressure is not applied to the selector port.

20-119 (1)

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

•

1) Disconnect pilot hose (4). 2) Fixing holder (5), loosen locknut (6). 3) Turn holder (5) to adjust the pressure. If the holder is • Turned to the right, the pressure rises. • Turned to the left, the pressure lowers. Quantity of adjustment per turn of holder: Approx. 20.5 MPa {Approx. 209 kg/cm2} 4) Fixing holder (5), tighten locknut (6). Lock nut: 49.0 – 58.8 Nm {5 – 6 kgm}

1) Fixing screw (9), loosen locknut (10). Fix the screw with a hexagonal wrench. 2) Turn screw (9) to adjust the pressure. If the screw is • Turned to the right, the pressure rises. • Turned to the left, the pressure lowers. Quantity of adjustment per turn of screw: Approx. 9.8 MPa {Approx. 100 kg/cm2} 3) Fixing screw (9), tighten locknut (10). Lock nut: 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}

5) Connect pilot hose (4). 6) After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above.

4) After finishing adjustment, check again that the pressure is normal according to the procedure for measurement described above.

2. Adjusting swing relief pressure If the relief pressure of the swing circuit is abnormal, adjust swing motor safety valves (7) and (8) according to the following procedure. • (7): Right swing relief safety valve • (8): Left swing relief safety valve

20-120 (1)

PC160LC-7

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE

INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE Control circuit oil pressure inspection and adjustment tools Mark 1

Part No. 799-101-5002 790-261-1204

K 2

799-101-5220 07002-11023

Part Name Hydraulic Tester Digital Type Hydraulic Tester Nipple (10 x 1.25 mm) O-ring

3. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. 4. Measure oil pressure with the engine running at high idling and all the control levers in the NEUTRAL position.

A nipple (quick coupler) is installed to the control circuit basic pressure pickup port of the Pm clinic specification machine. Lower the work equipment to the ground and stop the engine. After the engine stops, operate the control lever several times to release the remaining pressure in the piping. Then loosen the oil filler cap to release the pressure inside the hydraulic tank. 1. Remove oil pressure measurement plug (1). • (1): Control circuit basic pressure pickup plug

5. Detach all the measurement tools after the measurement, and make sure that the machine is back to normal condition. The relief valve for the control circuit basic pressure cannot be adjusted.

2. Fit nipple K2 and connect it to oil pressure gauge [1] of hydraulic tester K1. Use an oil pressure gauge with the capacity of 5.9 MPa {60 kg/cm2}.

PC160LC-7

20-121 (4)

INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE Pump PC control circuit oil pressure inspection and adjustment tools Mark 1

Part No. 799-101-5002 790-261-1204

L 2

799-101-5220 07002-11023

•

(2): Rear pump discharge pressure pickup plug

•

PC valve output pressure pickup plug

Part Name Hydraulic Tester Digital Type Hydraulic Tester Nipple (10 x 1.25 mm) O-ring

A nipples (quick couplers) are installed to the pump discharge pressure pickup port, PC valve output pressure pickup port, and PC-EPC valve output pressure pickup port of the Pm clinic specification machine. Measurement Implement measuring the pump PC control circuit oil pressure after confirming that the work equipment, swing and travel circuit oil pressure as well as the control circuit original oil pressure are normal. Lower the work equipment to the ground and stop the engine. After the engine stops, operate the control lever several times to release the remaining pressure in the piping. Then loosen the oil filler cap to release the pressure inside the hydraulic tank. 1. Measurement of PC valve output pressure (servo piston inlet pressure) Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure (both F and R) simultaneously and compare them with each other. 1) Remove oil pressure pickup plugs (1), (2), and (3). • (1): Front pump discharge pressure pickup plug

2) Fit nipple L2 and connect to oil pressure gauge [1] of hydraulic tester L1. Use an oil pressure gauge with the capacity of 58.8 MPa {600 kg/cm2}. The measuring instruments installed to the PC valve output pressure pickup port are shown in the figure.

3) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.

20-122 (4)

PC160LC-7

INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE

TESTING AND ADJUSTING

•

4) Measure the pump delivery pressure and PC valve output pressure (servo piston inlet pressure) together with the engine running at high idling, after setting the machine at the following conditions. • Working mode: A mode • Swing lock switch: ON (switched to high pressure relief with 2-stage relief turned ON) • Work equipment, swing and travel circuit: Arm digging relief Judgement method: When the ratio between the pump delivery pressure (Higher one of F and R) and PC valve output pressure (servo piston inlet pressure) reaches the following values, both pressures are judged normal. Pressure to be measured Pump delivery pressure PC valve outlet pressure

(4): PC-EPC valve output pressure pickup plug

2) Fit nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1. Use an oil pressure gauge with the capacity of 5.9 MPa {60 kg/cm2}.

Pressure ratio 1 Approx: 0.6 (Approx. 3/5)

3) Start the engine and keep it running until the hydraulic oil pressure rises to the operating range.

If there is any abnormality with PC valve or servo piston, the PC valve output pressure (servo piston inlet pressure) equals to the pump delivery pressure, or approximates to 0 pressure. 5) After finishing measurement, remove the measuring instruments and return the removed parts. 2. Measurement of PC-EPC valve output pressure 1) Remove oil pressure pickup plug (4). 4) Measure the hydraulic oil pressure with all the control levers kept in the NEUTRAL position and the engine running at high idling and at low idling.

PC160LC-7

20-123 (1)

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE

If the PC-EPC valve output pressure changes as shown below, it is normal. Engine

Control lever

Oil pressure

Neutral

2.9 MPa {30 kg/cm2} 0 MPa {0 kg/cm2}

Low idling High idling

3. Tighten locknut (7). Lock nut: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}

5) After finishing measurement, remove the measuring instruments and return the removed parts. Adjusting If the following phenomena occur and PC valve (5) seems to be defective, adjust PC valve (5) according to the procedure shown below. • When the working load is increased, the engine speed lowers largely. • The engine speed is normal but the working speed is low.

4. After finishing adjustment, check that the PC valve output pressure (servo piston inlet pressure) is normal according to the procedure for measurement described above.

1. Loosen locknut (7). The width across flats of the PC valve locknut is 13 mm and that (inside width) of the adjusting screw is 4 mm. All the locknuts and adjusting screws other than them affect the hydraulic pump performance. Accordingly, do not turn any of them. Before loosening the locknut, make match marks at the end of the adjusting screw so that you can see the position of the adjusting screw before adjustment (and you can return the adjusting screw to that position). 2. Turn the adjusting screw (6) to the right or left. Turn the adjusting screw in the following directions. • If the work equipment speed is low, turn the adjusting screw to the right (to increase the pump absorption torque). • If the engine speed is low, turn the adjusting screw to the left (to decrease the pump absorption torque).

20-124 (1)

PC160LC-7

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT OIL PRESSURE

INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT OIL PRESSURE Inspecting and adjusting instruments for pump LS control circuit Mark 1 M 2

Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023

799-401-2701

•

(2): Rear pump discharge pressure pickup plug

•

(3): LS valve output pressure pickup plug

Part Name Hydraulic tester Digital hydraulic tester Nipple (10 x 1.25 mm) O-ring Differential pressure gauge

A nipples (quick couplers) are installed to the pump discharge pressure pickup port, LS valve output pressure pickup port, and LS pressure pickup port of the Pm clinic specification machine. Measurement Before measuring the pump LS control circuit oil pressure, check that the work equipment, swing and travel circuit oil pressures are normal. Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the residual pressure from the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank. 1. Measurement of LS valve output pressure (Servo piston inlet pressure) Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure (both F and R) simultaneously and compare them with each other. 1) Remove oil pressure pickup plugs (1), (2), and (3). • (1): Front pump discharge pressure pickup plug

2) Install nipple M2 and connect oil pressure gauge [1] of hydraulic tester M1. Use the oil pressure gauge of 58.8 MPa {600 kg/cm2}. The measuring instruments installed to the LS valve output pressure pickup port are shown in the figure.

3) Run the engine and heighten the hydraulic oil temperature to the operating range.

PC160LC-7

20-125 (4)

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT OIL PRESSURE

4) Run the engine at high idling under the following condition and measure the pump discharge pressures (both F and R) and LS valve output pressure (servo piston inlet pressure) simultaneously. • Working mode: A • Measure with all of work equipment, swing, and travel levers in neutral and with the bucket curled (the bucket lever at stroke end). Judging method If the ratio of the pump discharge pressure (higher one of F and R) to the LS valve output pressure (servo piston inlet pressure) is as follows, those pressures are normal. Measured oil When bucket When in neutral pressure is curled Pump discharge 1 pressure Almost same pressure LS valve output Approx. 0.6 pressure (Approx. 3/5)

5) After finishing measurement, remove the measuring instruments and return the removed parts. 2. Measurement of LS differential pressure Measure the pump discharge pressure (either of F and R) and LS pressure (actuator load pressure) simultaneously and calculate the difference between them and use the result as the LS differential pressure. 1) Remove oil pressure pickup plugs (1), (2), and (4). • (1): Front pump discharge pressure pickup plug • (4): LS pressure pickup plug

20-126 (1)

•

(2): Rear pump discharge pressure pickup plug

2) Install nipple M2 and connect it to differential pressure gauge M3 or oil pressure gauge [2] of hydraulic tester M1. The measuring instruments installed to the LS pressure pickup plug are shown in the figure. When using the differential pressure gauge: Connect the pump pressure (either of F and R) to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12V power source, connect it to a battery. When using oil pressure gauge: Use the oil pressure gauge of 58.8 MPa {600 kg/cm2}. Since the differential pressure is about 2.5 MPa {25 kg/cm2} at maximum, measure it by installing the same gauge to the pickup plugs alternately.

PC160LC-7

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT OIL PRESSURE

Adjustment If the LS differential pressure is abnormal, adjust LS valve (5) according to the following procedure.

3) Run the engine and heighten the hydraulic oil temperature to the operating range. 1. Fixing adjusting screw (6), loosen locknut (7). 2. Turn adjusting screw (6) to adjust the LS differential pressure. If the adjusting screw is • Turned to the right, the differential pressure rises. • Turned to the left, the differential pressure lowers. Quantity of adjustment per turn of adjusting screw: Approx. 1.3 MPa {Approx. 13.3 kg/cm2} 4) Run the engine at high idling under the following condition and measure the pump discharge pressures (either of F and R) and LS pressure (actuator load pressure) simultaneously. • Working mode: A • Measure when all of work equipment, swing, and travel levers are in neutral and when the bucket is curled (the bucket lever is at stroke end). Calculation of LS differential pressure (When oil pressure gauge is used): LS differential pressure = Pump pressure – LS pressure If the LS differential pressure is as follows, it is normal. Operation of lever When all levers are in neutral When bucket is curled (lever is at stroke end)

LS differential pressure Unload pressure (See standard value) Standard LS differential pressure (See standard value)

3. Fixing adjusting screw (6), tighten locknut (7). Lock nut: 49 – 64 Nm {5 – 7 kgm}

4. After finishing adjustment, check again that the LS differential pressure is normal according to the procedure for measurement described above.

5) After finishing measurement, remove the measuring instruments and return the removed parts.

PC160LC-7

20-127 (1)

MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

TESTING AND ADJUSTING

MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE Measuring instruments for solenoid valve output pressure Mark

Part No. 799-101-5002 790-261-1204 799-401-3100 799-401-3200

1 N 2

Part Name Hydraulic tester Digital hydraulic tester Adapter (Size: 02) Adapter (Size: 03)

Before measuring the solenoid valve output pressure, check that the control circuit basic pressure is normal. Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the residual pressure from the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank. 1. Disconnect hoses (1) – (6) of the solenoid valves to be measured. No. 1 2 3 4 5 6

Solenoid valve to be measured PPC lock solenoid valve 2-stage relief solenoid valve Swing holding brake solenoid valve Travel speed selector solenoid valve Travel junction solenoid valve Pump merge-divider solenoid valve

Since hoses (2) – (6) are installed under the control valve, remove the control valve undercover.

2. Install adapter N2 and connect the disconnected hoses again. 3. Install nipple [1] of hydraulic tester N1 and connect it to oil pressure gauge [2]. Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}. The measuring instruments installed to the outlet hose of the PPC lock solenoid valve are shown in the figure.

Since hose (1) is installed under the cab, remove the cab undercover (rear one).

4. Run the engine and heighten the hydraulic oil temperature to the operating range.

20-128 (4)

PC160LC-7

MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

TESTING AND ADJUSTING

5. Run the engine at high idling and operate the control levers and switches and measure the pressure when each solenoid valve is turned ON or OFF. For the conditions for turning each solenoid valve ON and OFF, see the table for functioning conditions of each solenoid valve. The operating conditions of the solenoid valves can be checked with the monitoring function of the monitor panel (special function of the monitor panel). If the output pressure of a solenoid valve is as follows, that solenoid valve is normal. Solenoid valve

Output pressure

OFF (Demagnetized)

0 MPa {0 kg/cm2} Almost same as control basic pressure (See standard values table)

ON (Magnetized)

6. After finishing measurement, remove the measuring instruments and return the removed parts.

Table for Functioning Conditions - PPC lock solenoid valve Operating condition Safety lock lever

PC160LC-7

Functioning

LOCK

OFF

RESET

20-129 (1)

MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

TESTING AND ADJUSTING

Table for Functioning Conditions - 2-stage relief solenoid valve Functioning Condition

Functioning

When overheat setting of the 1st stage is ON When overheat setting of the 2nd stage is ON

OFF

When all the signals for work equipment, swing and travel are OFF When swing lock switch is ON When travel signal is ON When working mode is L mode

When boom LOWER signal is ON When working mode is A or E mode

When left knob switch is ON

If signals other than swing operation only is ON If swing operation only is ON

In conditions other than above

OFF

Table for Functioning Conditions - Swing holding brake solenoid Functioning Condition Work equipment, swing, travel, signaling

Functioning

When all of them is OFF

OFF

When any of them is ON

Table for Functioning Conditions - Travel speed shifting solenoid valve Functioning Condition

Functioning

When overheat setting of the 2nd stage is ON When the fuel dial indicates less than 1500 rpm When the travel speed switch is at Lo The travel signal is OFF When the travel speed switch is at Hi

The travel signal is ON

If front or rear pump pressure is 29.4 MPa{300 kg/cm2} If front or rear pump pressure is 15.3 MPa{156 kg/cm2}

OFF

In conditions other than above

Table for Functioning Conditions - Travel junction solenoid valve Functioning Condition

When the travel signal is ON

When machine travels without operating any work equipment (When work equipment, swing, and/or service signals are OFF) When machine travels and operates work equipment simultaneously (When work equipment, swing, and/or service signals are ON)

Functioning ON

OFF

When the travel signal is OFF

Table for Functioning Conditions - Merge/divide solenoid valve Functioning Condition

When travel signal is ON

Functioning ON

OFF

When travel signal is OFF

20-130 (1)

PC160LC-7

MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

TESTING AND ADJUSTING

MEASUREMENT OF PPC VALVE OUTPUT PRESSURE PPC valve output pressure measurement tools Mark P

Part No. 799-101-5002 790-261-1204

Part Name Hydraulic Tester Digital Type Hydraulic Tester

Measure PPC valve output pressure after confirming that control circuit original pressure is normal.

2. Fit fitting [1] of hydraulic tester P and connect oil pressure gauge [2]. Use an oil pressure gauge with the capacity of 5.9 MPa {60 kg/cm2}. The measuring instruments installed to the mounting part of the boom RAISE PPC oil pressure switch are shown in the figure.

1. Remove PPC oil pressure switches (1) through (10) in the hydraulic circuits to be measured. No. 1 2 3 4 5 6

Circuit to be Circuit to be No. measured measured Boom, RAISE (S06) 7 Swing, left (S03) Boom, LOWER (S02) 8 Swing, right (S07) Arm, IN (S04) 9 Travel (black) (S30) Arm, OUT (S08) 10 Steering (red) (S31) Bucket, CURL (S01) Bucket, DUMP (S05)

(1) – (8) are installed to the PPC junction block in the rear of the cab.

Since (9) and (10) are installed under the cab, remove cab undercover (front one).

3. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.

4. Measure the pressure when the engine is running at high idling and the control lever of the circuit to be measured is kept in the NEUTRAL position and at the full stroke. If PPC valve output pressure is at the level shown below, it is judged normal. Lever Control In NEUTRAL At full stroke

Hydraulic Pressure 0 MPa {0 kg/cm2} Nearly equal to control original pressure (see standard value table)

5. Detach all the measurement tools, and make sure that the machine is back to normal condition.

PC160LC-7

20-131 (4)

TESTING AND ADJUSTING

ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE

ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE If the work equipment/swing lever has large play, adjust the PPC valve according to the following procedure. 1. Remove work equipment and swing PPC valve assembly. 2. Take off boot (1). 3. Loosen lock nut (2) and screw in disc (3) until it contacts the heads of four pistons (4). Do not move the piston while doing this work. 4. Keep disc (3) in place and tighten lock nut (2) to the specified tightening torque. Lock nut: 98 – 127Nm {10 – 13 kgm} 5. Install boot (1). 6. Install work equipment and swing PPC valve ass'y.

20-132 (4)

PC160LC-7

TESTING AND ADJUSTING

INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT

INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT If there is any hydraulic drift in the work equipment (cylinders), check in the following manner to determine if the cause is in the cylinder packing or in the control valve. 1. Inspection of boom and bucket cylinders 1) Set the work equipment in the same posture as when measuring hydraulic drift, and stop the engine. Fill the bucket with earth or apply the rated load to the bucket.

2) Operate the control lever to the RAISE position or the bucket control lever to the CURL position. • If the lowering speed increases, the cylinder piston ring is defective. • If there is no change, the control valve is defective. Operate the control lever with the engine starting switch in the ON position. If the pressure in the accumulator of the PPC circuit is low, heighten it by running the engine for about 10 seconds. 2. Inspection of arm cylinder 1) Operate the arm cylinder to move the arm to the position 100 mm before the digging stroke end, and stop the engine.

PC160LC-7

2) Operate the arm control lever to move the arm to the digging side. • If the lowering speed increases, the cylinder piston ring is defective. • If there is no change, the control valve is defective. Operate the control lever with the engine starting switch in the ON position. If the pressure in the accumulator of the PPC circuit is low, heighten it by running the engine for about 10 seconds. [Reference]If the cause of the hydraulic drift is in the defective piston ring, and the above operation is carried out, downward movement is accelerated for the following reasons. 1) If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is small than the volume at the bottom end by the volume of the rod end, so the internal pressure at the head end increases because of the oil flowing in from the bottom end. 2) When the internal pressure at the head end increases, the pressure at the bottom end also rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this procedure. 3) When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit at the head end is opened to the drain circuit (the bottom end is closed by the pressure compensation valve), so the oil at the head end flows to the drain circuit and the downward movement becomes faster.

20-133 (1)

TESTING AND ADJUSTING

INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT

3. Inspection of boom lock valve 1) Set the work equipment at the maximum reach and the boom top horizontal. Then stop the engine. Lock the work equipment control levers and release the pressure inside the hydraulic tank. Do not allow anyone to come under the work equipment during the work. 2) Disconnect drain hose (1) of the control valve and plug it. • Part No. for the blind hose: 07376-70315 Leave the control valve end open. If any oil leaks out from the port that is left open, following hydraulic drift of the work equipment, the boom lock valve is defective (loose contact).

4. Inspection of PPC valve 1) Set the work equipment at the maximum reach with the boom top in level and stop the engine. 2) Heighten the pressure in the PPC accumulator and set the safety lock lever in the LOCK/ FREE position and measure the hydraulic drift of the work equipment. Operate the safety lock lever while the starting switch is in the ON position. If the pressure in the accumulator of the PPC circuit is low, heighten it by running the engine for about 10 seconds. If there is any difference in the hydraulic drift between LOCK and FREE positions, the PPC valve is defective (some internal failure).

20-134 (1)

PC160LC-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING TRAVEL DEVIATION

Inspection 1. Run the engine and heighten the hydraulic oil temperature to the operating range and set the machine in the travel posture. To set the machine in the travel posture, extract the bucket cylinder and arm cylinder fully and set the boom angle to 45 degrees. 2. Set the working mode to A and travel speed to Lo. 3. Run up for 10 m with the engine speed at high idling and continue travel under the same condition for 20 m and measure the deviation (a). Install an oil pressure gauge and check that the F and R discharge pressures of the hydraulic pump are even.

PC160LC-7

Adjustment If the machine deviates, it can be corrected by partially draining the oil discharged more from the pump through the travel deviation adjusting plug. (If the travel deviation is corrected by this method, howev er, the pump disc har ge is reduced. As a result, the travel speed, work equipment speed in compound operation, and relief pressure may lower.)

20-135 (1)

TESTING AND ADJUSTING

If the machine deviates in the same direction regardless of the travel direction, correct it according to the following procedure. (If the deviating direction of the machine depends on the travel direction, the cause of deviation may not be in the hydraulic pump. In this case, carry out troubleshooting.) Only when the travel deviation is 200 mm or less, it can be corrected by the following method. If the adjusting plug is loosened more than the adjustment limit, high-pressure oil will spout out. Take care extremely. Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the residual pressure from the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure from the tank. 1. Check the deviating direction and the locations of travel deviation adjusting plugs (1) and (2). • (1): Right deviation adjusting plug (F pump) • (2): Left deviation adjusting plug (R pump) Loosen only the plug on either side for adjustment. Do not loosen the plugs on both sides.

TESTING AND ADJUSTING TRAVEL DEVIATION

3. Loosen plug (3) to adjust the travel deviation. • Quantity of adjustment of deviation per turn of plug: 150 mm (Reference) The plug is fully tightened when shipped. Adjust the deviation by the loosening angle of the plug from the fully tightened position. If the plug is turned together with the locknut, tighten it fully again, then start adjustment. The plug can be loosened by 2 turns (720 degrees) from the fully tightened position. 4. Fixing plug (3) with a hexagonal wrench, tighten locknut (4). Locknut: 2.9 – 4.9 Nm {0.3 – 0.5 kgm} After tightening the locknut, seal its hole with a vinyl tape. 5. After finishing adjustment, check travel deviation again according to the procedure for inspection described above.

2. Fixing plug (3) with a hexagonal wrench (Width across flats: 4 mm), loosen locknut (4). If the locknut is sealed with a vinyl tape, remove that tape. Before loosening the locknut, make match marks on it and pump case. • Loosening angle of locknut: Approx. 90 – 180 degrees

20-136 (1)

PC160LC-7

TESTING AND ADJUSTING

RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT 1. Release of residual pressure from hydraulic tank The hydraulic tank is enclosed and pressurized. When removing a hose or a plug connected to the hydraulic tank, release the residual pressure from the hydraulic tank according to the following procedure. 1) Lower the work equipment to the ground in a stable posture and stop the engine. 2) Slowly loosen oil filler cap (1) of the hydraulic tank to release the air from the tank.

3. Release of residual pressure from swing motor circuit Release the residual pressure from the swing motor circuit by performing the procedure for 2. release of residual pressure from hydraulic cylinder circuit. 4. Release of residual pressure from travel motor circuit Since the control valve spool of the travel motor is open, release the residual pressure from the travel motor circuit by performing the procedure for 1. Release of residual pressure from hydraulic tank.

2. Release of residual pressure from hydraulic cylinder circuit

When disconnecting the piping between a hydraulic cylinder and the control valve, release the residual pressure from the piping according to the following procedure. Referring to 1. Release of residual pressure from hydraulic tank, release the residual pressure from the hydraulic tank. Leave the oil filler cap of the hydraulic tank removed. Turn the starting switch to the ON position and set the safety lock lever in the FREE position, and then operate the work equipment control levers on both sides forward, backward, to the right, and to the left. The control valve is driven with the pressure in the accumulator. If it is operated 2 - 3 times, the pressure lowers. Start the engine and run it at low idling for 5 seconds to heighten the pressure in the accumulator. Repeat above steps 2) and 3) 2 – 3 times, and all residual pressure is released from the piping.

PC160LC-7

20-137 (1)

MEASUREMENT OF OIL LEAKAGE

TESTING AND ADJUSTING

MEASUREMENT OF OIL LEAKAGE Measuring instruments for oil leakage Mark Part No. Q Commercially available

Part Name Measuring cylinder

2) Disconnect hose (2) on the cylinder head side and block it with a plate. Take care not to disconnect the hose on the cylinder bottom side.

1. Measurement of leakage from boom cylinder 1) Run the engine and heighten the hydraulic oil temperature to the operating range and raise the boom to the stroke end. Referring to RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT, release the residual pressure from the piping on the boom cylinder head side (Operate the lever only in the RAISE direction, however). 2) Disconnect hoses (1) on the cylinder head side and block it with a plate. Take care not to disconnect the hose on the cylinder bottom side.

3) Run the engine at high idling and relieve the arm cylinder by operating the arm control lever in the IN direction Take care not to operate the arm control lever in the OUT direction. 4) Start measuring the oil leakage 30 seconds after the arm cylinder is relieved and measure for 1 minute. 5) After finishing measurement, return the parts. 3. Measurement of leakage from bucket cylinder 1) Run the engine and heighten the hydraulic oil temperature to the operating range and curl the bucket to the stroke end.

3) Run the engine at high idling and relieve the boom cylinder by operating the boom control lever in the RAISE direction Take care not to operate the boom control lever in the LOWER direction. 4) Start measuring the oil leakage 30 seconds after the boom cylinder is relieved and measure for 1 minute. 5) After finishing measurement, return the parts.

Referring to RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT, release the residual pressure from the piping on the bucket cylinder head side (Operate the lever only in the CURL direction, however). 2) Disconnect hose (3) on the cylinder head side and block it with a plate. Take care not to disconnect the hose on the cylinder bottom side.

2. Measurement of leakage from arm cylinder 1) Run the engine and heighten the hydraulic oil temperature to the operating range and move in the arm to the stroke end. Referring to RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT, release the residual pressure from the piping on the arm cylinder head side (Operate the lever only in the IN direction, however).

20-138 (1)

PC160LC-7

TESTING AND ADJUSTING

MEASUREMENT OF OIL LEAKAGE

3) Run the engine at high idling and relieve the bucket cylinder by operating the bucket control lever in the CURL direction Take care not to operate the bucket control lever in the DUMP direction. 4) Start measuring the oil leakage 30 seconds after the bucket cylinder is relieved and measure for 1 minute. 5) After finishing measurement, return the parts. 4. Measurement of leakage from swing motor 1) Disconnect drain hose (4) and plug it. 3) Disconnect drain hose (5) of the travel motor and plug it.

2) Turn the swing lock switch ON. 3) Run the engine at high idling and relieve the swing circuit and measure the oil leakage. Start measuring the oil leakage 30 seconds after the swing motor circuit is relieved and measure for 1 minute. After measuring 1 time, swing the upper structure 180 degrees and measure again. 4) After finishing measurement, return the parts. 5. Measurement of leakage from travel motor 1) Remove the travel motor cover. 2) Start the engine and lock the travel mechanism. Set pin [1] between the sprocket and track frame to lock the travel mechanism securely.

PC160LC-7

4) Run the engine at high idling and relieve the travel circuit and measure the oil leakage. Since wrong operation of the levers can cause an accident, make signs and confirmation securely. Start measuring the oil leakage 30 seconds after the swing motor circuit is relieved and measure for 1 minute. Measure the oil leakage several times, moving the motor little by little (changing the positions of the valve plate and cylinder and those of the cylinder and piston). 5) After finishing measurement, return the parts.

20-139 (1)

BLEEDING AIR FROM EACH PART

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART Air bleeding item

Contents of work

• Replacement of hydraulic oil • Cleaning of strainer

Air bleeding procedure 1

Bleeding air from hydraulic pump

Starting engine

Bleeding air from cylinder

Bleeding air from swing motor

Bleeding air from travel motor

Checking oil level and starting work

q (See note)

• Replacement of return filter element • Replacement or repair of hydraulic pump • Removal of suction piping

q (See note)

q q

• Replacement or repair of control valve • Removal of control valve piping

• Replacement or repair of cylinder • Removal of cylinder piping

• Replacement or repair of swing motor • Removal of swing motor piping

• Replacement or repair of travel motor • Removal of travel motor piping

q q

Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases. 1. Bleeding air from hydraulic pump Keep the oil filler cap of the hydraulic tank loosened while the air is bled from the hydraulic pump. 1) Loosen air bleeder (1) and check that oil oozes out from it. 2) After oil containing no bubbles flows out, tighten air bleeder (1). Air bleeder: 27.5 – 35.3 Nm {2.8 – 3.6 kgm}

2. Starting engine When running the engine after performing step 1, keep its speed at low idling.

20-140 (1)

If the engine water temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset). 3. Bleeding air from cylinder If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idling for about 5 minutes. 2) Running the engine at low idling, raise and lower the boom 4 – 5 times. Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil. 3) Running the engine at high idling, perform step 2). 4) Running the engine at low idling, move the piston rod to the stroke end and relieve the oil. 5) Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4).

PC160LC-7

TESTING AND ADJUSTING

4. Bleeding air from swing motor 1) Run the engine at low idling. 2) Swing to the right and left slowly to bleed air.

BLEEDING AIR FROM EACH PART

If the oil level is below line L, add new oil.

5. Bleeding air from travel motor 1) Run the engine at low idling. 2) Loosen air bleeder (2) and check that oil oozes out from it. 3) After oil containing no bubbles flows out, tighten air bleeder (2). Air bleeder: 27.5 – 35.3 Nm {2.8 – 3.6 kgm}

6. Checking oil level and starting work 1) Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.

2) Check the oil level by sight gauge (3) of the hydraulic tank. If the oil leakage is between lines H and L, it is normal.

PC160LC-7

20-141 (1)

TESTING AND ADJUSTING

INSPECTION PROCEDURES FOR DIODE

INSPECTION PROCEDURES FOR DIODE Check an assembled-type diode (8 pins) and single diode (2 pins) in the following manner.

The conductive direction of each diode is marked on its surface as shown below.

1. When using digital type circuit tester 1) Switch the testing mode to diode range and confirm the indicated value. Voltage of the battery inside is displayed with conventional circuit testers. 2) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode, and confirm the displayed value. 3) Determine if a specific diode is good or no good with the indicated value. • No change in the indicated value: No continuity (defective). • Change in the indicated value: Continuity established (normal) (Note) Note: A silicon diode shows a value between 400 and 600.

20-142 (1)

2. When using analog type circuit tester 1) Switch the testing mode to resistance range. 2) Check the needle swing in case of the following connections. i) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode. ii) Put the red probe (+) of the test lead to the cathode (N) and the black probe (–) to the anode (P) of diode. 3) Determine if a specific diode is good or no good by the way the needle swings. • If the needle does not swing in Case i), but swings in Case ii): Normal (but the breadth of swing (i.e. resistance value) will differ depending on a circuit tester type or a selected measurement range) • If the needle swings in either case of i) and ii): Defective (short-circuited internally) • If the needle does not swing in any case of i) and ii): Defective (short-circuited internally)

PC160LC-7

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

[1] Figure input switch 1

[6] Figure input switch 6

[

] Return switch

[2] Figure input switch 2

[7] Figure input switch 7

[

] Upward move switch

[3] Figure input switch 3

[8] Figure input switch 8

[

] Downward move switch

[4] Figure input switch 4

[9] Figure input switch 9

[

] Input confirmation switch

[5] Figure input switch 5

[0] Figure input switch 0

PC160LC-7

20-143 (1)

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

Monitor panel functions - conventional and special The monitor panel is provided with conventional and special functions, and various kind of information are shown in the multi-display. Display items consists of automatic display items that are preset in the monitor panel and others that are shown by switch operations. 1. Conventional function: Operator's Menu This is a function by which an operator can set or show displays by switch operations. The display contents are those which are normally shown. 2. Special function: Service Menu This is a function by which a service mechanic can set or show displays by special switch operations. The display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trouble-shooting or special setting of machines. Operator's Menu 1

Function for inputting and setting password

Function for showing Komatsu's logo

Function for machine inspection before starting day's work

Function for showing machine maintenance

Function for showing precaution items

Function for confirming working mode and travel speed

Function for display of ordinary items

Function for adjusting display luminance and contrast

Function for adjusting breaker and attachment flow rate

Function for confirming maintenance information

Function for showing service meter reading

Function for checking display LCD

Function for showing occurrence of caution item

Function for showing users' code No.

Function for showing error code No. and failure code No.

20-144 (1)

Service Menu 16

Function for monitoring [01]

Function for failure history [02]

Function for maintenance history [03]

Function for maintenance mode change [04]

Function for recording phone No. [05]

Electrical system Mechanical system

Mode with key on (Change) 21

Function for initial value setting and default [06]

Language Unit Attachment installed/No attachment installed Adjustment of governor lever stroke

Function for adjustment [07]

Fuel pump absorbin torque RPM at low idling Adjustment of oil flow to attachment

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

Operation of Operator's Menu and Display This section introduces only the outline of the operator's menu. For details on the contents and operation steps of each menu, refer to the operation and maintenance manual or the chapter of "STRUCTURE AND FUNCTION" in this shop manual. 1. Function for inputting and setting password When the engine starting switch is turned ON, the password inputting display is shown. This display is shown only when a password is registered. 2. Function for showing KOMATSU logo When a password is inputted, or when the engine starting switch is turned ON, KOMATSU logo is shown for two seconds.

3. Function for machine inspection before starting day's work Following the KOMATSU logo, the display of machine inspection before starting day's work is shown for 2 seconds.

4. Function for machine maintenance Following the display of machine inspection before starting day's work, the maintenance mark appears for 30 seconds, if there is an oil filter whose maintenance time is approaching or has just passed. This display appears only when the maintenance function is set.

PC160LC-7

20-145 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

5. Function for showing precaution items If there is any item of machine inspection before starting day's work that indicates some abnormality, a corresponding symbol mark is shown after the display of machine inspection before starting day's work.

6. Function for confirming working mode and travel speed After the display of machine inspection before day's work, amplified symbol marks for working mode and travel speed are shown for two seconds to urge an operator to confirm the setting.

7. Function for display of ordinary items The display of confirming working mode and travel speed is switched to this display of ordinary items. If the working mode setting or travel speed setting is changed, or auto-deceleration or windshield wiper setting is activated while this is in display, an amplified corresponding symbol mark is shown for two seconds. In this display, a symbol mark for preheat monitor is shown only when preheating is carried out.

8. Function for adjusting display luminance and contrast Luminance as well as contrast of the display can be adjusted by operating the display adjusting switch.

20-146 (1)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

9. Function for adjusting breaker and attachment flow rate (For machines equipped with breaker attachment) When a breaker or other attachments are used, hydraulic pump flow rate can be adjusted by operating the select switch. Note that the symbol mark and contents of display partially differ between the breaker and the other attachments. (The items displayed when attachments are used are shown in the figure.)

10. Function for confirming maintenance information Detailed information on maintenance items (set time and elapse of time) can be confirmed and resetting after the confirmation is feasible by operating the maintenance switch. Use service Menu for setting or releasing maintenance items and setting maintenance time.

11. Function for showing service meter reading Only the service meter reading can be shown by the following switching operation, when the engine starting switch is turned OFF. • Switching operation: [ ] + [ ] (synchronized switching operation)

12. Function for checking display LCD Display of the Display LCD can be confirmed by the following switching operation in the display of inputting and setting password as well as in the display of ordinary items • Switching operation: [ ] + [A] (synchronized switching operation) All the LCD light up, turning the entire screen white. If there is no showing in black, the display is normal. This display returns to the immediately preceding one, if making any other switching operation.

PC160LC-7

20-147 (1)

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

13. Function for showing occurrence of caution item If any of the caution items occurs, the magnified corresponding symbol mark is shown for two seconds and thereafter stays on the display as a small symbol mark until it is dissolved.

14. Function for showing users' code No. When a trouble occurs on the machine, the user's code is automatically displayed depending on the magnitude of the trouble to call attention of the operator for a proper action. This display turns to the display of service code and failure code, if operating the switch (Refer to Item No. 15)

Relation between User Code and Action Directed to Operator User Code

Failed System

E02

Error in pump control system

Turn the emergency pump driving switch ON (Set it in the emergency position), and you can operate the machine normally. Have the machine inspected immediately, however.

E03

Error in swing brake system

Turn the swing holding brake release switch (ON) (Set it in the release position) to release the brake. To apply the swing brake, operate the swing lock switch manually. The brake may not be released, depending on the cause of the fault. Have the machine inspected immediately in any case.

E05

Error in governor system

The governor cannot be controlled. Have the machine inspected immediately in this case.

20-148 (1)

Action Directed to Operator

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

15. Function for showing error code No. and failure code No. If the following switching operation is made while the users' code No. is shown, a phone symbol (if registered), phone numbers (if registered), error code No. and failure code No. are shown in turn. • Switching operation: [ ] (keep the switch depressed) The following display is repeated in turn, while the switch is depressed. (1) Telephone symbol mark (2) Telephone No. (3) Error code No. and failure code No. The telephone symbol mark and telephone No. are shown only when they are registered in the monitor panel. For registration, correction and deletion of telephone No., use Service Menu. For details on the displayed error code No. and failure code No., refer to the Table for error and Failure Code Nos.

PC160LC-7

20-149 (1)

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

Error Code Code No.

Content

– E101 Abnormal data in error history

Failure Code Code No.

Location

Phenomenon

DAF0KT Monitor controller

Abnormality in controller

Short circuit in wiper motor drive, normal rotaWindshield wiper motor (norDY2DKB Short circuit tion system mal rotation) Short circuit in wiper motor drive, reverse rotaWindshield wiper motor – E113 DY2EKB Short circuit tion system (reverse rotation) – E114 Short circuit in windshield washer drive system DY2CKB Windshield washer motor Short circuit – E115 Abnormality of windshield wiper in motion DY20KA Windshield wiper motor Disconnection – E116 Abnormality of windshield wiper in retraction DY20MA Windshield wiper motor Malfunctioning – E201 Short circuit in travel junction solenoid DW91KB Travel neutral solenoid valve Short circuit Swing holding brake soleE03 E203 Short circuit in swing holding brake solenoid DW45KB Short circuit noid valve Pump merge/divider sole– E204 Short circuit in merge/divider solenoid DWJ0KB Short circuit noid valve – E205 Short circuit in 2-stage relief solenoid DWK0KB 2-stage relief solenoid valve Short circuit Travel Hi-Lo shifting solenoid – E206 Short circuit in travel speed shifting solenoid DW43KB Short circuit valve – E211 Disconnection in travel junction solenoid DW91KA Travel neutral solenoid valve Disconnection Swing holding brake soleE03 E213 Disconnection in swing holding brake solenoid DW45KA Disconnection noid valve Pump merge/divider sole– E214 Disconnection in merge/divider solenoid DWJ0KA Disconnection noid valve – E215 Disconnection in 2-stage relief solenoid DWK0KA 2-stage relief solenoid valve Disconnection Travel Hi-Lo shifting solenoid – E216 Disconnection in travel speed shifting solenoid DW43KA Disconnection valve NonconforS-NET communication of mance in model – E217 Abnormality in model code input DA2SKQ governor pump controller selecting signal S-NET communication of – E218 Disconnection in S_NET signal DA2SKA Disconnection governor pump controller – E224 Abnormality in F pump pressure sensor DHPAMA F pump pressure sensor Malfunctioning – E225 Abnormality in R pump pressure sensor DHPBMA R pump pressure sensor Malfunctioning Power source output of gov- Lowering in out– E226 Abnormality in pressure sensor power source DA25KP ernor pump controller put voltage – E227 Abnormality in engine revolution sensor DLE2MA Engine revolution sensor Malfunctioning – E228 Short circuit in ATT return switching relay D196KB ATT switching relay Short circuit E02 E232 Short circuit in PC-EPC solenoid DXA0KB TVC solenoid valve Short circuit E02 E233 Disconnection in PC-EPC solenoid DXA0KA TVC solenoid valve Disconnection – E238 Disconnection in ATT return switching relay D196KA ATT switching relay Disconnection Short circuit in ATT flow rate adjusting EPC Solenoid of attachment flow Short circuit DXE4KB – E245 solenoid rate PPC adjustment valve Disconnection in ATT flow rate adjusting EPC Solenoid of attachment flow – E246 DXE4KA Disconnection solenoid rate PPC adjustment valve – E306 Abnormality in governor potentiometer DK54KZ Body positioner sensor Short circuit E05 E308 Abnormality in fuel dial DK10KZ Throttle potentiometer Short circuit Short-circuiting in low-temperature starting Low-temperature starting Short circuit D199KB – E311 solenoid relay solenoid relay Low-temperature starting Short-circuiting in low-temperature starting D199KA Disconnection – E312 solenoid relay solenoid relay – E315 Short circuit in battery relay output D110KB Battery relay Short circuit – E316 Abnormality in governor motor step-out DY10K4 Governor motor Out of control

Failure Classification

User Code No.

Table for Error and Failure Code Nos.

20-150 (1)

Electrical system

– E112

PC160LC-7

Code No.

Content

Failure Code Code No.

Location

Phenomenon

E05 E317 Disconnection in both governor motors A and B DY10KA Governor motor

Disconnection

E05 E318 Short circuit in both governor motors A and B

DY10KB Governor motor

Short circuit

– None Engine high idling out of rate

A000N1 Engine

– None Engine low idling out of rate

A000N2 Engine

– None Air cleaner clogged

AA10NX Air cleaner element

– None Charging voltage abnormally low

AB00KE Alternator

– None Engine oil pressure abnormally low

B@BAZG Engine oil

– None Engine oil level abnormally low – None Engine cooling water overheated

B@BAZK Engine oil B@BCNS Engine cooling water

– None Radiator water level abnormally low

B@BCZK Engine cooling water

– None Hydraulic oil overheated

Overrunning Low-idling speed heightened Clogging Insufficient charging Oil pressure lowered Oil level lowered Overheating Cooling water level lowered Overheating

B@HANS Hydraulic oil Auto-lubrication system conDA80MA Malfunction troller Ass‘y

– None Auto-lubrication system abnormal

Mechanical system

User Code No.

Error Code

Electrical Failure system Classification

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

This table is arranged in the sequence of Error Code No. In case there is no number assigned in the column of User Code No., or in case "none" is described in the column of Code No. of Error Code, the corresponding service code or failure code is not shown in the display of ordinary items, even if some abnormality occurs. It is recorded only in the failure history (either in electrical system or mechanical system) of Service Menu. History Classification indicates that a specific failure is classified as belonging to either electrical system or mechanical system, when it is recorded in Service Menu. "E" at the head of Code No. of Error Code means the following status of a specific failure. • With "E": The failure is yet to be dissolved and continues. • Without "E": The failure has already been dissolved.

PC160LC-7

20-151 (1)

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

Operation and Display of Service Menu Way of switching to Service Menu When using Service Menu, change the display to Service Menu display through the following special operation. 1) Confirmation of display Confirm that the display of ordinary items is shown. Changing to Service Menu cannot be made from displays other than this. 2) Switch operation Operate the switch as instructed below. • Switch operation: [ ] + [1] [2] [3] (Enter a figure, depressing [

])

3) Showing Service Menu display The display is changed to the initial display of Service Menu program. Select an appropriate item from among the menu. No.

Service Menu

Return (Termination of Service Menu)

Monitoring

Abnormality Record

Maintenance Record

Maintenance Mode Change

Phone Number Entry

AAAAA / Default

Adjustment

–

4) Termination of Service Menu function When terminating the initial display or any subsequent display of Service Menu, do that through any one of the following methods. • Depress [ ] switch. (This method may be used for terminating any display) • If "Return" switch is shown, depress it. • If "Return" menu is shown, call that menu and depress [ ] switch.

20-152 (1)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

16. Function of monitoring [01] The monitor panel monitors signals from an assortment of switches, sensors and actuators installed in various parts of the machine. Monitored information can be put in display or confirmed on a real time basis through the following operations. 1) Selection of menu Select "01 Monitoring" in the initial display of Service Menu and depress [ ] switch. 2) Setting of monitoring item Select or register an item to be monitored through the following switch operation. • [ ] switch: Selection • [ ] switch: Selection • [ ] switch: Registration A monitoring item can be set in any number between the min. one to the max. four. (Depending upon the selected item, the max. number is less than four) In case of monitoring 1 to 3 items, move to the monitored information display through any of the following switch operations, after the registration work has been completed. • Keep [ ] switch depressed. (For about 3 seconds) • Select Menu 999 and depress [ ] switch. The display automatically moves to the display of monitored information, when all of the registrable items have been duly registered. Monitored information are transmitted via communication circuits. Thus the number of selected items can impact the communication speed. If truly real time monitoring is required, reduce the selected items to the minimum. For details on the monitoring items, display unit, etc., refer to the Table for Monitoring Items.

PC160LC-7

20-153 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

3) Monitoring operation Call the monitoring information display and confirm the monitored information, while operating the machine.

4) Monitored information holding function If [ ] switch is depressed while monitoring, all the monitored information are put on hold. If [ ] switch is depressed in this condition, information holding is released.

5) Machine setting mode switching function If it becomes necessary to change settings of working mode, select mode, travel speed and auto-decel while monitoring, depress the corresponding switch, then the mode confirmation display is shown. An illustration at right shows the display in A mode and E mode. Symbol marks are partially different in B mode. When a specific setting is confirmed, depress [ ] switch, then the display returns to that of monitoring. In case a specific setting has been changed while monitoring, the new setting is still maintained when returning from Service Menu to Operator's Menu after the monitoring is finished.

20-154 (1)

PC160LC-7

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

Table for Monitoring Items Code No.

Item to be monitored

Unit (Default: ISO) ISO

Meter

Inch

Remark

000

Return

(Not displayed)

Return menu

999

To Display Screen

(Not displayed)

Execute Command menu

002

Controller Model Select

Figure

003

Controller Model Select

Figure

010

Engine Speed

011

r/min

F Pump Pressure

rpm

rpm 2

psi

MPa

kg/cm

psi mA

012

R Pump Pressure

MPa

kg/cm2

013

PC-EPC Sol. Curr.

015

LS-EPC Sol. Curr.

016

2nd Eng. Speed Command

r/min

rpm

017

Service Sol. Curr.

Swing

019

021

022

023

024

027

Pressure Switch 1

Pressure Switch 2

Switch Input 1

Solenoid valve 1

Solenoid valve 2

Switch Input 2

ON/OFF

Travel

ON/OFF

Boom Lower

ON/OFF

Boom Raise

ON/OFF

Arm In

ON/OFF

Arm Out

ON/OFF

Bucket Curl

ON/OFF

Bucket Dump

ON/OFF

Offset

ON/OFF

Service

ON/OFF

Travel differential Pressure

ON/OFF

Knob Sw.

ON/OFF

Swing Release Sw.

ON/OFF

Swing holding Brake Sw.

ON/OFF

Travel Junction

ON/OFF

Swing holding Brake

ON/OFF

Merge-divider

ON/OFF

2-stage Relief

ON/OFF

Travel Speed

ON/OFF

ATT Return

ON/OFF

Model Select 1

ON/OFF

Model Select 2

ON/OFF

Model Select 3

ON/OFF

Model Select 4

ON/OFF

Model Select 5

ON/OFF

Low-viscosity fuel mode 030

Fuel Dial Vol.

(Not used)

ON/OFF V

031

Gov. Motor Potentio Vol.

032

Battery Voltage

033

Gov. Motor Phase A Curr.

034

Gov. Motor Phase B Curr.

035

Battery Relay O/P Vol.

036

Switch Input 3

Key Switch

037

Controller Output

Batt. Relay Dr.

041

Engine Water Temperature

PC160LC-7

(Not used)

ON/OFF ON/OFF ºC

ºC

ºF

20-155 (1)

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

Code No.

Item to be monitored

Unit (Default: ISO) ISO

Meter

Inch

042

Fuel Lever Sensor Vol.

043

Battery Charge Vol.

044

Hydr. Oil Temperature

ºC

ºF

045

046

049

Monitor Input 1

Monitor Input 2

Monitor Input 3

Key Switch

ON/OFF

Start

ON/OFF

Preheat

ON/OFF

Light

ON/OFF

Radiator water Level

ON/OFF

Aircleaner

ON/OFF

Engine Oil Pressure

ON/OFF

Engine Oil Level

ON/OFF

Spare

ON/OFF

Battery Charge

ABN•NOR

Swing Holding Brake Switch

ON/OFF

Buzzer cancel Switch

ON/OFF

Window Limit Switch

ON/OFF

W Limit Switch

ON/OFF

P Limit Switch

Remark

ON/OFF MPa

{kg/cm2}

159

Boom bottom Pressure

200

Monitor Prog. Version

Figure

201

Controller Prog. Version

Figure

PSI

(Not used)

Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu. Abbreviations, ABN and NOR, stand for the following conditions. ABN: Abnormal, NOR: Normal

20-156 (1)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

17. Function for Abnormality Record [02] The monitor panel records failures that occurred on the machines in the past after classifying them into failures in the electric system and those in the mechanical system. Information on them can be displayed through the following operation. 1) Selection of menu Select 02 Abnormality Record in the initial display of Service Menu and depress [ ] switch. 2) Selection of Submenu Select an appropriate item from Submenu in the Abnormality Record display and depress [ ] switch. No. 00 01 02

Abnormality Record Submenu Return (termination of Abnormality Record) Electrical System Mechanical Systems

3) Information shown in display of Abnormality Record in the electrical system [1]: The numerator expresses sequence of failure occurrence, counting from the latest one. The denominator expresses the t o ta l n u m b e r o f a s p e c i f i c f a i l u r e recorded. [2]: Error Code [3]: Abnormality Code No. (system in 4 digits and phenomenon in 2 digits) [4]: Time elapsed since the occurrence of the first failure [5]: Contents of failure Refer to "Table for Error Code and Abnormality Code" in Operator's Menu. 4) Information shown in display of Failure History in the mechanical systems [1]: Record No. [2]: Contents of Abnormality [3]: Abnormality Code No. (system in 4 digits and phenomenon in 2 digits) [4]: Total number of occurrence [5]: Service meter reading at the initial occurrence Refer to "Table for Error Code and Abnormality Code" in Operator's Menu.

PC160LC-7

20-157 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

5) Resetting Electrical Systems Resetting Electrical Systems (deletion) is possible only with the electrical system. The failure history in the mechanical system cannot be reset. For resetting any specific or all information in the Electrical Systems, follow the operation explained below. i) Through the following switch operation, call the resetting display in the display of Electrical Systems. • Switch operation: [ ]+[1] [2] [3] This is the same switch operation in changing the display to Service Menu. ii) Operate the switch, following the instructions shown in the resetting display. When resetting specific information only, call the display of that specific information and reset it with either [ ] switch or [ ] switch. When resetting all the information, a display of any information will do.

20-158 (1)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

18. Function for Maintenance Record [03] The monitor panel records information on the maintenance of filters and oils. The stored information can be displayed through the following switch operation. 1) Selection of menu Select 03 Maintenance Record in Service Menu and depress [ ] switch.

2) Information to be displayed • Name of oils and filters • Times of replacement to date • Service meter reading at the latest replacement

PC160LC-7

20-159 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

19. Function for Maintenance Mode Change [04] Conditions set for controlling maintenance display function can be changed in the following manner. • Turn the function effectual or ineffectual. • Change the set interval for replacement. 1) Selection of menu Select 04 Maintenance Mode Change in the initial display of Service Menu, and depress [ ] switch.

2) Selection of item to be changed Select an item to be changed in the display of Maintenance Mode Change Selecting Menu. No. 00 01 02 03 04 05 06 07 08 09 10 11 12

Maintenance mode change item Return Maintenance Mode On/Off Engine Oil Exch. Int. Engine Oil Filter Exch. Int. Fuel Filter Exch. Int. Hydr. Oil Filter Exch. Int. H/Tank Breather Exch. Int. Corro. Resis. Exch. Int. Damper Case Oil Service Int. Final Drive Oil Exch. Int. S/Machinery Oil Exch. Int. Hydraulic Oil Exch. Int. Use Default Values

01 and 12 menus are provided for setting the whole maintenance mode, while those from 02 through 11 are for setting individual items. 3) Contents of Maintenance Mode On/Off • Use: The maintenance display function of all oil and filter-related items are turned effectual. (Irrespective of whether "On" or "Off" set for individual items, this setting prevails) • Do not use: The maintenance display function of all oil and filter-related items are turned ineffectual. (Irrespective of whether "On" or "Off" set for individual items, this setting prevails)

20-160 (1)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

4) Set contents of individual items (1): Default: The maintenance time set in the monitor (recommended by the manufacturer and cannot be changed). (2): Set: Maintenance time that can be freely set. The maintenance mode program functions based on this maintenance time. (The maintenance time can be increased or decreased by 50 hours with [ ] or [ ] switch) (3): Off: Maintenance display with this instruction becomes ineffectual. (4): On: Maintenance display function with this instruction becomes effectual. The lowest maintenance time is 50 h. 5) Set contents of "Use Default Values" When selecting this menu and depressing the switch [ ], all individual time settings are reduced to the initial settings.

PC160LC-7

20-161 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

20. Function for Phone Number Entry [05] In the display of User Code, a telephone number and Service Code are shown alternately. Phone number can be inputted or modified in the following manner. If there is no Phone number registered, the display for Phone numbers does not appear. 1) Selection of menu Select 05 Phone Number Entry menu in the display of Service Menu, and depress [ ] switch. 2) Changing the display Select Entry next to change the display to the Phone Number Entry display. Even if a Phone number is already inputted, it is deleted, upon switching to the Phone Number Entry display.

3) Entry and setting Phone number Following the method explained below, Entry a Phone number in the Phone Number Entry display. (Entry automatically begins with a cursor at the left end) (1) Enter a number into a cursor at the left end with a ten-key. Numbers can be entered up to the max. 12 digits, but omit unnecessary digits. When entering a wrong number, depress [B] switch, then the cursor goes back by one digit. (2) Depress [ ] switch when all the numbers have been entered. When input is finished, the display changes to Entry display shown above. If the inputted Phone number is shown in this display, the input is normal.

20-162 (1)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

21. Function for AAAAA/Default [06] It is possible to change the following settings for the monitor panel as well as the machine. Make a change as is required. • Working mode when the engine starting switch is in the ON position. • Display language in Service Menu • Display unit in the monitoring function • With/Without Service Cir. 1) Selection of menu Select 06 "AAAAA/Default menu" in the initial display of Service Menu, and depress [ ] switch. 2) Selection of submenu Select an item to change from the submenu, and depress [ ] switch. No. 00 01 02 03 04

AAAAA/Default submenu Return (termination of AAAAA/Default) Key-on Mode AA/Language Unit With/Without Service Cir.

3) Function for Key-on Mode When the engine starting switch is turned ON, a working mode can be set that is shown in the monitor panel. • A, E, L and B Modes: If any of them is set, the machine always ramps up with that working mode, when turning the engine starting switch ON. • Mode at Previous Key-off: If this mode is set, the machine ramps up with the working mode that was last used in the previous machine operation. • Default Value: If this mode is set, the machine ramps up with the default mode (A mode) that was originally set at the time of delivery from the factory. Irrespective of this setting mode, a machine "With attachment" always ramps up with B mode, when the engine starting switch is turned ON at the subsequent operation, if that was the working mode used in the last machine work.

PC160LC-7

20-163 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

4) Function for AA/Language In Service Menu, the language in use can be changed between Japanese and English. English is used as the language for default setting in the monitor panel. If the monitor panel for spare parts is to be used in a Japanese-speaking region or organization, change the language from English to Japanese, using this function.

5) Function for unit selection As the unit to be used in the monitoring function display of Service Menu, three kinds of unit are provided. Unit used for default setting in the monitor panel is SI, i.e. International System of Units.

6) Function for selecting distinction of With/ Without Service Cir. It is possible in this function to set a distinction between with or without attachment. • With Service Circuit: When an attachment is installed. • Without Service Circuit: When no attachment is installed. If "With Service Circuit" setting is not made in this display, while it is actually installed on a specific machine, SELECT function in Operator's Mode (attachment oil flow rate adjustment) cannot be utilized.

20-164 (1)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

22. Function for Adjustment [07] The monitor panel has a function of making various adjustments of the machine. 1) Selection of menu Select 07 adjustment in the initial display of Service Menu, and depress [ ] switch.

2) Selection of submenu Select an item to change from the submenu and depress [ ] switch. No. 00 01 02 03 04

Adjustment submenu Return (termination of adjustment) Governor lever stroke adjustment Pump Absorption Torque Low Idle Speed Service Current Adjustment

3) Function of adjusting governor lever stroke After the governor actuator, the fuel injection pump, or governor spring is removed and installed or when the engine speed does not rise to high idling or is not stable, adjust the governor lever stroke according to the following procedure. (1) Select Adjustment on the Governor lever stroke adjustment screen and set the fuel control dial to the MAX position. Under this condition, the governor actuator lever moves to the FULL position. Keep this screen while you are adjusting the governor lever stroke. The engine speed is displayed in 10 rpm on the center of the screen. The rotation direction of the governor spring when you see the governor actuator side from the fuel injection pump side is indicated. To adjust the governor spring, turn the square part on the governor motor side with a spanner, etc.

PC160LC-7

20-165 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTION OF MONITOR PANEL

(2) Loosen locknut (2) on the governor actuator side of governor spring (1). (3) Turn governor spring (1) clockwise to decrease installed length (a) and return governor lever (3) of the fuel injection pump to a position where it will not touch the full stopper. (4) Turn governor spring (1) counterclockwise to increase installed length (a) and stop it when governor lever (3) of the fuel injection pump touches the full stopper. • Standard installed length (a) (Reference): 259.9 mm (5) Turn governor spring (1) counterclockwise further by 2.5 turns to shorten the internal spring of governor spring (1). Since the internal spring is shortened, only the outer cylinder of governor spring (1) moves about 3.1 mm toward the fuel injection pump (The installed length does not change). (6) With governor spring (1) fixed, tighten locknut (2) on the governor actuator side. Before fixing the locknut, check that the water drain hole of the governor spring is directed down. If the water drain hole is not directed down, loosen locknut (4) on the fuel injection pump side and turn the whole governor spring (Take care that the adjustment length of the governor spring will not change). Locknut: 11.8 – 19.6 Nm {1.2 – 2.0 kgm} (7) Return the fuel control dial to the MIN position, and then turn it again gradually toward the MAX position. At this time, check that the governor spring is shortened about 3.1 mm after governor lever (3) touches the full stopper. 4) Function for Pump Absorption Torque adjustment The pump absorption torque can be adjusted within the range shown in the table below. Adjustment value 220 221 222 223 224 225 226 227 228

20-166 (1)

Torque adjustment value +4.0 kgm +3.0 kgm +2.0 kgm +1.0 kgm 0.0 kgm –1.0 kgm –2.0 kgm –3.0 kgm –4.0 kgm

PC160LC-7

SPECIAL FUNCTION OF MONITOR PANEL

TESTING AND ADJUSTING

5) Function for Low Idle Speed adjustment The engine rotation at low idling can be adjusted within the range shown in the table below. Adjustment value 320 321 322 323

Low idling rotation 1,030 ± 50 rpm 1,100 rpm 1,200 rpm 1,300 rpm

6) Function for Service Current Adjustment When a machine is used for a compound operation, distribution of hydraulic pump oil flow can be adjusted within the range shown in the table below. Adjustment value 370 371 372 373

PC160LC-7

Distribution of oil flow to attachment 0.5 Time 0.7 Time 1.0 Time 0.4 Time

20-167 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Section to display special functions

Section to operate special function 1 (Basic operation)

Section to operate special function 2 (Selecting operation and special operation)

1. Display section

3. Caution buzzer stop switch

7. Working mode selector (UP) switch

2. Service meter section

4. Auto-decelerator switch

8. Working mode selector (DOWN) switch

5. Setting switch (Black switch) 6. Travel speed shifting switch

PC160LC-7

20-169 (3)

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

TESTING AND ADJUSTING

Ordinary functions and special functions of monitor panel The monitor panel has the ordinary functions and special functions and displays various pieces of information on display section (1) and service meter section (2). Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed by operating switches. 1. Ordinary functions: Operator menu The items in this menu are displayed normally or displayed automatically when a trouble occurs. 2. Special functions: Service menu The items in this menu are not displayed normally. Each serviceman can display them by operating special switches. These functions are used for special setting, testing, adjusting, or troubleshooting.

Flow of each function

1 Function of displaying service meter O <Automatic> 2 Function of displaying user code

Special functions (Service menu) <Operation of switch> O

Ordinary functions (Operator menu)

3 Function of displaying service code [01] 4 Monitoring function [02] 5 Function of adjusting governor [03] 6 Function of selecting maintenance period [04] 7 Function of selecting default working mode [05] 8 Function of setting installation of attachment [16] 9

Special function of monitoring replacement of engine oil

a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.

20-170 (3)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Display of operator menu a Only outline of the operator menu is described in this section. For details of each menu, see OPERATION MANUAL or the volume of STRUCTURE AND FUNCTION. 1. Function of displaying service meter While the machine is used normally, the monitor panel displays the following information. • Display section (1): Nothing is displayed • Service meter section (2): Service meter

2. Function of displaying user code If the machine has any trouble, the corresponding user code is displayed automatically in display section (1) and the caution buzzer is turned ON to urge the operator to take a proper remedy, depending on the degree of the trouble. a Service meter section (2) continues displaying the service meter. a For displayed user codes and the remedies shown to the operator, see "User codes and remedies shown to operator". a Each user code simply shows occurrence of a trouble to the operator. To find out the cause of the trouble, a serviceman must check the service code with the "Function of displaying service code [01]" in the service menu. <Reference> A user code is displayed only when a serious trouble occurs. Even if a user code is not displayed, a trouble may have occurred. If you feel any abnormality, be sure to check for a service code with the "Function of displaying service code [01]" in the service menu. a User codes and remedies shown to operator User code

Error mode

Remedy (shown to operator)

Caution buzzer

E02

Error in pump control system

If the emergency pump drive switch is set in the upper position, the machine can operate normally. Have the machine inspected immediately, however.

Error in swing E03 brake system

Set the swing holding brake release switch in the upper position to release the brake. When applying the swing brake, operate the swing lock switch manually. The brake may not be released, depending on the cause of the failure. In this case, have the machine inspected immediately.

E05

Error in governor Have the machine inspected immediately. system

PC160LC-7

20-171 (3)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Operation and display of service menu How to select service menu a When using the general functions in the service menu, perform the following switch operation to change the screen of the monitor panel. 3. Function of displaying service code [01] 4. Monitoring function [02] 5. Function of adjusting governor [03] 6. Function of selecting maintenance period [04] 7. Function of selecting default working mode [05] 8. Function of setting installation of attachment [16] 1) Operating switches While holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds. 2) Displaying display section and service meter section If the switches are operated as shown above, the first menu No. [01] (Monitoring function) is displayed in service meter section (2). a Nothing is displayed in display section (1). 3) Selecting menu While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a menu you will use. • UP switch (7): Increase Menu No. • DOWN switch (8): Decrease Menu No. Menu Service menu No. (Excluding special functions) 01 Function of displaying error code 02 Monitoring function 03 Function of adjusting governor 04 Function of selecting maintenance period 05 Function of selecting default working mode 16 Function of setting installation of attachment 4) Executing menu Select a menu you will use and press set switch (5), and the menu is executed. 5) Finishing service menu While holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds (similarly to the selecting operation). a The service menu is finished and the ordinary screen appears. a The service menu can be also finished by turning the starting switch OFF while the service menu is selected. (In this case, the ordinary screen appears when the starting switch is turned ON again.)

20-172 (3)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

a To use the following special function, you must operate the switches differently from the above. See details of this function "9. Special function of monitoring replacement of engine oil".

3. Function of displaying service code [01] With this function, you can check the service code of a trouble which is occurring at present or has occurred in the past. 1) Selecting and executing function i) Select menu No. [01] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Information displayed in display section and service meter section 1 (When service code is recorded) If a service code is recorded, the following information is displayed in display section (1) and service meter section (2). (a): Service code (b): Service meter reading increased after trouble occurred (c): Mark [E] to indicate that trouble is occurring at present a Mark [E] to indicate that a trouble is occurring at present indicates that the service code is being detected now. It is not displayed if the trouble has been repaired or the service code is not detected. a For the service codes which the monitor panel and engine throttle and pump controller can detect, see the "Service codes table". 3) Information displayed in display section and service meter section 2 (When service code is not recorded) If a service code is not recorded, display section (1) and service meter section (2) display as shown in the figure. 4) Number of recorded service codes and display order of them This function can record up to 20 service codes, which are displayed in order from the latest one. a If a new trouble occurs while 20 service codes are recorded, the oldest service code is deleted and the service code of the new trouble is recorded.

PC160LC-7

20-173 (3)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

1) Change of displayed service codes While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to change the displayed service codes. • UP switch (7): Next service code appears. • DOWN switch (8): Previous service code appears. 2) How to delete service code i) While holding caution buzzer stop switch (3), turn the starting switch OFF and keep holding caution buzzer stop switch (3). ii) Under the above condition, turn the starting switch ON again and hold caution buzzer stop switch (3) for 5 seconds. a A service code having the mark [E] is not deleted.

20-174 (3)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

Service codes table User code

Service code

Trouble

—

E101

Abnormality in error history data

—

E104

Clogging of air cleaner (Equivalent to error code [AA10NX])

—

E108

Overheating of engine coolant (Equivalent to error code [B@BCNS])

—

E112

Short circuit in wiper motor drive forward system

—

E113

Short circuit in wiper motor drive reverse system

—

E114

Short circuit in windshield washer drive system

—

E115

Trouble in operation of windshield wiper

—

E116

Trouble in storage of windshield wiper

—

E201

Short circuit in travel junction solenoid

E03

E203

Short circuit in swing holding brake solenoid

—

E204

Short circuit in merge-divider solenoid

—

E205

Short circuit in 2-stage relief solenoid

—

E206

Short circuit in travel speed shifting solenoid

—

E211

Disconnection in travel junction solenoid

E03

E213

Disconnection in swing holding brake solenoid

—

E214

Disconnection in merge-divider solenoid

—

E215

Disconnection in 2-stage relief solenoid

—

E216

Disconnection in travel speed shifting solenoid

—

E217

Abnormality in input model code

—

E218

Disconnection in S-NET signal line

—

E222

Short circuit in LS-EPC solenoid

—

E223

Disconnection in LS-EPC solenoid

—

E224

Abnormality in F pump pressure sensor

—

E225

Abnormality in R pump pressure sensor

—

E226

Abnormality in pressure sensor power supply

—

E227

Abnormality in engine speed sensor

—

E228

Short circuit in ATT return selector relay

E02

E232

Short circuit in PC-EPC solenoid

E02

E233

Disconnection in PC-EPC solenoid

—

E238

Disconnection in ATT return selector relay

—

E256

Illegal non-volatile memory data

—

E304

Short circuit in engine stop solenoid relay

—

E306

Abnormality in governor potentiometer

E05

E308

Abnormality in fuel control dials

—

E313

Abnormality in auto grease system (Equivalent to error code [DA80MA])

—

E314

Disconnection in engine stop solenoid relay

—

E315

Short circuit in battery relay output line

—

E316

Abnormality in step-out of governor motor

E05

E317

Disconnection in phases A and B of governor motor

E05

E318

Short circuit in phases A and B of governor motor

a For troubleshooting for a service code having the description of (Equivalent to error code [******]), see the section of the corresponding "Error code of mechanical system". a "E" at the head of each service code indicates the following condition. • With E: The trouble has not been repaired. • Without E: The trouble has been repaired. PC160LC-7

20-175 (3)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

4. Monitoring function [02] With this function, you can monitor the revolution speed, oil pressure, current, voltage, input condition, output condition, etc. in real time by the signals from the sensors, switches, and solenoids installed to various parts of the machine. 1) Selecting and executing function i) Select menu No. [02] in the menu selection mode. ii) Press set switch (5) to execute this function.

2) Selecting and executing monitoring code While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a monitoring code displayed in service meter section (1). • UP switch (7): Increase code No. • DOWN switch (8): Decrease code No. a This function displays monitoring code [001] and its information first. a For the items and code Nos. which you can monitor, see the "Monitoring codes table".

3) Information displayed in display section and service meter section 1 (When numeral code is displayed) If a numeral monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (Value is displayed)

4) Information displayed in display section and service meter section 2 (When 6-bit code is displayed) If a 6-bit monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (6 pieces of information are displayed in bits) a In the 6-bit display mode, only the top and bottom of the 7-segments mark are used to display. "Solid black" indicates the ON state, and "white on black background" indicates the OFF state. a For the No. of each bit, see the "Monitoring codes table" and the drawing attached to it.

20-176 (3)

PC160LC-7

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

TESTING AND ADJUSTING

Monitoring codes table Code

Monitoring item

002

Engine throttle and pump controller model code

Numeral

003

Engine throttle and pump controller model code

Numeral

010

Engine speed

10 rpm

011

F pump discharge pressure

kg/cm2

012

R pump discharge pressure

kg/cm2

013

PC-EPC solenoid output current

10 mA

015

LS-EPC solenoid output current

10 mA

016

2nd throttle speed

10 rpm

017

(Unused)

019

021

022

023

024

Input condition 1 of switch

Input condition 2 of switch

Input condition 3 of switch

Drive condition of solenoid valve 1

Drive condition of solenoid valve 2

PC160LC-7

Unit

Remarks

— a Swing oil pressure switch (ON)

(6 bit)

b Travel oil pressure switch (ON)

(6 bit)

c Boom LOWER oil pressure switch (ON)

(6 bit)

d Boom RAISE oil pressure switch (ON)

(6 bit)

e Arm IN oil pressure switch (ON)

(6 bit)

f Arm OUT oil pressure switch (ON)

(6 bit)

a Bucket CURL oil pressure switch (ON)

(6 bit)

b Bucket DUMP oil pressure switch (ON)

(6 bit)

c (Unused)

(6 bit)

d Service oil pressure switch (ON)

(6 bit)

e Travel differential pressure switch

(6 bit)

f (Unused)

(6 bit)

a (Unused)

(6 bit)

b (Unused)

(6 bit)

c One-touch power maximizing switch (ON)

(6 bit)

d Swing holding brake release switch (RELEASE)

(6 bit)

e Swing lock switch (LOCK)

(6 bit)

f (Unused)

(6 bit)

a (Unused)

(6 bit)

b Travel junction solenoid (ON)

(6 bit)

c Swing holding brake solenoid (ON)

(6 bit)

d Merge-divider solenoid (ON)

(6 bit)

e 2-stage relief solenoid (ON)

(6 bit)

f Travel speed shifting solenoid (ON)

(6 bit)

a (Unused)

(6 bit)

b (Unused)

(6 bit)

c (Unused)

(6 bit)

d ATT return selector relay (ON)

(6 bit)

e (Unused)

(6 bit)

f (Unused)

(6 bit)

20-177 (3)

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

TESTING AND ADJUSTING

Code

027

Monitoring item

Input condition of model selection signal

Unit

a Model selection 1 (Connected to ground)

(6 bit)

b Model selection 2 (Connected to ground)

(6 bit)

c Model selection 3 (Connected to ground)

(6 bit)

d Model selection 4 (Connected to ground)

(6 bit)

e Model selection 5 (Connected to ground)

(6 bit)

f Kerosene mode (Connected to ground)

(6 bit)

030

Fuel control dial input voltage

10 mV

031

Governor potentiometer input voltage

10 mV

032

Controller power source voltage

100 mV

033

Governor motor phase A output current

10 mA

034

Governor motor phase B output current

10 mA

035

Battery relay BR output voltage

100 mV

036

037

Input condition of signal

Output condition of signal

a (Unused)

(6 bit)

b (Unused)

(6 bit)

c (Unused)

(6 bit)

d (Unused)

(6 bit)

e Starting switch signal C (START)

(6 bit)

f (Unused)

(6 bit)

a Battery relay (DRIVEN)

(6 bit)

b (Unused)

(6 bit)

c Engine stop solenoid relay (DRIVEN)

(6 bit)

d (Unused)

(6 bit)

e (Unused)

(6 bit)

f (Unused)

(6 bit)

041

Engine coolant sensor input voltage

10 mV

042

Fuel level sensor input voltage

10 mV

043

Alternator input voltage

100 mV

044

Hydraulic oil temperature sensor input voltage

10 mV

045

046

Input condition of switch 4

Input condition of sensor

20-178 (3)

a Starting switch signal ACC (ON)

(6 bit)

b Starting switch signal C (START)

(6 bit)

c Starting switch signal R1 (HEAT)

(6 bit)

d Lamp switch (ON)

(6 bit)

e Radiator coolant level switch (OPEN)

(6 bit)

f (Unused)

(6 bit)

a Air cleaner clogging switch (OPEN)

(6 bit)

b (Unused)

(6 bit)

c Engine oil pressure switch (OPEN)

(6 bit)

d Engine oil level switch (OPEN)

(6 bit)

e (Unused)

(6 bit)

f Alternator (Normal generation)

(6 bit)

Remarks

PC160LC-7

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

TESTING AND ADJUSTING

Code

049

Monitoring item

Input condition of switch 5

Unit

a Swing lock switch (LOCK)

(6 bit)

b Caution buzzer stop switch (ON)

(6 bit)

c Windows limit switch (ON)

(6 bit)

d Wiper contact W (ON)

(6 bit)

e Wiper contact P (ON)

(6 bit)

f (Unused)

(6 bit)

200

Monitor panel program version

Numeral

201

Engine throttle and pump controller program version

Numeral

Remarks

a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or (d) and (e) light up. Display of numeral code

PC160LC-7

Display of 6-bit code

20-179 (3)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

5. Function of adjusting governor [03] This function is used to adjust the governor lever stroke after the governor actuator, fuel injection pump, or governor spring is removed and installed or replaced, or when the high idling speed is low or engine speed is not stabilized. 1) Selecting and executing function i) Select menu No. [03] in the menu selection mode. ii) Press set switch (5) to execute this function.

2) Condition of governor motor If this function is executed, all the governor control functions are cancelled, and then the operating angle of the governor actuator follows up only the operation signal of the fuel control dial. a While this function is executed, [GOV] is displayed in display section (1) and [gSET] is displayed in service meter section (2).

3) Adjusting governor lever stroke i) Keep the fuel control dial to the MAX position. ii) Loosen nuts (2) and (3) of governor spring (1). a Nut (2) is left-handed. iii) Turn and adjust rod (5) so that governor lever (4) of the fuel injection pump will touch the full stopper. iv) Tighten rod (5) a little less than 1 turn to compress governor spring (1) by 2.0 mm. a At this time, distance (a) between the pins does not change but the spring in the go ver nor spr in g is c ompressed. v) Tighten nuts (2) and (3). 3 Nut: 11.8 – 19.6 Nm {1.2 – 2.0 kgm} vi) Return the fuel control dial to the MIN position, and then turn it again slowly toward the MAX position. At this time, check that governor spring (1) expands by about 2.0 mm after it reaches the full stopper.

20-180 (3)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

6. Function of selecting maintenance period [04] With this function, you can adjust the maintenance period of the engine oil for the function of the engine oil replacement monitor. 1) Selecting and executing function i) Select menu No. [04] in the menu selection mode. ii) Press set switch (5) to execute this function.

2) Selecting maintenance period The current display mode or maintenance period is displayed in service meter section (2). Press set switch (5) to select a maintenance period. a Nothing is displayed in display section (1). a Each time the set switch is pressed, the display mode or maintenance period changes in the following order. Display

Display mode/ Maintenance period

Maintenance function is reset.

125

125-hour interval

250

250-hour interval

500

500-hour interval

Demonstration mode

3) Settling maintenance period The display or maintenance period becomes effective when it is selected. Accordingly, perform the ordinary finishing operation. <Special functions of engine oil replacement monitor> a For the method of displaying the engine oil replacement monitor, method of checking the elapsed time after replacement of engine oil, method of clearing the elapsed time, and method of displaying demonstration mode, see "9. Special functions of engine oil replacement monitor".

PC160LC-7

20-181 (3)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

7. Function of selecting default working mode [05] With this function, you can freely select the working mode which is set automatically when the starting switch is turned ON (When the machine is delivered, mode A is set). 1) Selecting and executing function i) Select menu No. [05] in the menu selection mode. ii) Press set switch (5) to execute this function.

2) Selecting default working mode The currently set working mode is displayed in service meter section (2). Press working mode selector switches (7) and (8) to select a working mode. • UP switch (7): Next mode is displayed. • DOWN switch (8): Previous mode is displayed. a Nothing is displayed in display section (1). a The working mode changes in the following order: A o E o B 3) Settling default working mode Press set switch (5) to settle the selected working mode.

20-182 (3)

PC160LC-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

8. Function of setting installation of attachment [16] With this function, you can set installation of attachment. a When an attachment is installed, if INSTALLED is not set with this function, the Bmode function (automatic single/double operation selecting function) cannot be used. 1) Selecting and executing function i) Select menu No. [16] in the menu selection mode. ii) Press set switch (5) to execute this function. a While this function is executed, [16SET] is displayed in the service meter section (2) and [0] or [1] is displayed in display section (1). 2) Selecting installation of attachment i) The current setting is displayed in service meter section (1). Check the actual installation of attachment and setting. • [0]: Attachment is not installed. • [1]: Attachment is installed. ii) While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select [0] or [1]. • UP switch (7): [1] is selected. • DOWN switch (8): [0] is selected. 3) Settling installation of attachment Press set switch (5) to settle the selected setting of installation of attachment.

PC160LC-7

20-183 (3)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

9. Special functions of engine oil replacement monitor 1) Ordinary display of engine oil replacement monitor If the rest of time before the set engine oil replacement time is 10 hours or shorter, engine oil replacement monitor (10) lights up and display the elapsed time in service meter section (2) for 20 seconds each time the starting switch is turned ON. 2) Checking elapsed time To check the elapsed time while engine oil replacement monitor (10) is OFF, turn the starting switch OFF and press set switch (5) and then turn the starting switch ON and keep holding set switch (5). 3) Clearing elapsed time To clear the elapsed time after replacing the engine oil, hold set switch (5) for 3 seconds while the elapsed time is displayed in service meter section (2). a If the above operation is performed, the elapsed time in the monitor panel is set to 0 hours. 4) Function of demonstration mode If the demonstration mode is selected, you can perform demonstration of the oil maintenance function when teaching the operation to a customer. The functions and display of the demonstration mode are as follows. i) The internally set interval is recognized as 250 hours and the elapsed time is recognized as 240 hours. ii) When the starting switch is turned ON after the demonstration mode is set, the ordinary display is repeated up to 3 times (number of the times of turning the starting switch ON). iii) After the demonstration is finished, resetting of maintenance setting [0] is recognized. a When the demonstration is repeated 3 times, resetting of maintenance setting is recognized. If setting is necessary at this time, see "Function of selecting maintenance period".

20-184 (3)

PC160LC-7

TESTING AND ADJUSTING

PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM

PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM Serial No.: 10001 – 11000 When diagnosing electric circuits related to the monitor panel and governor pump controller, first open up the connector portions in the following manner. 1. Monitor panel 1) Take off cover (1). The cover is fixed with two upper and lower clips. Pull it up for the removal. If a sunlight sensor is equipped for an air conditioner, detach P15 connector at the cover rear side.

2) Remove three securing screws and take monitor panel (2) off the mount. Be careful not to let fall the securing screws inside the console. 3) Insert or connect a T-adaptor for diagnosis with P01, P02 and P70 (multi-monitor only) connectors.

20-186 (4)

2. Governor pump controller The governor pump controller is installed under a cover behind the operator's seat. 1) Remove three caps (3) and then three securing bolts. When removing the caps, use of a thin flat-head screw driver is recommended. 2) Take off cover (4).

3) Insert or connect a T-adapter for diagnosis with C01, C02 and C03 connectors of governor pump controller (5). The connectors are fixed with screws. Loosen the screws and detach the connectors. When putting the connectors back into position, tighten them to the specified torque. Screw: 2.82 Nm {0.288 kgm}

PC160LC-7

TESTING AND ADJUSTING

PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM

Serial No.: 11001 and up a When diagnosing electric circuits related to the monitor panel and governor pump controller, first open up the connector portions in the following manner.

2. Governor pump controller a The governor pump controller is installed under a cover behind the operator's seat. 1) Remove three bolts and then cover (5).

1. Monitor panel 1) Take off cover (1). a The cover is fixed with two upper and lower clips. Pull it up for the removal. a If a sunlight sensor is equipped for an air conditioner, detach P15 connector at the cover rear side.

2) Insert or connect a T-adapter for diagnosis with C01, C02 and C03 connectors of governor pump controller (6). a The connectors are fixed with screws. Loosen the screws and detach the connectors. a When putting the connectors back into position, tighten them to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm} 2) Remove three securing screws and take monitor panel (2) off the mount. a Be careful not to let fall the securing screws inside the console. 3) Insert or connect a T-adaptor for diagnosis with P01, P02 and P70 (multi-monitor only) connectors.

PC160LC-7

20-186-1 (4)

PC160LC-7

20-187 (3)

20-188 (3)

PC160LC-7

20-189 (3)

20-190 (3)

PC160LC-7

20-191 (3)

TROUBLESHOOTING Points to remember when troubleshooting.................................................................................................. 20-202 Sequence of events in troubleshooting ....................................................................................................... 20-203 Points to remember when carrying out maintenance.................................................................................. 20-204 Checks before troubleshooting ................................................................................................................... 20-212 Classification and steps for troubleshooting................................................................................................ 20-213 Connector location chart and electrical circuit diagram by system ............................................................. 20-218 Connection table for connector pin numbers .............................................................................................. 20-236 T-adapter - boxes and T-adapter table........................................................................................................ 20-258 Troubleshooting error code "electrical system" and failure code "mechanical system" are indicated......... 20-301 Troubleshooting of electrical system (E-mode)........................................................................................... 20-401 Troubleshooting of hydraulic and mechanical system (H-mode) ................................................................ 20-501

PC160LC-7

20-201 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers. 4) Check the stroke of the control valve spool.

20-202 (1)

5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure • Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting • Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure • Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

PC160LC-7

TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PC160LC-7

20-203 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil). 1. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. Main failures occurring in wiring harness (1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

(2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

20-204 (1)

PC160LC-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

(3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

(4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. (5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

PC160LC-7

20-205 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and wiring harnesses (1) Disconnecting connectors • Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. Never pull with one hand. •

When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. If the connector is twisted up and down or to the left or right, the housing may break.

•

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

20-206 (1)

PC160LC-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

(2) Connecting connectors • Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. If there is any damage or breakage, replace the connector. •

Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position.

•

Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. If the connector cannot be corrected easily, remove the clamp and adjust the position.

•

If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

(3) Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c

PC160LC-7

20-207 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

(4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. • Disconnect the connector and wipe off the water with a dry cloth. If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. •

Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

•

Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. After completely drying the connector, blow it with contact restorer and reassemble.

20-208 (1)

PC160LC-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box (1) The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. (2) Do not open the cover of the control box unless necessary.

(3) Do not place objects on top of the control box. (4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. (5) During rainy weather, do not leave the control box in a place where it is exposed to rain.

(6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). (7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. If there is any change, there is probably defective contact in that circuit.

PC160LC-7

20-209 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.

4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

20-210 (1)

PC160LC-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7) Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

PC160LC-7

20-211 (1)

CHECKS BEFORE TROUBLESHOOTING

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Hydraulic, Electrical mechanical equipment equipment

Lubricating oil, coolant

Item

Electrics, electrical equipment

Action

1. Check fuel level, type of fuel

—

Add fuel

2. Check for impurities in fuel

—

Clean, drain

3. Check for clogging of fuel filter cartridge

—

Replace

4. Check engine oil level in oil pan, type of oil

—

Add oil

5. Check for clogging of engine oil filter

—

Replace

6. Check coolant level

—

Add water

7. Check for clogging of air cleaner

—

Clean or replace

8. Check hydraulic oil level, type of oil

—

Add oil

9. Check for clogging of hydraulic oil strainer

—

Clean, drain

10. Check for clogging of hydraulic oil filter

—

Replace

11. Check swing machinery oil level, type of oil

—

Add oil

12. Check final drive oil level, type of oil

—

Add oil

1. Check for looseness, corrosion of battery terminal, wiring

—

Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring

—

Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring

—

Tighten or replace

1. Check for abnormal noise, smell

—

Repair

2. Check for oil leakage

—

Repair

3. Carry out air bleeding

—

Bleed air

20 – 30V

Replace

1. Check battery voltage (engine stopped) 2. Check battery electrolyte level

—

Add or replace

3. Check for discolored, burnt, exposed wiring

—

Replace

4. Check for missing wiring clamps, hanging wiring

—

Repair

5. Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals)

—

Disconnect connector and dry

6. Check for blown, corroded fuses

7. Check alternator voltage (engine running at 1/2 throttle or above)

8. Check operating sound of battery relay (when switch is turned ON/OFF)

20-212 (1)

Judgement value

—

Replace

After running for several minutes : 27.5 – 29.5V

Replace

—

Replace

PC160LC-7

TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING Classification of troubleshooting Mode

Content

Code display

Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are displayed.

E mode

Troubleshooting of electrical system

H mode

Troubleshooting of hydraulic and mechanical systems

S mode

Troubleshooting of engine assembly

Steps for troubleshooting If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed to the explanations for diagnosis. 1. Troubleshooting steps when calling User Code display in the monitor panel In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Service Code for the electrical system, carry out the troubleshooting along the corresponding code display. 2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is recorded in the failure history: If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system Failure Code, using the failure history function of the monitor panel. If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the display again to check if the same abnormality still persists. Failure Code in the mechanical system cannot be deleted. 3. Troubleshooting steps without User Code display and no failure history is available If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting related to the phenomenon in question.

PC160LC-7

20-213 (4)

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

TROUBLESHOOTING

Failure-looking Phenomenon and Troubleshooting No. Troubleshooting No.

Failure-looking phenomenon

Code display

E mode

H mode

S mode

Action to be taken concerning Error Code, User Code and Failure Code 1

Display User Code in monitor panel

Display Error Code in electrical system after checking failure history

Display Failure Code in mechanical system after checking failure history

According to displayed code

Engine-related failure 4

Starting performance is poor (Starting always takes time)

S-1

Engine does not turn

Engine turns but no exhaust smoke comes out (Fuel is not being injected)

S-2 (2)

Exhaust smoke comes out but engine does not start (Fuel is being injected)

S-2 (3)

Engine does not start

Engine does not start easily or at all low temperature

8 9

E-1 (1)

S-2 (1)

E-1 (2)

Engine does not pick-up smoothly (Follow-up is poor)

S-3

10 Engine stops while in operation

E-2

S-4

11 Engine rotations unstably hunting

E-3

S-5

12 Engine lacks output (or lacks power)

S-6

13 Exhaust gas is black

S-7

14 Oil consumption is excessive (or exhaust gas is blue)

S-8

15 Oil becomes contaminated quickly

S-9

16 Fuel consumption is excessive

S-10

17 Oil is in cooling water, or water spurts back, or water level goes down

S-11

18 Oil level rises (Water, fuel in oil)

S-13

19 Abnormal noise is made

S-15

20 Vibrations is excessive

S-16

21 Engine does not stop

E-4

22 Auto-decelerator does not work

E-5

23 Auto engine warm-up device does not work

E-6

24 Preheater does not operate

E-7

H-5

Failure related to work equipment, swing and travel 25 Speed or power of all work equipment, swing, and travel are low

H-1

26 Engine speed sharply drops or engine stalls

H-2

27 No work equipment, travel and swing move

E-8

H-3

28 Abnormal noise is heard from around hydraulic pump

H-4

29 Fine control mode does not function

H-6

20-214 (4)

S-4

PC160LC-7

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

TROUBLESHOOTING

Troubleshooting No.

Failure-looking phenomenon

Code display

E mode

H mode

30 Speed or power of boom is low

E-22, 23

H-7

31 Speed or power of arm is low

E-24, 25

H-8

32 Speed or power of bucket is low

E-26, 27

H-9

S mode

Work equipment-related failure

33 Work equipment does not move in its single operation

H-10

34 Hydraulic drift of work equipment is large

H-11

35 Time lag of work equipment is large

H-12

36 One-touch power max system does not operate

E-9

H-13

37 Attachment circuit does not change

E-10

H-28

38 Flow rate in attachment circuit cannot be adjusted

H-29

Compound operation-related failure 39 Work equipment loaded more is slower during compound operation

H-14

40 Boom RAISE speed is low in compound operation of swing + boom RAISE

H-15

Travel speed lowers largely during compound operation of work equipment/swing + travel

H-16

Travel-related failure 42 Machine deviates during travel

H-17

43 Travel speed is low 44 Machine cannot be steered easily or steering power is low 45 Travel speed does not change or it is kept low or high

E-29

H-18

E-29, 30

H-19

E-29

H-20

46 Track does not move (only either side)

H-21 Swing-related failure

47 Machine does not swing

H-22

48 Swing acceleration or swing speed is low

E-28

H-23

49 Excessive overrun when stopping swing

H-24

50 When upper structure stops swinging, it makes large shock

H-25

51 When upper structure stops swinging, it makes large sound

H-26

52 Hydraulic drift of swing is large

H-27

Monitor panel-related failure (Operator's Menu: ordinary display) 53 No display in monitor panel at all

E-11

54 Monitor panel does not display partially

E-12

55 Contents of monitor panel are different from mounted model

E-13

56 Abnormally lowered radiator water level

B@BCZK

57 Abnormally lowered engine oil pressure

B@BAZK

PC160LC-7

20-215 (4)

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

TROUBLESHOOTING

Troubleshooting No.

Failure-looking phenomenon

Code display

E mode

H mode

S mode

58 In startup inspection, maintenance hour monitor lamp lights up red

Refer to Operation and Maintenance Manual

59 Abnormally lowered charging voltage

AB00KE

60 Fuel level monitor lights up in red while engine is running

E-14

61 Air cleaner clogging

AA10NX

62 Engine cooling water overheating

B@BCNS

63 Hydraulic oil overheating

B@HANS

64 Engine cooling water temperature gauge does not indicate correctly

E-15

65 Hydraulic oil temperature gauge does not display correctly

E-16

66 Fuel gauge does not display correctly

E-17

67 Swing lock monitor does not display correctly

E-18

68 When monitor switch is operated, nothing is displayed

E-19

69 Windshield wiper and window washer does not work

E-20

70 Alarming buzzer cannot be cancelled

E-21

Monitor panel-related failure (Service Menu: Special Function Display) 71 "Boom RAISE" is not correctly displayed in monitor function

E-22

72 "Boom LOWER" is not correctly displayed in monitor function

E-23

73 "Arm IN" is not correctly displayed in monitor function

E-24

74 "Arm OUT" is not correctly displayed in monitor function

E-25

75 "Bucket CURL" is not correctly displayed in monitor function

E-26

76 "Bucket DUMP" is not correctly displayed in monitor function

E-27

77 "SWING" is not correctly displayed in monitor function

E-28

78 "TRAVEL" is not correctly displayed in monitor function

E-29

79 "Travel differential pressure" is not correctly displayed in monitor function

E-30

80 "Service" is not correctly displayed in monitor function

E-31

Other failure 81 Air Conditioner does not work

E-32

82 Travel alarm does not sound or does not stop sounding

E-33

20-216 (4)

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM Connector table Serial No.: 10001 – 11000 Connector No.

Type

No. of pin

A01

A02

A03

Address Name of device

Stereogram

M circuit

G circuit

P circuit

Intermediate connector

T-1

H-6

I-5

I-8

Intermediate connector

T-1

H-6

I-4

H-6

SWP

Intermediate connector

N-1

H-6

I-2

I-8

A04

SWP

Intermediate connector

O-1

A05

SWP

Intermediate connector

T-1

H-5

I-7

A06

SWP

Intermediate connector

N-1

H-5

I-6

I-5

A07

SWP

Intermediate connector

S-1

H-4

I-5

I-4

A08

SWP

Intermediate connector

N-2

A09

SWP

Intermediate connector

N-2

A10

Terminal

Revolving frame grounding

H-1

A11

Terminal

Revolving frame grounding

H-1

I-1

A12

Terminal

Revolving frame grounding

H-1

I-1

A13

Terminal

Revolving frame grounding

H-1

A14

Terminal

Revolving frame grounding

A15

Terminal

A16

Terminal

A20

I-7

I-4 I-5

J-4

I-1

I-4

J-8

K-1

I-1

J-4

Revolving frame grounding

H-2

I-1

J-4

Revolving frame grounding

I-2

I-1

J-1

Terminal

Battery relay (E terminal)

L-2

I-2

J-4

A21

Terminal

Battery relay (BR terminal)

L-2

I-1

J-4

A22

Terminal

Battery relay (M terminal)

J-2

K-4

A23

Terminal

Battery relay (B terminal)

J-2

J-1

K-4

A25

Terminal

Heater relay (coil)

L-1

A26

Terminal

Heater relay (contact)

K-1

K-2

L-6

A27

Starter safety relay (S and R terminals)

K-3

J-2

K-3

A29

Terminal

Starter safety relay (C terminal)

J-1

A30

YAZAKI

Air conditioner outside air temperature sensor

L-6

A31

Air cleaner clogging sensor

L-4

K-4

A33

Radiator water level sensor

L-6

K-5

A34

Fusible link (65A)

L-5

K-6

K-5

A35

Fusible link (30A)

K-3

K-6

K-4

A40

Y090

Alarm horn (low tone)

G-1

A41

Y090

Alarm horn (high tone)

G-1

A42

Intermediate connector

G-9

A43

Travel alarm

G-9

A44

Front right lamp

D-9

K-7

A50

KES0

Window washer monitor (tank)

E-9

K-5

20-218 (4)

K-6

L-3

J-8 K-4

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Address

Connector No.

Type

No. of pin

A51

F pump hydraulic oil pressure sensor

I-9

A52

R pump hydraulic oil pressure sensor

L-5

K-5

A60

Fuel level sensor

F-9

K-4

Name of device

Stereogram

M circuit

G circuit

P circuit K-5 K-5

A61

Hydraulic oil temperature sensor

H-9

K-5

C01

DRC

Governor pump controller

V-9

A-3

A-8

C02

DRC

Governor pump controller

W-9

A-3

A-7

C03

DRC

Governor pump controller

W-9

A-2

A-4

C09

Model selection connector

W-6

D01

SWP

Assembled type diode

W-7

A-9

D-1

D02

SWP

Assembled type diode

W-7

A-8

D-1

D03

SWP

Assembled type diode

P-1

D04

SWP

Assembled type diode

Q-1

A-8

K-9

L-2

L-8

K-6

E01

Terminal

Suction type air heater (electrical intake air heater)

E02

Terminal

Engine oil pressure switch

C-9

H-1

E03

Engine oil level switch

L-7

K-5

E04

Engine rotation sensor

L-8

K-8

E05

Engine cooling water temperature sensor (for high temperature)

J-9

K-4

E06

Fuel dial

O-8

E06

Air conditioner compressor electromagnetic switch

K-9

E08

Intermediate connector

L-6

E10

Governor potentiometer

J-9

E11

Governor motor

L-9

E12

–

Alternator

L-7

E12

Engine cooling water temperature sensor (for low temperature)

L-7

G-1

I-1 L-6

K-8

F-1 J-3

J-5 K-2 K-2

K-3

K-5 K-3

F02

YAZAKI

Revolving warning lamp

AA-9

FB1

–

Fuse box

W-5

I-9

H08

Intermediate connector

W-4

K-8

H09

Intermediate connector

W-5

J-8

H10

Intermediate connector

T-9

D-6

I-8

H11

Intermediate connector

S-9

D-5

I-8

H12

Intermediate connector

S-9

D-5

I-7

H15

S090

Intermediate connector

N-7

C-2

E-2

C-2

J01

Junction connector (black)

W-8

C-9

D-9

C-9

J02

Junction connector (black)

W-8

D-9

J03

Junction connector (green)

W-8

D-9

E-9

D-9

J04

Junction connector (green)

W-7

E-9

J05

Junction connector (pink)

W-6

E-9

J06

Junction connector (orange)

W-6

F-9

J07

Junction connector (orange)

U-9

F-9

J08

Junction connector (pink)

U-9

PC160LC-7

B-2

F-9

B-9

H-9 F-9

H-9 I-9

20-219 (4)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Address Connector No.

Type

No. of pin

K19

Pump resistor (for driving emergency pump)

U-2

K30

CAN terminating resistor

K31

M07

M09

Name of device

M circuit

G circuit

T-9

A-2

C-1

CAN terminating resistor

N-4

A-4

K-7

Lamp switch

P-8

C-1

Working lamp (boom)

E-9

K-7

M13

KES0

Speaker (right)

AC-8

M19

YAZAKI

Cigarette lighter

N-3

M21

Radio

U-2

M22

Y090

Horn switch

N-7

M23

Y090

One-touch power max. switch

T-1

M26

Air conditioner unit

W-5

M27

SWP

Air conditioner unit

W-5

M28

SWP

Air conditioner unit

W-4

M29

040

Air control panel

W-3

M30

040

Air control panel

W-3

M31

Option power source (2)

U-2

M32

Option power source (1)

S-9

M33

Option power source (3)

–

M33

SWP

Air conditioner unit

W-3

M34

YAZAKI

Air conditioner inside air sensor

W-8

M40

YAZAKI

Working lamp

Z-8

K-8

M41

YAZAKI

Working lamp (additional)

Y-7

K-8

M42

Intermediate connector

H-9

J-7

M43

Working lamp (rear)

I-9

K-7

M45

Intermediate connector

U-2

M46

S090

RS232C relaying connector

U-9

M71

Room lamp

Z-8

M72

DC/AC converter

U-2

M73

KES0

Speaker (left)

AD-8

M79

12V electrical equipment socket

V-9

P01

070

Monitor panel

N-6

A-7

P02

040

Monitor panel

N-5

A-6

P03

Alarm buzzer stop switch

P-9

D-1

P05

Revolving warning lamp switch

W-3

P15

Y050

Air conditioner sun light sensor

N-6

P70

040

Monitor panel

N-4

20-220 (4)

Stereogram

P circuit

A-9

B-9

A-5

K-8

A-9

K-8

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Address Connector No.

Type

No. of pin

R10

Lamp relay

O-8

E-1

R11

Engine starting motor cutting relay (PPC lock)

P-8

E-1

R13

Engine starting motor cutting relay (personal code)

Q-9

F-1

R20

Attachment return switching relay

W-6

R21

Additional relay connector

W-7

R22

Cold starting solenoid relay

W-5

S01

Bucket CURL oil pressure switch

J-3

K-3

S02

Boom LOWER oil pressure switch

K-3

S03

Swing oil pressure switch, left

K-4

K-2

S04

Arm IN oil pressure switch

K-3

S05

Bucket DUMP oil pressure switch

L-5

K-2

S06

Boom RAISE oil pressure switch

K-4

K-3

S07

Swing oil pressure switch, right

K-3

K-2

S08

Arm OUT oil pressure switch

K-4

K-3

S09

Service oil pressure switch (intermediate connector)

J-3

K-2

S10

Service oil pressure switch, front

J-3

K-2

S11

Service oil pressure switch, rear

J-3

K-1

S14

Safety lever lock switch

S-1

S21

Terminal

Pump emergency driving switch

R-9

E-2

S22

Terminal

Swing holding brake releasing switch

R-9

E-2

S25

S090

Intermediate connector

Q-9

E-3

S30

Travel oil pressure switch

O-1

A-1

S31

Travel steering oil pressure switch

P-1

A-1

Terminal

Engine starting motor (C terminal)

I-9

SSW

Terminal

Engine starting switch

N-7

T05

Terminal

Floor frame grounding

W-3

T06

Terminal

Radio body grounding

–

T06A

Intermediate connector

T-2

T11

Terminal

Operator's cab grounding

AD-3

T13

Intermediate connector

L-6

V01

PPC oil pressure lock solenoid valve

I-2

K-1

V02

Travel junction solenoid valve

I-2

K-6

V03

Merge/divide valve solenoid valve

I-2

K-7

V04

Travel speed solenoid valve

J-3

K-5

V05

Swing holding brake solenoid valve

I-2

K-6

V06

2-stage relief solenoid valve

I-2

K-6

Cold starting solenoid

L-8

V07

PC160LC-7

Name of device

StereoM gram circuit

G circuit

P circuit

B-9 C-9 F-9

K-8

E-8

J-8

J-3

J-6

K-7

20-221 (4)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Address Connector No.

Type

No. of pin

V12

Attachment return switching solenoid valve

G-9

K-4

V21

PC-EPC solenoid valve

H-9

K-7

V22

EPC solenoid connector (spare)

V30

Attachment oil flow rate adjusting EPC solenoid valve

P-1

W03

Rear limit switch (window)

AB-9

W04

Windshield wiper motor

Y-4

B-9

X05

Swing lock switch

Q-9

D-2

20-222 (4)

Name of device

Stereogram

M circuit

G circuit

P circuit

K-7 A-1

C-1

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Connector No.

Detailed information

D or DT

Japanese and German makes DT type connector (08192-XXXXX)

Product of Yazaki Corporation L type connector (08056-2XXXX)

Product of Sumitomo Wiring Systems 090 type splice

Product of Yazaki M type connector (08056-0XXXX)

Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector

Product of Yazaki S type connector (08056-1XXXX)

Product of Yazaki X type connector (08055-0XXXX)

Product of Yazaki PA type connector

SWP

Product of Yazaki SWP type connector (08055-1XXXX)

DRC

Japanese and German makes DRC type connector

040

Product of Japan AMP 040 type connector

070

Product of Japan AMP 070 type connector

Y050

Product of Yazaki 050 type connector

S090

Product of Sumitomo 090 type connector

Y090

Product of Yazaki 090 type connector

YAZAKI

Yazaki-made connector

KES0

KESO type connector (08027-0XXXX)

Terminal

Round pin type single terminal connector

Terminal

Round terminal

*An affiliated company of Mitsubishi Cable Industries, Ltd.

PC160LC-7

20-223 (1)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Connector table Serial No.: 11001 and up Connector No.

Type

No. of pin

A01

A02

A03

Address Name of device

Stereogram

M circuit

G circuit

P circuit

Intermediate connector

M-8

H-6

I-5

I-8

Intermediate connector

M-9

H-6

I-4

H-6

SWP

Intermediate connector

M-9

H-6

I-2

I-8

A04

SWP

Intermediate connector

O-8

L-7

A05

SWP

Intermediate connector

M-8

H-5

I-7

A06

SWP

Intermediate connector

O-9

H-5

I-6

I-5

A07

SWP

Intermediate connector

M-8

H-4

I-5

I-4

A08

SWP

Intermediate connector

O-9

A09

SWP

Intermediate connector

O-9

I-4

A10

Terminal

Revolving frame grounding

H-1

A11

Terminal

Revolving frame grounding

H-1

I-1

A12

Terminal

Revolving frame grounding

H-1

I-1

A13

Terminal

Revolving frame grounding

H-1

A14

Terminal

Revolving frame grounding

A15

Terminal

A16

Terminal

A20

I-7

I-4 I-5

J-4

I-1

I-4

J-8

K-1

I-1

J-4

Revolving frame grounding

H-2

I-1

J-4

Revolving frame grounding

I-2

I-1

J-1

Terminal

Battery relay (E terminal)

L-2

I-2

J-4

A21

Terminal

Battery relay (BR terminal)

L-2

I-1

J-4

A22

Terminal

Battery relay (M terminal)

J-2

K-4

A23

Terminal

Battery relay (B terminal)

J-2

J-1

K-4

A25

Terminal

Heater relay (coil)

L-1

A26

Terminal

Heater relay (contact)

K-1

K-2

L-6

A27

Starter safety relay (S and R terminals)

K-3

J-2

K-3

A29

Terminal

Starter safety relay (C terminal)

J-1

K-2

L-3

A31

Air cleaner clogging sensor

L-4

K-4

A33

Radiator water level sensor

L-6

K-5

A34

Fusible link (65A)

L-6

K-6

K-5

A35

Fusible link (30A)

K-3

K-6

K-4

A40

Y090

Alarm horn (low tone)

G-1

A41

Y090

Alarm horn (high tone)

G-1

A42

Intermediate connector

G-9

A43

Travel alarm

G-9

A44

Front right lamp

D-9

K-7

A50

KES0

Window washer monitor (tank)

E-9

K-5

A51

F pump hydraulic oil pressure sensor

I-9

A52

R pump hydraulic oil pressure sensor

L-5

20-223-1 (4)

K-6

J-7 K-4

K-5

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Connector No.

Type

No. of pin

A60

A61

C01

Address Name of device

Stereogram

M circuit

Fuel level sensor

F-9

K-4

Hydraulic oil temperature sensor

H-9

K-5

DRC

Governor pump controller

U-9

C02

DRC

Governor pump controller

C03

DRC

Governor pump controller

C09

Model selection connector

U-9

D01

SWP

Assembled type diode

W-9

A-9

D-1

D02

SWP

Assembled type diode

W-7

A-8

D-1

K-9

L-2

L-6

L-8

K-6

E01

Terminal

Suction type air heater (electrical intake air heater)

E02

Terminal

Engine oil pressure switch

G circuit

P circuit

A-3

A-8

V-9

A-3

A-7

W-9

A-2

A-4

C-9

E03

Engine oil level switch

L-7

K-6

E04

Engine rotation sensor

L-8

K-8

E05

Engine cooling water temperature sensor (for high temperature)

J-9

K-4

E06

Fuel dial

O-8

E06

Air conditioner compressor electromagnetic switch

K-9

E08

Intermediate connector

L-6

E10

Governor potentiometer

J-9

G-1

K-8

F-1 J-3

J-5 K-2

E11

Governor motor

L-9

K-2

E12

–

Alternator

L-7

K-5

E12

Engine cooling water temperature sensor (for low temperature)

L-7

K-3

F02

YAZAKI

Revolving warning lamp

AA-9

FB1

–

Fuse box

U-2

H-9

H08

Intermediate connector

W-6

K-8

H09

Intermediate connector

W-6

J-8

H10

Intermediate connector

S-9

D-6

I-8

H11

Intermediate connector

S-9

D-6

I-8

H12

Intermediate connector

S-9

D-5

I-7

H15

S090

Intermediate connector

N-7

C-2

E-2

C-2

J01

Junction connector (black)

T-1

C-9

D-9

C-9

J02

Junction connector (black)

V-2

D-9

J03

Junction connector (green)

V-2

D-9

E-9

D-9

J04

Junction connector (green)

V-3

E-9

J05

Junction connector (pink)

V-3

E-9

J06

Junction connector (orange)

V-3

F-9

J07

Junction connector (orange)

W-3

F-9

H-9

K19

Pump resistor (for driving emergency pump)

W-3

K30

CAN terminating resistor

S-9

A-2

C-1

K31

CAN terminating resistor

N-4

A-4

K-7

PC160LC-7

B-2

F-9

B-9

20-223-2 (4)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Address Connector No.

Type

No. of pin

M07

M09

M13

Name of device

Stereogram

M circuit

Lamp switch

P-8

C-1

Working lamp (boom)

E-9

K-7

KES0

Speaker (right)

AC-8

M19

YAZAKI

Cigarette lighter

N-3

M21

Radio

T-1

M22

Y090

Horn switch

N-7

M23

Y090

One-touch power max. switch

S-1

M26

Air conditioner unit

W-3

M27

Y090

Air conditioner unit

W-5

M29

040

Air control panel

T-2

M30

040

Air control panel

U-2

M31

Option power source (2)

W-6

M32

Option power source (1)

W-5

M33

Option power source (3)

W-7

M33

SUMITOMO

Air conditioner unit

W-5

M40

YAZAKI

Working lamp

Z-8

K-8

M41

YAZAKI

Working lamp (additional)

Y-7

K-8

M42

Intermediate connector

H-9

J-7

M43

Working lamp (rear)

I-9

K-7

M45

Intermediate connector

W-7

M46

S090

RS232C relaying connector

V-9

M71

Room lamp

Z-8

M72

DC/AC converter

W-7

M73

KES0

Speaker (left)

AD-8

M79

12V electrical equipment socket

W-8

P01

070

Monitor panel

N-6

A-7

P02

040

Monitor panel

N-5

A-6

P03

Alarm buzzer stop switch

P-9

D-1

P05

Revolving warning lamp switch

U-2

P15

Y050

Air conditioner sun light sensor

N-6

P17

090

Air conditioner high/low pressure switch

P70

040

Monitor panel

N-4

A-5

R10

Lamp relay

O-8

E-1

R11

Engine starting motor cutting relay (PPC lock)

P-8

E-1

R13

Engine starting motor cutting relay (personal code)

Q-9

F-1

R20

Attachment return switching relay

U-9

R22

Cold starting solenoid relay

T-9

R30

SUMITOMO

Air conditioner blower relay

W-4

R31

AMP

Air conditioner compressor relay

W-3

20-223-3 (4)

G circuit

P circuit

E-3

A-9

B-9

K-8

A-9

K-8 B-9 C-9 F-9

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Address Connector No.

Type

No. of pin

S01

Bucket CURL oil pressure switch

J-3

K-3

S02

Boom LOWER oil pressure switch

K-3

S03

Swing oil pressure switch, left

K-4

K-2

S04

Arm IN oil pressure switch

K-3

S05

Bucket DUMP oil pressure switch

L-5

K-2

S06

Boom RAISE oil pressure switch

K-4

K-3

S07

Swing oil pressure switch, right

K-3

K-2

S08

Arm OUT oil pressure switch

K-4

K-3

S09

Service oil pressure switch (intermediate connector)

J-3

K-2

S10

Service oil pressure switch, front

J-3

K-2

S11

Service oil pressure switch, rear

J-3

K-1

S14

Safety lever lock switch

S-1

S21

Terminal

Pump emergency driving switch

R-9

E-2

S22

Terminal

Swing holding brake releasing switch

R-9

F-2

S25

S090

Intermediate connector

Q-9

E-3

S30

Travel oil pressure switch

O-1

A-1

S31

Travel steering oil pressure switch

P-1

A-1

Terminal

Engine starting motor (C terminal)

I-9

SSW

Terminal

Engine starting switch

N-7

T05

Terminal

Floor frame grounding

U-2

T06

Terminal

Radio body grounding

T-1

T06A

Intermediate connector

T-1

T11

Terminal

Operator's cab grounding

AD-3

T13

Intermediate connector

L-6

V01

PPC oil pressure lock solenoid valve

I-2

V02

Travel junction solenoid valve

I-2

K-6

V03

Merge/divide valve solenoid valve

I-2

K-7

V04

Travel speed solenoid valve

J-3

K-5

V05

Swing holding brake solenoid valve

I-2

K-6

V06

2-stage relief solenoid valve

I-2

K-6

Cold starting solenoid

L-8

V07

Name of device

StereoM gram circuit

G circuit

K-9

P circuit

F-8

J-8

J-3

J-6

K-7

V12

Attachment return switching solenoid valve

G-9

K-4

V21

PC-EPC solenoid valve

H-9

K-7

V22

EPC solenoid connector (spare)

V30

Attachment oil flow rate adjusting EPC solenoid valve

P-1

W03

Rear limit switch (window)

AB-9

W04

Windshield wiper motor

Y-3

B-9

X05

Swing lock switch

Q-9

D-1

PC160LC-7

K-7 A-1

C-1

20-223-4 (4)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

TROUBLESHOOTING

Connector No.

Detailed information

D or DT

Japanese and German makes DT type connector (08192-XXXXX)

Product of Yazaki Corporation L type connector (08056-2XXXX)

Product of Sumitomo Wiring Systems 090 type splice

Product of Yazaki M type connector (08056-0XXXX)

Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector

Product of Yazaki S type connector (08056-1XXXX)

Product of Yazaki X type connector (08055-0XXXX)

Product of Yazaki PA type connector

SWP

Product of Yazaki SWP type connector (08055-1XXXX)

DRC

Japanese and German makes DRC type connector

040

Product of Japan AMP 040 type connector

070

Product of Japan AMP 070 type connector

AMP

Japan AMP-mode connector

Y050

Product of Yazaki 050 type connector

S090

Product of Sumitomo 090 type connector

Y090

Product of Yazaki 090 type connector

Y090

Product of Yazaki Y090

YAZAKI

Yazaki-made connector

KES0

KESO type connector (08027-0XXXX)

Terminal

Round pin type single terminal connector

Terminal

Round terminal

type connector

*An affiliated company of Mitsubishi Cable Industries, Ltd.

20-223-5 (4)

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

CONNECTOR LOCATION STEREOGRAM Serial No.: 10001 – 11000

20-224 (4)

PC160LC-7

TROUBLESHOOTING

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

20-225 (1)

TROUBLESHOOTING

20-226 (1)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

PC160LC-7

TROUBLESHOOTING

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

20-227 (4)

TROUBLESHOOTING

20-228 (1)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

Serial No.: 11001 and up

20-229-1 (4)

PC160LC-7

TROUBLESHOOTING

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

20-229-2 (4)

TROUBLESHOOTING

20-229-3 (4)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

PC160LC-7

TROUBLESHOOTING

PC160LC-7

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

20-229-4 (4)

TROUBLESHOOTING

20-229-5 (4)

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

Monitor Panel System Circuit Diagram (M Circuit) Serial No.: 10001 – 11000

20-230 (4)

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

This circuit diagram is made of the monitor panel system, engine preheating and starting system, and night lighting system extracted from the general electric circuit diagram.

PC160LC-7

20-231 (1)

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

Serial No.: 11001 and up

20-231-1 (4)

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

This circuit diagram has been compiled by extracting the monitor panel system and engine starting system from the overall electrical circuit diagram.

PC160LC-7

20-231-2 (4)

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controlle Serial No.: 10001 – 11000

20-232 (4)

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

This circuit diagram has been compiled by extracting the governor•pump controller system (power source, governor control, model selection and communication) from the overall electrical circuit diagram.

PC160LC-7

20-233 (1)

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

Serial No.: 11001 and up

20-233-1 (4)

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

PC160LC-7

20-233-2 (4)

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller Serial No.: 10001 – 11000

20-234 (4)

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

This circuit diagram has been compiled by extracting the governor•pump controller system (pump control), PPC lock system and backup alarm system from the overall electrical circuit diagram.

PC160LC-7

20-235 (1)

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

Serial No.: 11001 and up

20-235-1 (4)

PC160LC-7

TROUBLESHOOTING

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM

This circuit diagram has been compiled by extracting the governor•pump controller system (pump control), PPC lock system and backup alarm system from the overall electrical circuit diagram.

PC160LC-7

20-235-2 (4)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.

X type connector

No.of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

Part No.: 08055-00181

Part No.: 08055-00191

799-601-7010

799-601-7020

Part No.: 08055-00282

Part No.: 08055-00292

799-601-7030

Part No.: 08055-00381

Part No.: 08055-00391

799-601-7040

Part No.: 08055-00481

Part No.: 08055-00491

—

Terminal part No.: 79A-222-3370 • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20

Terminal part No.: 79A-222-3390 • Electric wire size: 0.85 • Grommet: Black • Q’ty : 20

—

Terminal part No.: 79A-222-3380 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20

Terminal part No.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20

—

20-236 (1)

PC160LC-7

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector Male (female housing)

Female (male housing)

799-601-7050

Part No.: 08055-10681

Part No.: 08055-10691

799-601-7060

Part No.: 08055-10881

Part No.: 08055-10891

799-601-7310

Part No.: 08055-11281

Part No.: 08055-11291

799-601-7070

Part No.: 08055-11481

PC160LC-7

T-adapter Part No.

Part No.: 08055-11491

20-237 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No. of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

799-601-7320

Part No.: 08055-11681

Part No.: 08055-11691

—

Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20

—

Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20

—

20-238 (1)

PC160LC-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector

No.of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

Part No.: 08056-00171

Part No.: 08056-00181

799-601-7080

799-601-7090

Part No.: 08056-00271

Part No.: 08056-00281

799-601-7110

Part No.: 08056-00371

Part No.: 08056-00381

799-601-7120

Part No.: 08056-00471

Part No.: 08056-00481

799-601-7130

Part No.: 08056-00671

Part No.: 08056-00681

799-601-7390

Part No.: 08056-00871

PC160LC-7

Part No.: 08056-00881

20-239 (1)

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector Male (female housing)

Female (male housing)

799-601-7140

Part No.: 08056-10871

Part No.: 08056-10881

10 (White)

799-601-7150

Part No.: 08056-11071

Part No.: 08056-11081

12 (White)

799-601-7350

Part No.: 08056-11271

Part No.: 08056-11281

16 (White)

799-601-7330

Part No.: 08056-11671

20-240 (1)

T-adapter Part No.

Part No.: 08056-11681

PC160LC-7

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

No.of pins

S type connector Male (female housing)

Female (male housing)

10 (Blue)

—

12 (Blue)

799-601-7160

Part No.: 08056-11272

Part No.: 08056-11282

16 (Blue)

799-601-7170

Part No.: 08056-11672

PC160LC-7

T-adapter Part No.

Part No.: 08056-11682

20-241 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

Body part No.: 79A-222-2640 (Q’ty: 5)

Body part No.: 79A-222-2630 (Q’ty: 5)

—

Body part No.: 79A-222-2680 (Q’ty: 5)

Body part No.: 79A-222-2670 (Q’ty: 5)

—

799-601-2710

Body part No.: 79A-222-2620 (Q’ty: 5)

Body part No.: 79A-222-2610 (Q’ty: 5)

799-601-2950

Body part No.: 79A-222-2660 (Q’ty: 5)

Body part No.: 79A-222-2650 (Q’ty: 5)

799-601-2720

Body part No.: 79A-222-2710 (Q’ty: 2)

20-242 (1)

Body part No.: 79A-222-2690 (Q’ty: 2)

PC160LC-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

799-601-2730

Body part No.: 79A-222-2730 (Q’ty: 2)

Body part No.: 79A-222-2720 (Q’ty: 2)

799-601-2740

Body part No.: 79A-222-2750 (Q’ty: 2)

Body part No.: 79A-222-2740 (Q’ty: 2)

Terminal part No.: 79A-222-2770 (Q’ty: 50)

Terminal part No.: 79A-222-2760 (Q’ty: 50)

PC160LC-7

—

20-243 (1)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

No.of pins

AMP040 type connector Male (female housing)

Female (male housing)

T-adapter Part No.

799-601-7180

—

Housing part No.: 79A-222-3430 (Q’ty: 5)

799-601-7190

—

Housing part No.: 79A-222-3440 (Q’ty: 5)

799-601-7210

—

Housing part No.: 79A-222-3450 (Q’ty: 5)

799-601-7220

—

Housing part No.: 79A-222-3460 (Q’ty: 5)

! Terminal part No.: 79A-222-3470 (No relation with number of pins)

20-244 (1)

PC160LC-7

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

No.of pins

AMP070 type connector Male (female housing)

Female (male housing)

799-601-7510

—

Part No.: 08195-10210

799-601-7520

—

Part No.: 08195-12210

799-601-7530

—

Part No.: 08195-14210

799-601-7540

—

Part No.: 08195-18210

799-601-7550

—

PC160LC-7

T-adapter Part No.

Part No.: 08195-20210

20-245 (1)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

No.of pins

L type connector Male (female housing)

Female (male housing)

—

No.of pins

—

Connector for PA Male (female housing)

Female (male housing)

—

Bendix MS connector Male (female housing)

Female (male housing)

(1)

T-adapter Part No.

799-601-3460

—

20-246

T-adapter Part No.

—

No.of pins

T-adapter Part No.

—

PC160LC-7

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

KES 1 (Automobile) connector

No.of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

—

Part No.: 08027-10210 (Natural color) 08027-10220 (Black)

Part No.: 08027-10260 (Natural color) 08027-10270 (Black)

—

Part No.:08027-10310

Part No.:08027-10360

—

Part No.: 08027-10410 (Natural color) 08027-10420 (Black)

Part No.: 08027-10460 (Natural color) 08027-10470 (Black)

—

Part No.: 08027-10610 (Natural color) 08027-10620 (Black)

PC160LC-7

Part No.: 08027-10660 (Natural color) 08027-10670 (Black)

20-247 (1)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

KES 1 (Automobile) connector

No.of pins

Male (female housing)

Female (male housing)

—

Part No.: 08027-10810 (Natural color) 08027-10820 (Black)

No.of pins

Part No.: 08027-10860 (Natural color) 08027-10870 (Black)

Connector for relay (Socket type) Male (female housing)

Female (male housing)

—

799-601-7370

—

20-248

T-adapter Part No.

799-601-7360

—

(1)

T-adapter Part No.

—

PC160LC-7

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

No.of pins

F type connector Male (female housing)

Female (male housing)

—

PC160LC-7

T-adapter Part No.

—

20-249 (1)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9210

18-8 (1)

Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)

Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206 Pin (male terminal)

Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106 Pin (female termial)

799-601-9220

Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206 18-14 (2) Pin (female terminal)

Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106 Pin (male termial)

799-601-9220

Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206

20-250 (1)

Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106

PC160LC-7

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9230

18-20 (3)

Part No.:08191-31201, 08191-31202

Part No.:08191-34101, 08191-34102

Pin (female terminal)

Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202

Part No.:08191-33101, 08191-33102

Pin (male terminal)

Pin (female termial)

799-601-9240

18-21 (4)

Part No.:08191-41201, 08191-42202

Part No.:08191-44101, 08191-44102

Pin (female terminal)

Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202

PC160LC-7

Part No.:08191-43101, 08191-43102

20-251 (1)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9250

24-9 (5)

Part No.:08191-51201, 08191-51202

Part No.:08191-54101, 08191-54102

Pin (female terminal)

Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202

Part No.:08191-53101, 08191-53102

Pin (male terminal)

Pin (female termial)

799-601-9260

Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206 24-16 (6) Pin (female terminal)

Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106 Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206

20-252 (1)

Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106

PC160LC-7

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9270

24-21 (7)

Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206 Pin (female terminal)

Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106 Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206 Pin (male terminal)

Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106 Pin (female termial)

799-601-9280

Part No.: 08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206 24-22 (8) Pin (female terminal)

Part No.: 08191-84101, 08191-84103, 08191-84105,

08191-84102 08191-84104 08191-84106

Pin (male termial)

799-601-9280

Part No.: 08191-82201, 08191-82203, 08191-82205,

PC160LC-7

08191-82202 08191-82204 08191-82206

Part No.: 08191-83101, 08191-83103, 08191-83105,

08191-83102 08191-83104 08191-83106

20-253 (1)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male termial)

Pin (female terminal)

T-adapter Part No.

799-601-9290

24-31 (9)

Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206 Pin (female terminal)

Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106 Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206

20-254 (1)

Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106

PC160LC-7

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector

No.of pins

Body (plug)

Body (receptacle)

T-adapter Part No.

799-601-9020

Part No.: 08192-12200 (normal type) 08192-22200 (fine wire type)

Part No.: 08192-12100 (normal type) 08192-22100 (fine wire type)

799-601-9030

Part No.: 08192-13200 (normal type) 08192-23200 (fine wire type)

Part No.: 08192-13100 (normal type) 08192-23100 (fine wire type)

799-601-9040

Part No.: 08192-14200 (normal type) 08192-24200 (fine wire type)

Part No.: 08192-14100 (normal type) 08192-24100 (fine wire type)

799-601-9050

Part No.: 08192-16200 (normal type) 08192-26200 (fine wire type)

PC160LC-7

Part No.: 08192-16100 (normal type) 08192-26100 (fine wire type)

20-255 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector

No.of pins

Body (plug)

Body (receptacle)

T-adapter Part No.

8GR: 799-601-9060 8B: 799-601-9070 8G: 799-601-9080 8BR: 799-601-9090

Part No.: 08192-1820T (normal type) Part No.: 08192-1810T (normal type) 08192-2820T (fine wire type) 08192-2810T (fine wire type)

12GR: 799-601-9110 12B: 799-601-9120 12G: 799-601-9130 12BR: 799-601-9140

Part No.: 08192-1920T (normal type) Part No.: 08192-1910T (normal type) 08192-2920T (fine wire type) 08192-2910T (fine wire type)

20-256 (1)

PC160LC-7

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] DTM Series connector

No.of pins

Body (plug)

Body (receptacle)

T-adapter Part No.

799-601-9010

Part No.: 08192-02200

Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)] DTHD Series connector

No.of pins

Body (plug)

Body (receptacle)

T-adapter Part No.

—

Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12) 08192-41200 (Contact size #8) 08192-41100 (Contact size #8) 08192-51200 (Contact size #4) 08192-51100 (Contact size #4)

PC160LC-7

20-257 (1)

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins

DRC26 Series connector Body (plug)

Body (receptacle)

T-adapter Part No.

799-601-9360

—

Part No.:7821-93-3110

40 (A)

799-601-9350

—

Part No.:7821-93-3120

40 (B)

799-601-9350

—

20-257-1 (4)

Part No.:7821-93-3130

PC160LC-7

T-ADAPTER - BOXES AND T-ADAPTER TABLE

TROUBLESHOOTING

T-ADAPTER - BOXES AND T-ADAPTER TABLE

Q Q

799-601-2600 Box for measurement

Econo-21P

799-601-3100 Box for measurement

MS-37P

799-601-3200 Box for measurement

MS-37P

799-601-3300 Box for measurement

Econo-24P

799-601-3360 Plate

For MS box

799-601-3370 Plate

For MS box

799-601-3380 Plate

For MS box

799-601-3410 BENDIX(MS)

24P

Q Q

799-601-3420 BENDIX(MS)

24P

Q Q

799-601-3430 BENDIX(MS)

17P

Q Q

799-601-3440 BENDIX(MS)

17P

799-601-3450 BENDIX(MS)

799-601-3460 BENDIX(MS)

10P

799-601-3510 BENDIX(MS)

Q Q

799-601-3520 BENDIX(MS)

14P

Q Q

799-601-3530 BENDIX(MS)

19P

799-601-2910 BENDIX(MS)

14P

—

799-601-9300

799-601-9200

Q Q Q Q Q Q

Q Q Q Q Q

799-601-2710 MIC

Q Q

799-601-2720 MIC

13P

Q Q

799-601-2730 MIC

17P

Q Q Q Q

Q Q

799-601-2740 MIC

21P

Q Q Q Q

Q Q

799-601-2950 MIC

Q Q Q

799-601-2750 ECONO

Q Q

799-601-2760 ECONO

Q Q

799-601-2770 ECONO

Q Q

799-601-2780 ECONO

Q Q

799-601-2790 ECONO

12P

Q Q

799-601-2810 DLI

Q Q

799-601-2820 DLI

12P

Q Q

799-601-2830 DLI

16P

Q Q Q Q

799-601-2840 Extension cable

799-601-2850 Case 799-601-7000 X

799-601-7020 X

Q Q Q

799-601-7030 X

Q Q Q

799-601-7040 X

Q Q Q

799-601-7050 SWP

Q Q Q

799-601-7060 SWP

Q Q Q

799-601-7310 SWP

12P

799-601-7070 SWP

14P

799-601-7320 SWP

16P

(1)

799-601-9100

799-601-3470 Case

20-258

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

No. of pins

799-601-2800

Type of connector

799-601-2700

Part No.

799-601-2500

The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker assemblies are shown in the lines.

Q Q

PC160LC-7

799-601-7080 M

799-601-7090 M

Q Q Q

799-601-7110 M

Q Q Q

799-601-7120 M

Q Q Q

799-601-7130 M

Q Q Q

799-601-7340 M

799-601-7140 S

Q Q Q

799-601-7150 S

10P-White

Q Q Q

799-601-7160 S

12P-Blue

Q Q Q

799-601-7170 S

16P-Blue

Q Q Q

799-601-7330 S

16P-White

799-601-7350 S

12P-White

799-601-7180 AMP040

799-601-7190 AMP040

12P

799-601-7210 AMP040

16P

Q Q Q

799-601-7220 AMP040

20P

Q Q Q

799-601-7230 Short connector

X-2

Q Q Q

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-2900

799-601-2800

No. of pins

799-601-2700

Type of connector

799-601-2500

Part No.

799-601-3000

T-ADAPTER - BOXES AND T-ADAPTER TABLE

TROUBLESHOOTING

Q Q Q

Q Q

799-601-7240 Case

799-601-7270 Case 799-601-7510 070

10P

799-601-7520 070

12P

799-601-7530 070

14P

799-601-7540 070

18P

799-601-7550 070

20P

799-601-7360 Relay connector

799-601-7370 Relay connector

799-601-7380 JFC connector

799-601-9010 DTM

799-601-9020 DT

799-601-9030 DT

799-601-9040 DT

799-601-9050 DT

799-601-9060 DT

8P-Gray

799-601-9070 DT

8P-Black

799-601-9080 DT

8P-Green

799-601-9090 DT

8P-Brown

799-601-9110 DT

12P-Gray

799-601-9120 DT

12P-Black

799-601-9130 DT

12P-Green

799-601-9140 DT

12P-Brown

799-601-9210 HD30

18-8

Q Q

799-601-9220 HD30

18-14

Q Q

799-601-9230 HD30

18-20

Q Q

799-601-9240 HD30

18-21

Q Q

799-601-9250 HD24

24-9

Q Q

PC160LC-7

20-259 (1)

799-601-9260 HD30

24-16

Q Q

799-601-9270 HD30

24-21

Q Q

799-601-9280 HD30

24-23

Q Q

799-601-9290 HD30

24-31

Q Q

799-601-9310 Plate

For HD30

Q Q

799-601-9320 Box for measurement

For DT, HD

Q Q

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-2900

799-601-2800

No. of pins

799-601-2700

Type of connector

799-601-2500

Part No.

799-601-3000

T-ADAPTER - BOXES AND T-ADAPTER TABLE

TROUBLESHOOTING

799-601-9330 Case

799-601-9340 Case 799-601-9350 DRC26

40P

799-601-9360 DRC26

24P

799-601-9410 For NE, G sensor

For fuel, boost 799-601-9420 pressure

799-601-9430 PVC socket

20-260 (4)

PC160LC-7

TROUBLESHOOTING ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED

BEFORE TROUBLESHOOTING FOR DISPLAYED CODE ....................................................................... 20-304 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-310 Error Code in Electrical System E101 (Abnormal data in error history) ..................................................... 20-312 Error Code in Electrical System E112 (Short-circuiting in normal rotation system of windshield wiper motor drive)............................................................................................................... 20-314 Error Code in Electrical System E113 (Short-circuiting in reverse rotation system of windshield wiper motor drive)............................................................................................................... 20-316 Error Code in Electrical System E114 (Short-circuiting in window washer drive system) .......................... 20-318 Error Code in Electrical System E115 (Abnormal operation of windshield wiper) ...................................... 20-320 Error Code in Electrical System E116 (Abnormality operation of retracting windshield wiper) .................. 20-322 Error Code in Electrical System E201 (Short-circuiting in travel junction solenoid) ................................... 20-324 Error Code in Electrical System E203 (Short-circuiting in swing holding brake solenoid).......................... 20-326 Error Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)..................................... 20-328 Error Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)..................................... 20-330 Error Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) ......................... 20-332 Error Code in Electrical System E211 (Disconnection in travel junction solenoid)..................................... 20-334 Error Code in Electrical System E213 (Disconnection in swing holding brake solenoid) ........................... 20-336 Error Code in Electrical System E214 (Disconnection of merge/divide solenoid) ...................................... 20-338 Error Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) ...................................... 20-340 Error Code in Electrical System E216 (Disconnection in travel speed shifting solenoid) ........................... 20-342 Error Code in Electrical System E217 (Abnormality in inputting model code)............................................ 20-344 Error Code in Electrical System E218 Disconnection of S-NET signal) ..................................................... 20-346 Error Code in Electrical System E224 (Abnormality in F pump pressure sensor) ...................................... 20-348 Error Code in Electrical System E225 (Abnormality in R pump pressure sensor) ..................................... 20-350 Error Code in Electrical System E226 (Abnormality in pressure sensor power source) ............................ 20-352 Error Code in Electrical System E227 (Abnormality in engine rotation sensor) ......................................... 20-354 Error Code in Electrical System E228 (Short-circuiting in attachment return switching relay) ................... 20-356 Error Code in Electrical System E232 (Short-circuiting in PC-EPC solenoid) ............................................ 20-358 Error Code in Electrical System E233 (Disconnection in PC-EPC solenoid) ............................................. 20-360 Error Code in Electrical System E238 (Disconnection in attachment return switching relay) .................... 20-362 Error Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC solenoid) ....................................................................................................................... 20-364 Error Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC solenoid) ....................................................................................................................... 20-365 Error Code in Electrical System E306 (Abnormality in governor potentiometer)........................................ 20-366 Error Code in Electrical System E308 (Abnormality in fuel dial) ................................................................ 20-368 Error Code in Electrical System E311 (Short-circuiting in cold starting solenoid relay) ............................. 20-370 Error Code in Electrical System E312 (Disconnection in cold starting solenoid relay)............................... 20-372 Error Code in Electrical System E315 (Short-circuiting in battery relay) .................................................... 20-374 Error Code in Electrical System E316 (Step-out in governor motor) .......................................................... 20-376 Error Code in Electrical System E317 (Disconnection in governor motor Phase A and B)........................ 20-377 Error Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) ........... 20-380

PC160LC-7

20-301 (1)

Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling) .......................... 20-382 Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)............................ 20-382 Failure Code in Mechanical System AA10NX (Air cleaner clogging) ......................................................... 20-383 Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage).............................. 20-384 Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ........................ 20-386 Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)............................... 20-387 Failure Code in Mechanical System B@BCNS (Engine cooling water overheating).................................. 20-388 Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level) ........................ 20-389 Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-390

20-302 (1)

PC160LC-7

Error code Failure code

E101 E112 E113 E114 E115 E116 E201 E203 E204 E205 E206 E211 E213 E214 E215 E216 E217 E218 E224 E225 E226 E227 E228 E232 E233 E238 E245 E246 E306 E308 E311 E312 E315 E316 E317 E318 – – – – – – – – –

DAF0KT DY2DKB DY2EKB DY2CKB DY20KA DY20MA DW91KB DW45KB DWJ0KB DWK0KB DW43KB DW91KA DW45KA DWJ0KA DWK0KA DW43KA DA2SKQ DA2SKA DHPAMA DHPBMA DA25KP DLE2MA D196KB DXA0KB DXA0KA D196KA DXE4KB DXE4KA DK54KZ DK10KZ D199KB D199KA D110KB q DY10K4 DY10KA DY10KB A000N1 A000N2 AA10NX AB00KE B@BAZG B@BAZK B@BCNS B@BCZK B@HANS

20-304

(4) q q q q q q q

q q q q q q q

q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q

q q q q

q q

q q q q

Defective adjustment of governor lever

Defective mechanical system of engine

Defective alternator

Defective air cleaner clogging switch

Defective radiator water level switch

Defective engine water temperature sensor (for monitor)

Defective engine oil level switch

Defective engine oil pressure switch

Defective cold starting solenoid relay

Defective engine speed sensor (including adjustment)

Defective governor potentiometer

Defective governor motor

Defective fuel control dial

Model selector connector

Defective emergency pump driving switch

Defective swing lock switch

Defective windshield washer motor

Defective wiper motor

Defective sensor power supply (5 V)

Governor pump controller

Defective monitor panel

Defective fuse or fusible link

Defective battery relay

TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE

BEFORE TROUBLESHOOTING FOR DISPLAYED CODE

Error codes and failure codes and possible causes of them Possible causes

q q

PC160LC-7

q q q q

q q

q q q q q q

q q

q q q q q q q q q

q q

q q q

q q

q q q

q q q q q

q q

Short-circuiting with power source in wiring harness

Grounding fault in wiring harness

Disconnection in wiring harness

Defective diode block

Overheating of hydraulic oil

Defective hydraulic oil temperature sensor

Defective R pump pressure sensor

Defective F pump pressure sensor

Defective attachment flow rate adjustment EPC solenoid

Defective attachment return switching relay

Defective travel speed shifting solenoid

Defective 2-stage relief solenoid

Defective pump merge-divider solenoid

Defective swing holding brake solenoid

Defective travel junction solenoid

Defective PC-EPC solenoid

Clogged air cleaner

Low water level in radiator sub tank

Overheating of engine

Low engine oil level

Low engine oil pressure

Defective fuel control of engine

TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE

Possible causes

q q q q q

q q q

q q

q q q q

q q

20-305

(4)

BEFORE TROUBLESHOOTING FOR DISPLAYED CODE

TROUBLESHOOTING

Connection table of fuse box This connection table shows the devices to which each power supply of the fuse box (FB1) supplies power directly (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). When carrying out troubleshooting for an electric system, you should check its fuse box and fusible link to see if the power is supplied normally. Type of power supply

Fuse No.

Fuse capacity

Destination of power Governor pump controller (Controller power supply)

10A

Emergency pump drive resistor Swing holding brake release switch Governor pump controller (Solenoid power supply)

Switch power supply (Fusible link: A34)

Constant power supply (Fusible link: A35)

20-306 (4)

20A

Cold starting solenoid relay (Coil side and contact side) Attachment return switching relay (Coil side and contact side)

10A

Safety lock switch

10A

Horn switch

10A

(Spare)

10A

(Spare)

20A

Air conditioner unit

20A

Light switch

10A

Service power supply (M32 connector)

10A

Radio

20A

(Spare)

10A

Room lamp

10A

(Spare)

Cigarette lighter Windshield washer motor

Rotary lamp switch Additional relay (Coil side and contact side) Light relay (Contact side) One-touch power maximizing switch Radio

Starting motor cut-out (Personal code) relay (Coil side) Monitor panel

Travel alarm DC/DC converter

Starting switch / Monitor panel —

PC160LC-7

TROUBLESHOOTING

BEFORE TROUBLESHOOTING FOR DISPLAYED CODE

Problems which occur when controller power supply of governor pump controller is defective The controller power supply (FB1-1) of the governor pump controller drives the controller system. Accordingly, if the controller power supply is turned off, the controller cannot control the governor motor and battery relay and the following problems occur. 1) The engine can be started but cannot be started. 2) The engine speed cannot be controlled with the fuel control dial. If the above problems occur, check the related fuse (FB1-1) and "green LED" of the governor pump controller to see if the power is supplied normally. • Lighting: The controller power is supplied (There is not an error and the power supply is normal). • Flashing: The controller power is supplied (There is an error). • Put out: The controller power is not supplied. Green LED of governor pump controller (GREEN)

PC160LC-7

20-307 (1)

TROUBLESHOOTING

BEFORE TROUBLESHOOTING FOR DISPLAYED CODE

Problems which occur when solenoid power supply of governor pump controller is defective The solenoid power supply (FB1-2) of the governor pump controller is used by the controller to drive the solenoids and relays. Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids or relays, the power is not supplied to any of the solenoids and relays and all or some of the following error codes are displayed simultaneously. • [E212]: Disconnection in travel junction solenoid • [E213]: Disconnection in swing holding brake solenoid • [E214]: Disconnection in pump merge-divider solenoid • [E215]: Disconnection in 2-stage relief solenoid • [E216]: Disconnection in travel speed shifting solenoid • [E233]: Disconnection in PC-EPC solenoid • [E248]: Disconnection in attachment flow rate adjustment EPC solenoid (when attachment is installed) If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the governor pump controller. 1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side. 2) Turn the starting switch ON. 3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33). • Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins. • If the voltage is 20 – 30 V, it is normal. Power supply connector (C03) of governor pump controller

20-308 (1)

PC160LC-7

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work. User Code

Error Code

Failure Code

Display in monitor panel

Failure content

Failure status as detected by monitor panel or controller

Response from monitor panel or controller

Action taken by the monitor panel or controller to protect an affected system or equipment, when they detect some failure.

Phenomenon occurring on machine

Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or controller

Relative information

Information on the failure occurred as well as the troubleshooting Cause

Presumed cause and standard value in normalcy

Cause that presumably triggered failure in question 3 (The assigned No. is for filing purpose only. It does not stand for any priority)

20-310 (1)

Failure phenomenon

Title of failure phenomenon shown in failure history

Standard value in normalcy and references for troubleshooting <Content Included> • Standard value in normalcy by which to pass "Good" or "No good" judgement over the presumed cause • Reference for passing the above "Good" or "No Good" judgement <Phenomenon of Wiring Harness Failure> • Disconnection There is a faulty contact at the connector or disconnection of wiring harness occurred. • Defective grounding A wiring harness that is not connected with a grounding circuit has a contact with the grounding circuit. • Short-circuiting A wiring harness that is not connected with a 24 V electric circuit has a contact with the electric circuit. <Precaution for Troubleshooting> 1) Connector No. display method and handling of T-adapter Insert or connect T-adapters in the following manner before starting troubleshooting unless otherwise instructed. • If there is no indication of "male" or "female" in a specific connector No., disconnect the connector and insert the T-adapter into both male and female sides. • If there is an indication of "male" or "female" in a specific connector No., disconnect the connector and connect the T-adepter with only one side of either "male" or "female". 2) Entry sequence of pin No. and handling of circuit tester lead Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the following manner unless otherwise instructed. • Connect the positive (+) lead with the pin No. indicated at the front or the wiring harness. • Connect the negative (–) lead with the pin No. indicated at the front or the wiring harness.

PC160LC-7

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

Relative Electrical Circuit Diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.

PC160LC-7

20-311 (1)

E101

TROUBLESHOOTING

Error Code in Electrical System E101 (Abnormal data in error history) User Code

Error Code

Failure Code

E101

DAF0KT

—

Failure phenomenon

Abnormal data in error history (in Monitor Panel system)

Failure content

• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or exceeded 36 V.

Response from Monitor Panel

• None in particular

Phenomenon occurring on machine

• A display for information on the failure history (in the electrical system) cannot be called.

Cause

Standard value in normalcy and references for troubleshooting

1 Fuse No. 17 defective

If the fuse No. 17 is blown, there is a big possibility that the circuit has a grounding fault. (cause 4 reference)

Fusible link No. A35 defective

If the fusible link No. A35 is blown, there is a big possibility that the circuit has a grounding fault. (cause 4 reference)

Presumed cause and standard value in normalcy

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Disconnection of wiring harness 3 (Disconnection or connector contact fault)

Between wiring harness from P01 (female) (8) to J07 to FB1-17 outlet

Resistance value

Below 1 Ω

Wiring harness between FB1-17 inlet and A35 (male) (2)

Resistance value

Below 1 Ω

Wiring harness between A35 (male) (1) and A23 (B terminal)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit)

Between wiring harness between P01 (female) (8) to J07 and FB1-17 outlet and grounding

Resistance value

Above 1 MΩ

Between wiring harness between FB1-17 inlet and A35 (male) (2) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between A35 (male) (1) and A23 (B terminal) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. 5 Monitor Panel defective

20-312 (1)

P01

Voltage

Between (8) and (6) (7)

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E101

Related circuit diagram Serial No.: 10001 – 11000

Serial No.: 11001 and up

PC160LC-7

20-313 (4)

E112

TROUBLESHOOTING

Error Code in Electrical System E112 (Short-circuiting in normal rotation system of windshield wiper motor drive) User Code

Error Code

Failure Code

—

E112

DY2DKB

Failure phenomenon

Short-circuiting in normal rotation system of windshield wiper motor drive (in monitor panel system)

Failure content

• Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.

Response from Monitor Panel

• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.

Phenomenon occurring on machine

• The windshield wiper stops moving.

Presumed cause and standard value in normalcy

Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female)

Continuity and resistance value

Between (3) and (1)

Continued

Between (3) and grounding

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Between wiring harness between P01 (female) (9) and W04 (male) (3) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective

P01 Between (9) and grounding

20-314 (1)

Windshield wiper switch

Voltage

OFF

Below 3 V

Below 3 V⇔20 – 30 V (at constant cycle)

PC160LC-7

TROUBLESHOOTING

E112

Related circuit diagram

PC160LC-7

20-315 (1)

E113

TROUBLESHOOTING

Error Code in Electrical System E113 (Short-circuiting in reverse rotation system of windshield wiper motor drive) User Code

Error Code

Failure Code

—

E113

DY2EKB

Failure phenomenon

Short-circuiting in reverse rotation system of windshield wiper motor drive (in Monitor Panel system)

Failure content

• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the windshield wiper was set in motion.

Response from Monitor Panel

• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.

Phenomenon occurring on machine

• The windshield wiper stopped moving.

Presumed cause and standard value in normalcy

Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female)

Continuity and resistance value

Between (1) and (3)

Continued

Between (1) and grounding

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Between wiring harness between P01 (female) (10) and W04 (male) (1) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective

P01 Between (10) and grounding

20-316 (1)

Windshield wiper switch

Voltage

OFF

Below 3 V

Below 3 V⇔20 – 30 V (at constant cycle)

PC160LC-7

TROUBLESHOOTING

E113

Related circuit diagram

PC160LC-7

20-317 (1)

E114

TROUBLESHOOTING

Error Code in Electrical System E114 (Short-circuiting in window washer drive system) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

E114

DY2CKB

—

Failure phenomenon

Short-circuiting in window washer drive system (in Monitor Panel system)

Response from Monitor Panel

• Power supply to the grounding in the window washer motor circuit was switched OFF.

Phenomenon occurring on machine

• The window washer stopped moving.

Presumed cause and standard value in normalcy

Failure content

• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was switched ON.

Cause Window washer drive 1 motor defective (Internal short-circuiting)

Short-circuiting of wiring harness 2 (Contact with 24 V circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. A50 (male)

Resistance value

Between (1) and (2)

5 – 20 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. Between wiring harness from P01 (female) (3) to J04 to A50 (female) (2) and grounding, or between wiring harness between P01 (female) (3) and D04 (female) (8) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective

P01 Between (3) and grounding

20-318 (4)

Window washer switch

Voltage

OFF

20 – 30 V

Below 1 V

PC160LC-7

TROUBLESHOOTING

E114

Related circuit diagram

PC160LC-7

20-319 (1)

E114

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

—

E114

DY2CKB

Failure phenomenon

Short-circuiting in window washer drive system (in Monitor Panel system)

• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was switched ON.

Response from Monitor Panel

• Power supply to the grounding in the window washer motor circuit was switched OFF.

Phenomenon occurring on machine

• The window washer stopped moving.

Presumed cause and standard value in normalcy

Failure content

Cause Window washer drive 1 motor defective (Internal short-circuiting)

Short-circuiting of wiring harness 2 (Contact with 24 V circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. A50 (male)

Resistance value

Between (1) and (2)

5 – 20 z

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 3 Monitor panel defective

P01 Between (3) and grounding

20-319-1 (4)

Window washer switch

Voltage

OFF

20 – 30 V

Below 1 V

PC160LC-7

TROUBLESHOOTING

E114

Related circuit diagram

PC160LC-7

20-319-2 (4)

E115

TROUBLESHOOTING

Error Code in Electrical System E115 (Abnormal operation of windshield wiper) User Code

Error Code

Failure Code

E115

DY20KA

—

Failure phenomenon

Abnormal operation of windshield wiper (in Monitor Panel system)

Failure content

• W signal is not inputted at both ends of movement, when it is in motion.

Response from Monitor Panel

• Power to the windshield wiper motor is turned OFF.

Phenomenon occurring on machine

• The windshield wiper motor does not work.

Relative information

• Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function. (Code No. 049: Monitor input 3) Cause

Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Windshield wiper motor 1 defective (Internal disconnection)

W04 (female)

Between (6) and (5)

Disconnection of wiring harness 2 (Disconnection or faulty contact with connector)

Windshield wiper blade

Resistance value

At upper end of operation range

Below 1 Ω

Outside upper end of operation range

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Wiring harness between P01 (female) (5) and W04 (male) (6)

Resistance value

Below 1 Ω

Wiring harness between W04 (male) (5) and grounding

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. P01 3 Monitor panel defective Between (5) and grounding

20-320 (1)

Windshield wiper blade

Voltage

At upper end of operation range

Below 1 V

Outside upper end of operation range

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E115

Related circuit diagram

PC160LC-7

20-321 (1)

E116

TROUBLESHOOTING

Error Code in Electrical System E116 (Abnormality operation of retracting windshield wiper) User Code

Error Code

Failure Code

E116

DY20MA

—

Failure phenomenon

Abnormal operation of retracting windshield wiper (in Monitor Panel system)

Failure content

• P signal in the retraction range is not inputted, when the wiper is retracted.

Response from Monitor Panel

• Power supply to the windshield wiper motor is switched OFF, when the wiper is retracted.

Phenomenon occurring on machine

• The windshield wiper cannot be retracted completely.

Relative information

• It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation range is inputted or not. (Code No. 049: Monitor Input 3)

Presumed cause and standard value in normalcy

Cause

Windshield wiper motor 1 defective (Internal disconnection)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between (4) and (5)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector)

Windshield wiper blade

Resistance value

Retraction range

Below 1 Ω

Operation range

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female) (12) and W04 (male) (4)

Resistance value

Below 1 Ω

Between wiring harness W04 (male) (5) and grounding

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3 Monitor panel defective

P01 Between (12) and grounding

20-322 (1)

Windshield wiper blade

Voltage

Retraction range

Below 1V

Operation range

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E116

Related circuit diagram

PC160LC-7

20-323 (1)

E201

TROUBLESHOOTING

Error Code in Electrical System E201 (Short-circuiting in travel junction solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

E201

DW91KB

—

Failure phenomenon

Short-circuiting in travel junction solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the travel junction circuit, when power was supplied to the circuit.

Response from controller

• Power supply to the travel junction circuit is switched OFF. • Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• It is difficult to steer the machine at turns. (Both travel circuits are not separated)

Relative information

• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)

Presumed cause and standard value in normalcy

Cause Travel junction solenoid defective 1 (Internal short-circuiting or grounding fault)

Assembled-type diode 2 D03 defective (Internal short-circuiting)

Grounding fault of wiring harness 3 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)

Resistance value (Continuity)

Between (3) and (7)

Above 1 Mz (No continuity)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (7) to J06 to V02 (female) (1) and grounding, or between wiring harness between C03 (female) (7) and D03 (female) (3) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4

Governor • pump controller defective

C03 Between (7) and grounding

20-324 (4)

Left and right travel control lever

Voltage

NEUTRAL

Below 1 V

Steering

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E201

Related circuit diagram

PC160LC-7

20-325 (1)

E201

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

—

E201

DW91KB

Failure phenomenon

Short-circuiting in travel junction solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the travel junction circuit, when power was supplied to the circuit.

Response from controller

Phenomenon occurring on machine

• It is difficult to steer the machine at turns. (Both travel circuits are not separated)

Relative information

• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)

Presumed cause and standard value in normalcy

Cause Travel junction solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (7) to V02 (female) (1) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3

Governor • pump controller defective

C03 Between (7) and grounding

20-325-1 (4)

Left and right travel control lever

Voltage

NEUTRAL

Below 1 V

Steering

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E201

Related circuit diagram

PC160LC-7

20-325-2 (4)

E203

TROUBLESHOOTING

Error Code in Electrical System E203 (Short-circuiting in swing holding brake solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

E203

DW45KB

E03

Failure phenomenon

Short-circuiting in swing holding brake solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the circuit.

Response from controller

• Power supply to the swing holding brake solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the swing and steering brake does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The upper structure cannot swing. (The swing holding brake is not released)

Relative information

• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) • If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing holding brake releasing switch to the FREE position. (In this case, however, the holding brake does not work, when stopping the machine)

Presumed cause and standard value in normalcy

Cause Swing holding brake solenoid defective 1 (Internal short-circuiting or grounding fault)

Assembled-type diode 2 D03 defective (Internal short-circuiting)

Grounding fault of wiring harness 3 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)

Resistance value (Continuity)

Between (4) and (8)

Above 1 Mz (No continuity)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (37) to D01 to J02 to X05 to J06 to V05 (female) (1), or between wiring harness between C03 (female) (37) and D03 (female) (4), or between wiring harness between C03 (female) (37) and S25 (female) (8) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4

Governor • pump controller defective

C03

Swing control lever

Voltage

NEUTRAL

Below 1 V (5 sec after the lever is set in neutral)

Swing

20 – 30 V

Between (37) and grounding

20-326 (4)

PC160LC-7

TROUBLESHOOTING

E203

Related circuit diagram

PC160LC-7

20-327 (1)

E203

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

E03

E203

DW45KB

Failure phenomenon

Short-circuiting in swing holding brake solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the circuit.

Response from controller

Phenomenon occurring on machine

• The upper structure cannot swing. (The swing holding brake is not released)

Relative information

Presumed cause and standard value in normalcy

Cause Swing holding brake solenoid defective 1 (Internal short-circuiting or grounding fault)

Assembled-type diode 2 D03 defective (Internal short-circuiting)

Grounding fault of wiring harness 3 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)

Resistance value (Continuity)

Between (4) and (8)

Above 1 Mz (No continuity)

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4

Governor • pump controller defective

C03

Swing control lever

Voltage

NEUTRAL

Below 1 V (5 sec after the lever is set in neutral)

Swing

20 – 30 V

Between (37) and grounding

20-327-1 (4)

PC160LC-7

TROUBLESHOOTING

E203

Related circuit diagram

PC160LC-7

20-327-2 (4)

E204

TROUBLESHOOTING

Error Code in Electrical System E204 (Short-circuiting in merge/divide solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

—

E204

DWJ0KB

Failure phenomenon

Short-circuiting in merge/divide solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.

Response from controller

• Power supply to the merge/divide solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation. (The F and R pumps are not separated)

Relative information

• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)

Presumed cause and standard value in normalcy

Cause Merge/divide solenoid defective 1 (Internal short-circuiting or grounding fault)

Assembled-type diode 2 D03 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)

Resistance value

Between (1) and (5)

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to J06 to V03 (female) (1), or between wiring harness between C03 (female) (17) and D03 (female) (1) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4

Governor • pump controller defective

C03

Left and right travel control lever

Voltage

NEUTRAL

Below 1 V

Between (17) and grounding When operated for straight travel

20-328 (4)

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E204

Related circuit diagram

PC160LC-7

20-329 (1)

E204

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Service Code

Failure Code

—

E204

DWJ0KB

Failure phenomenon

Short-circuiting in merge/divide solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.

Response from controller

Phenomenon occurring on machine

• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation. (Front and rear pumps are not separated)

Relative information

• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)

Presumed cause and standard value in normalcy

Cause Merge/divide solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (17) to V03 (female) (1) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3

Governor • pump controller defective

C03 Between (17) and grounding

20-329-1 (4)

Travel control lever

Voltage

NEUTRAL

Below 1 V

When operating one side only

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E204

Electrical Circuit Diagram for Merge/Divide Solenoid

PC160LC-7

20-329-2 (4)

E205

TROUBLESHOOTING

Error Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

—

E205

DWK0KB

Failure phenomenon

Short-circuiting in 2-stage relief solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.

Response from controller

• Power supply to the 2-stage relief solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)

Relative information

• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)

Presumed cause and standard value in normalcy

Cause 2-stage relief solenoid defective 1 (Internal short-circuiting or grounding fault)

Assembled-type diode 2 D03 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V06 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)

Resistance value (Continuity)

Between (2) and (6)

Above 1 Mz (No continuity)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to J06 to V06 (female) (1), or between wiring harness between C03 (female) (28) and D03 (female) (2) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4

Governor • pump controller defective

C03 Between (28) and grounding

20-330 (4)

Working mode

Voltage

Other than L mode

Below 1 V

L mode

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E205

Related circuit diagram

PC160LC-7

20-331 (1)

E205

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

—

E205

DWK0KB

Failure phenomenon

Short-circuiting in 2-stage relief solenoid (in governor • pump controller system)

• Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.

Response from controller

Phenomenon occurring on machine

• The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)

Relative information

• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)

Presumed cause and standard value in normalcy

Failure content

Cause 2-stage relief solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V06 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (28) to V06 (female) (1) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3

Governor • pump controller defective

C03 Between (28) and grounding

20-331-1 (4)

Working mode

Voltage

Other than L mode

Below 1 V

L mode

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E205

Related circuit diagram

PC160LC-7

20-331-2 (4)

E206

TROUBLESHOOTING

Error Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

E206

DW43KB

—

Failure phenomenon

Short-circuiting in travel speed shifting solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.

Response from controller

• Power supply to the travel speed shifting solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The travel speed does not turn to Hi. (The swash plate angle of the travel motor is not minimized)

Relative information

• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)

Presumed cause and standard value in normalcy

Cause Travel speed shifting solenoid defective 1 (Internal short-circuiting or grounding fault)

Assembled-type diode 2 D04 defective (Internal short-circuiting) Grounding fault of wiring harness 3 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D04 (male)

Resistance value (Continuity)

Between (2) and (6)

Above 1 Mz (No continuity)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to J06 to V04 (female) (1), or between wiring harness between C03 (female) (27) and D04 (female) (2) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4

Governor • pump controller defective

C03 Between (27) and grounding

20-332 (4)

Travel speed + Travel control lever

Voltage

Lo + Neutral

Below 1 V

Hi + Travel operation

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E206

Related circuit diagram

PC160LC-7

20-333 (1)

E206

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

—

E206

DW43KB

Failure phenomenon

Short-circuiting in travel speed shifting solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.

Response from controller

Phenomenon occurring on machine

• The travel speed does not turn to Hi. (The swash plate angle of the travel motor is not minimized)

Relative information

• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)

Presumed cause and standard value in normalcy

Cause Travel speed shifting solenoid defective 1 (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (27) to V04 (female) (1) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3

Governor • pump controller defective

C03 Between (27) and grounding

20-333-1 (4)

Travel speed + Travel control lever

Voltage

Lo + Neutral

Below 1 V

Hi + Travel operation

20 – 30 V

PC160LC-7

TROUBLESHOOTING

E206

Related circuit diagram

PC160LC-7

20-333-2 (4)

E211

TROUBLESHOOTING

Error Code in Electrical System E211 (Disconnection in travel junction solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

—

E211

DW91KA

Failure phenomenon

Disconnection in travel junction solenoid (in governor • pump controller system)

Failure content

• No current flows to the travel junction solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• It is difficult to steer the machine while traveling. (Both travel circuits are not separated)

Relative information

• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E201].)

Presumed cause and standard value in normalcy

Cause Travel junction 1 solenoid defective (Internal disconnection)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump 4 controller defective

20-334 (4)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (7) to J06 to V02 (female) (1)

Resistance value

Below 1 z

Wiring harness between V02 (female) (2) and grounding

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (7) to J06 to V02 (female) (1), or between wiring harness C03 (female) (7) and D03 (female) (3) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (7) and grounding

20 – 60 z

PC160LC-7

TROUBLESHOOTING

E211

Related circuit diagram

PC160LC-7

20-335 (1)

E211

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

—

E211

DW91KA

Failure phenomenon

Disconnection in travel junction solenoid (in governor • pump controller system)

Failure content

• No current flows to the travel junction solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• It is difficult to steer the machine while traveling. (Both travel circuits are not separated)

Relative information

Presumed cause and standard value in normalcy

Cause Travel junction 1 solenoid defective (Internal disconnection)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump controller defective

20-335-1 (4)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (7) to J06 to V02 (female) (1)

Resistance value

Below 1 z

Wiring harness from C03 (female) (3), (13), (23) to V02 (female) (2)

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from C03 (female) (7) to V02 (female) (1) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (7) and grounding

20 – 60 z

PC160LC-7

TROUBLESHOOTING

E211

Related circuit diagram

PC160LC-7

20-335-2 (4)

E213

TROUBLESHOOTING

Error Code in Electrical System E213 (Disconnection in swing holding brake solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

E03

E213

DW45KA

Failure phenomenon

Disconnection in swing holding brake solenoid (in governor • pump controller system)

Failure content

• No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• The machine's upper structure does not swing. (The swing holding brake is not released)

Relative information

• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) • If the solenoid and wiring harness are free from abnormality, the machine can swing by setting the swing holding brake release switch in the RELEASE position (The parking brake does not work when the machine stops, however). • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the RELEASE position. aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E203].) Cause

Presumed cause and standard value in normalcy

Swing holding brake solenoid defective 1 (Internal disconnection)

Swing lock switch defective 2 (Internal disconnection)

Assembled-type diode D01 defective 3 (Internal disconnection)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (3) and (4)

Swing lock switch

Resistance value

OFF

Below 1 z

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)

Digital type circuit tester

Continuity

Between (7) and (3)

Diode mode

Continued

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 4 (Disconnection or defective contact with connector)

Short-circuiting of Wiring harness 5 (Contact with 24V circuit)

Governor • pump controller defective

Wiring harness between C03 (female) (37) and D01 (female) (7)

Resistance value

Below 1 z

Wiring harness from D01 (female) (3) to J02 to X05 (male) (3)

Resistance value

Below 1 z

Wiring harness from X05 (male) (4) to J06 to V05 (female) (1)

Resistance value

Below 1 z

Wiring harness between V05 (female) (2) and grounding

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (37) and D01 (female) (7) and grounding

(4)

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (37) and grounding

20-336

Voltage

Disconnect D01 and connect pins (3) and (7) of the male side.

Resistance value 20 – 60 z

PC160LC-7

TROUBLESHOOTING

E213

Electrical Circuit Diagram for Swing and Parking Brake Solenoid

PC160LC-7

20-337 (1)

E213

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

E03

E213

DW45KA

Failure phenomenon

Disconnection in swing holding brake solenoid (in governor • pump controller system)

Failure content

• No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• The machine's upper structure does not swing. (The swing holding brake is not released)

Relative information

Presumed cause and standard value in normalcy

Swing holding brake solenoid defective 1 (Internal disconnection) Swing lock switch defective 2 (Internal disconnection) Assembled-type diode D01 defective 3 (Internal disconnection)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (3) and (4)

Swing lock switch

Resistance value

OFF

Below 1 z

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)

Digital type circuit tester

Continuity

Between (7) and (3)

Diode mode

Continued

Short-circuiting of Wiring harness 5 (Contact with 24V circuit)

Governor • pump controller defective

Wiring harness between C03 (female) (37) and D01 (female) (7)

Resistance value

Below 1 z

Wiring harness from D01 (female) (3) to J02 to X05 (male) (3)

Resistance value

Below 1 z

Wiring harness from X05 (male) (4) to V05 (female) (1)

Resistance value

Below 1 z

Wiring harness from C03 (female) (3), (13), (23) to V05 (female) (2)

Resistance value

Below 1 z

(4)

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (37) and grounding

20-337-1

Voltage

Disconnect D01 and connect pins (3) and (7) of the male side.

Resistance value 20 – 60 z

PC160LC-7

TROUBLESHOOTING

E213

Electrical Circuit Diagram for Swing and Parking Brake Solenoid

PC160LC-7

20-337-2 (4)

E214

TROUBLESHOOTING

Error Code in Electrical System E214 (Disconnection of merge/divide solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

—

E214

DWJ0KA

Failure phenomenon

Disconnection in merge/divide solenoid (in governor • pump controller system)

Failure content

• No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• In L mode, speeds of the work equipment and swing in its single operation are too fast (The F and R pumps are not separated)

Relative information

• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E204].)

Presumed cause and standard value in normalcy

Cause Merge/divide solenoid 1 defective (Internal disconnection)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump 4 controller defective

20-338 (4)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to J06 to V03 (female) (1)

Resistance value

Below 1 z

Wiring harness between V03 (female) (2) and grounding

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (17) to J06 to V03 (female) (1), or between wiring harness between C03 (female) (17) and D03 (female) (1) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (17) and grounding

20 – 60 z

PC160LC-7

TROUBLESHOOTING

E214

Related circuit diagram

PC160LC-7

20-339 (1)

E214

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

—

E214

DWJ0KA

Failure phenomenon

Disconnection in merge/divide solenoid (in governor • pump controller system)

Failure content

• No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• In L mode, speeds of the work equipment and swing in its single operation are too fast (The F and R pumps are not separated)

Relative information

Presumed cause and standard value in normalcy

Cause Merge/divide solenoid 1 defective (Internal disconnection)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump controller defective

20-339-1 (4)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (1)

Resistance value

Below 1 z

Wiring harness from C03 (female) (3), (13), (23) to V03 (female) (2)

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from C03 (female) (17) to V03 (female) (1) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (17) and grounding

20 – 60 z

PC160LC-7

TROUBLESHOOTING

E214

Related circuit diagram

PC160LC-7

20-339-2 (4)

E215

TROUBLESHOOTING

Error Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

—

E215

DWK0KA

Failure phenomenon

Disconnection in 2-stage relief solenoid (in governor • pump controller system)

Failure content

• No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)

Relative information

• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E205].)

Presumed cause and standard value in normalcy

Cause 2-stage relief solenoid 1 defective (Internal disconnection)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump 4 controller defective

20-340 (4)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V06 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to J06 to V06 (female) (1)

Resistance value

Below 1 z

Wiring harness between V06 (female) (2) and grounding

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (28) to J06 to V06 (female) (1), or between wiring harness between C03 (female) (28) and D03 (female) (2) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (28) and grounding

20 – 60 z

PC160LC-7

TROUBLESHOOTING

E215

Related circuit diagram

PC160LC-7

20-341 (1)

E215

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

—

E215

DWK0KA

Failure phenomenon

Disconnection in 2-stage relief solenoid (in governor • pump controller system)

Failure content

• No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)

Relative information

Presumed cause and standard value in normalcy

Cause 2-stage relief solenoid 1 defective (Internal disconnection)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump controller defective

20-341-1 (4)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V06 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to V06 (female) (1)

Resistance value

Below 1 z

Wiring harness from C03 (female) (3), (13), (23) to V06 (female) (2)

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from C03 (female) (28) to V06 (female) (1) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (28) and grounding

20 – 60 z

PC160LC-7

TROUBLESHOOTING

E215

Related circuit diagram

PC160LC-7

20-341-2 (4)

E216

TROUBLESHOOTING

Error Code in Electrical System E216 (Disconnection in travel speed shifting solenoid) Serial No.: 10001 – 11000 User Code

Error Code

Failure Code

E216

DW43KA

—

Failure phenomenon

Disconnection in travel speed shifting solenoid (in governor • pump controller system)

Failure content

• No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• The travel speed does not shift to Hi. (The swash plate angle of the travel motor is not minimized)

Relative information

• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E206].)

Presumed cause and standard value in normalcy

Cause Travel speed shifting 1 solenoid defective (Internal disconnection)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump controller defective

20-342 (4)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to J06 to V04 (female) (1)

Resistance value

Below 1 z

Wiring harness between V04 (female) (2) and grounding

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (27) to J06 to V04 (female) (1), or between wiring harness between C03 (female) (27) and D04 (female) (2) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (27) and grounding

20 – 60 z

PC160LC-7

TROUBLESHOOTING

E216

Related circuit diagram

PC160LC-7

20-343 (1)

E216

TROUBLESHOOTING

Serial No.: 11001 and up User Code

Error Code

Failure Code

—

E216

DW43KA

Failure phenomenon

Disconnection in travel speed shifting solenoid (in governor • pump controller system)

Failure content

• No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• The travel speed does not shift to Hi. (The swash plate angle of the travel motor is not minimized)

Relative information

Presumed cause and standard value in normalcy

Cause Travel speed shifting 1 solenoid defective (Internal disconnection)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump controller defective

20-343-1 (4)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)

Resistance value

Between (1) and (2)

20 – 60 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (1)

Resistance value

Below 1 z

Wiring harness from C03 (female) (3), (13), (23) to V04 (female) (2)

Resistance value

Below 1 z

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (27) and grounding

20 – 60 z

PC160LC-7

TROUBLESHOOTING

E216

Related circuit diagram

PC160LC-7

20-343-2 (4)

E217

TROUBLESHOOTING

Error Code in Electrical System E217 (Abnormality in inputting model code) User Code

Error Code

Failure Code

E217

DA2SKQ

—

Failure phenomenon

Abnormality in inputting model code (in governor • pump controller system)

Failure content

• A model code signal was inputted which indicates another model that is not registered in the controller.

Response from controller

• The controller treats it as a default-set model (PC200-7). • Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The engine does not output sufficient power or it stalls.

Relative information

• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring function. (Code No. 002: Controller Model Code: No. 003) !Input of model selecting signals (ON or OFF) can be confirmed in the monitoring function.(Code No. 027:Switch Input 2) Cause

Presumed cause and standard value in normalcy

Model selecting connector defective 1 (Internal disconnection or short-circuiting)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C09 (female)

Resistance value

Between (2), (4) and (8)

Below 1 Ω

Between (1), (3), (7) and (8)

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)

Wiring harness between C02 (female) (7) and C09 (male) (4)

Resistance value

Below 1 Ω

Wiring harness between C02 (female) (27) and C09 (male) (2)

Resistance value

Below 1 Ω

Between wiring harness between C09 (male) (8) and grounding

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 3 (Contact with grounding circuit)

Between wiring harness between C02 (female) (13) and C09 (male) (7) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between C02 (female) (17) and C09 (male) (3) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between C02 (female) (37) and C09 (male) (1) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4

Governor • pump controller defective

20-344 (1)

C02

Voltage

Between (13), (17), (37) and grounding

20 – 30 V

Between (7), (27) and grounding

Below 1 V

PC160LC-7

TROUBLESHOOTING

E217

Related circuit diagram

PC160LC-7

20-345 (1)

E218

TROUBLESHOOTING

Error Code in Electrical System E218 Disconnection of S-NET signal) User Code

Error Code

Failure Code

—

E218

DA2SKA

Failure phenomenon

Disconnection in S-NET signal (in governor • pump controller system)

Failure content

• A failure occurred in S-NET communication between the monitor panel and controller in the past. (The machine operation returned to normalcy, when the display was resumed)

Response from controller

• While the failure is still continuing, the machine operation is controlled by the following default setting. 1) Working mode: E mode 2) Travel speed: Lo 3) Auto-decelerator: ON 4) Attachment oil flow rate: Minimum (When an attachment is installed) • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon occurring on machine

• The working mode cannot be changed. (The display changes normally in the monitor panel) • The travel speed cannot be shifted. (The display changes normally in the monitor panel) • The auto-decelerator cannot be released. (The display changes normally in the monitor panel) • The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel)

Relative information

• This Error Code No. is displayed to inform that there was a failure occurred in the past, when S-NET communication between the monitor panel and the governor • pump controller is returned to normalcy. • The communication has already returned to normalcy by the time this Error Code No. is displayed. But thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a failure in order to prevent recurrence of failures.

Presumed cause and standard value in normalcy

Cause Disconnection of wiring harness 1 (Disconnection or defective contact with connector)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (9) (10) and C02 (female) (21)

Resistance value

Below 1 Ω

Wiring harness between P02 (female) (20) and C02 (female) (31)

Resistance value

Below 1 Ω

Grounding fault of wiring harness 2 (Contact with grounding circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between P02 (female) (9) (10) and C02 (female) (21) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective

Governor • pump controller defective

20-346 (1)

P02 (male)

Voltage

Between (9) (10) and (20)

6–9V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02 (male)

Voltage

Between (21) and (31)

6–9V

PC160LC-7

TROUBLESHOOTING

E218

Related circuit diagram

PC160LC-7

20-347 (1)

E224

TROUBLESHOOTING

Error Code in Electrical System E224 (Abnormality in F pump pressure sensor) User Code

Error Code

Failure Code

E224

DHPAMA

—

Failure phenomenon

Abnormality in F pump pressure sensor (in governor • pump controller system)

Failure content

• Signal voltage from the F pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.

Response from controller

• The controller controls the F pump pressure at 0 MPa{0 kg/cm2}. • If the failure cause disappears, the sensor returns to normalcy of itself.

Phenomenon occurring on machine

• The travel speed does not shift automatically.

Relative information

!If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected reversely, the pressure sensor will be broken. Accordingly, take care extremely when checking. • Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function. (Code No. 011: F pump pressure) Cause

Sensor power source fault

Standard value in normalcy and references for troubleshooting If the Service Code No. [E226] is displayed, troubleshoot the failure first. !Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. A51

Presumed cause and standard value in normalcy

F pump pressure sensor 2 defective (Internal failure)

Voltage

Between (B) and (A)

Power source

4.5 – 5.5 V

Between (C) and (A)

Signal

0.5 – 4.5 V

The voltage of the pressure sensor is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller to confirm that there is not another cause of the failure before judging the troubleshooting result. !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

Grounding fault of wiring harness 4 (Contact with grounding circuit)

Short-circuiting of wiring harness 5 (Contact with 24 V circuit)

Wiring harness from C01 (female) (22) to J07 to A51 (female) (B)

Resistance value

Below 1 Ω

Wiring harness between C01 (female) (10) and A51 (female) (A)

Resistance value

Below 1 Ω

Wiring harness between C01 (female) (8) and A51 (female) (C)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (8) and A51 (female) (C) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C01 (female) (22) to J07 and A51 (female) (B) and grounding

Voltage

Below 1 V

Between wiring harness between C01 (female) (8) and A51 (female) (C) ang grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6

Governor • pump controller defective

20-348 (1)

C01

Voltage

Between (22) and (10)

Power source

4.5 – 5.5 V

Between (8) and (10)

Signal

0.5 – 4.5 V

PC160LC-7

TROUBLESHOOTING

E224

Related circuit diagram

PC160LC-7

20-349 (1)

E225

TROUBLESHOOTING

Error Code in Electrical System E225 (Abnormality in R pump pressure sensor) User Code

Error Code

Failure Code

E225

DHPBMA

—

Failure phenomenon

Abnormality in R pump pressure sensor (in governor • pump controller system)

Failure content

• Signal voltage from the R pump pressure sensor dropped below 0.3 V or exceeded 4.42 V.

Response from controller

• The controller controls the R pump pressure as 0 MPa {0 kg/cm2}. • If the failure cause disappears, the sensor returns to normalcy of itself.

Phenomenon occurring on machine

• The travel speed does not shift automatically.

Relative information

!If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected reversely, the pressure sensor will be broken. Accordingly, take care extremely when checking. • Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function. (Code No. 012: R pump pressure) Cause

Sensor power source fault

Presumed cause and standard value in normalcy

R pump pressure sen2 sor defective (Internal failure)

Voltage

Between (B) and (A)

Power source

4.5 – 5.5 V

Between (C) and (A)

Signal

0.5 – 4.5 V

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

Grounding fault of wiring harness 4 (Contact with grounding circuit)

Short-circuiting of wiring harness 5 (Contact with 24 V circuit)

Wiring harness from C01 (female) (22) to J07 and A52 (female) (B)

Resistance value

Below 1 Ω

Wiring harness between C01 (female) (10) and A52 (female) (A)

Resistance value

Below 1 Ω

Wiring harness between C01 (female) (2) and A52 (female) (C)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (2) and A52 (female) (C) and grounding

Resistance value

Above 1 MΩ

Voltage

Below 1 V

Between wiring harness between C01 (female) (2) and A52 (female) (C) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6

Governor • pump controller defective

20-350 (1)

C01

Voltage

Between (22) and (10)

Power source

4.5 – 5.5 V

Between (2) and (10)

Signal

0.5 – 4.5 V

PC160LC-7

TROUBLESHOOTING

E225

Related circuit diagram

PC160LC-7

20-351 (1)

E226

TROUBLESHOOTING

Error Code in Electrical System E226 (Abnormality in pressure sensor power source) User Code

Error Code

Failure Code

—

E226

DA25KP

Failure phenomenon

Abnormality in pressure sensor power source (in governor • pump controller system)

Failure content

• Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.

Response from controller

• The controller turns OFF power supply to the power source circuit (5 V). • Even when the failure cause disappears of itself, the current does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• Signals from the pressure sensors and potentiometer are not inputted correctly. • The Error Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at the same time. Cause

Presumed cause and standard value in normalcy

Pressure sensor or 1 potentiometer defective (Internal short-circuit)

Standard value in normalcy and references for troubleshooting Disconnect the following equipment one by one. Equipment that shows no error code is defective, having an internal failure. !Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Fuel dial

E06 Connector

Governor potentiometer

E10 Connector

F pump pressure sensor

A51 Connector

R pump pressure sensor

A52 Connector

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness 2 (Contact with grounding circuit)

Governor • pump controller defective

20-352 (1)

Between wiring harness from C01 (female) (22) to J07 to E06 (female) (1) and grounding [Fuel dial system]

Resistance value

Above 1 MΩ

Between wiring harness from C01 (female) (22) to J07 to E10 (female) (A) and grounding [Governor potentiometer system]

Resistance value

Above 1 MΩ

Between wiring harness from C01 (female) (22) to J07 to A51 (female) (B) and grounding [F pump pressure sensor system]

Resistance value

Above 1 MΩ

Between wiring harness from C01 (female) (22) to J07 to A52 (female) (B) and grounding [R pump pressure sensor system]

Resistance value

Above 1 MΩ

Between wiring harness from C01 (female) (22) to J07 to A08 (male) (7) and grounding [Attachment system]

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C01

Voltage

Between (22) and (10)

4.5 – 5.5 V

PC160LC-7

TROUBLESHOOTING

E226

Related circuit diagram

PC160LC-7

20-353 (1)

E227

TROUBLESHOOTING

Error Code in Electrical System E227 (Abnormality in engine rotation sensor) User Code

Error Code

Failure Code

—

E227

DLE2MA

Failure phenomenon

Abnormality in engine rotation sensor (in governor • pump controller system)

Failure content

• A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.

Response from controller

• The controller exercises a control equivalent to E mode. • If the failure cause disappears of itself, the signal input returns to normalcy.

Phenomenon occurring on machine

• The machine lacks power a bit. (The engine speed cannot be sensed)

Relative information

• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function. (Code No. 010: Engine RPM)

Presumed cause and standard value in normalcy

Cause Engine rotation sensor fault 1 (Internal short-circuiting or disconnection)

Engine rotation sensor adjustment improper

Disconnection of wiring harness 3 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E04 (male)

Resistance value

Between (1) and (2)

500 – 1,000 Ω

Between (1) and grounding

Above 1 MΩ

For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation Sensor" in this manual. !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (40) and E04 (female) (1)

Resistance value

Below 1 Ω

Wiring harness between C02 (female) (29) (39) and E04 (female) (2)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) (40) and E04 (female) (1) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5

Governor • pump controller defective

20-354 (1)

C02 (female)

Resistance value

Between (40) and (29) (39)

500 – 1,000 Ω

Between (40) and grounding

Above 1 MΩ

PC160LC-7

TROUBLESHOOTING

E227

Related circuit diagram

PC160LC-7

20-355 (1)

E228

TROUBLESHOOTING

Error Code in Electrical System E228 (Short-circuiting in attachment return switching relay) User Code

Error Code

Failure Code

—

E228

D196KB

Failure phenomenon

Short-circuiting in attachment return switching relay (in governor • pump controller system)

• Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).

Response from controller

• The controller turned OFF power to the attachment return switching relay circuit. • Even when the failure cause disappears of itself, the current does not return to normalcy.

Phenomenon occurring on machine

• The hydraulic circuit for attachments is not switched to the single operation circuit. (The selector valve is not switched to the tank circuit)

Relative information

• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No. 024:Solenoid 2) • This error code detects abnormality on the primary side (coil side) of the attachment return switching relay but does not detect abnormality on the secondary side (contact side).

Presumed cause and standard value in normalcy

Failure content

Cause Attachment return switching relay defective 1 (Internal short-circuiting or grounding fault) Short-circuiting of wiring harness 2 (Contact with 24 V circuit)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male)

Resistance value

Between (1) and (2)

100 – 500 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) (8) and R20 (female) (2) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3

Governor • pump controller defective

C02 Between (8) and grounding

20-356 (1)

Working mode

Voltage

Other than B mode

20 – 30 V

B mode

Below 1 V

PC160LC-7

TROUBLESHOOTING

E228

Related circuit diagram

PC160LC-7

20-357 (1)

E232

TROUBLESHOOTING

Error Code in Electrical System E232 (Short-circuiting in PC-EPC solenoid) User Code

Error Code

Failure Code

E232

DXA0KB

E02

Failure phenomenon

Short-circuiting in PC-EPC solenoid (in governor • pump controller system)

Failure content

• Abnormal current flew to the PC-EPC solenoid circuit.

Response from controller

• The controller reduces the output to the PC-EPC solenoid circuit to OFF. • Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled)

Relative information

• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No. 013: PC-EPC solenoid current) • If the solenoid and wiring harness are free from abnormality, the machine can be operated with the output equivalent to E-mode by setting the emergency pump driving switch in the emergency position (Error code [E233] is displayed at this time, but it does not indicate abnormality). • Keep the emergency pump driving switch in the normal position during troubleshooting.

Presumed cause and standard value in normalcy

Cause PC-EPC solenoid defective 1 (Internal short-circuiting or grounding fault)

Defective emergency pump driving switch 2 (Internal short-circuiting or grounding fault)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V21 (male)

Resistance value

Between (1) and (2)

7 – 14 Ω

Between (1) and grounding

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S25 (male)

Emergency pump driving switch

Between (3) and (4) Between (3) and grounding

Grounding fault of wiring harness 3 (Contact with grounding circuit)

Normal

Resistance value Above 1 MΩ Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (16) to S25 (female) (3) and grounding

Resistance value

Above 1 MΩ

Between wiring harness from S25 (female) (2) to V21 (female) (1) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4

Governor • pump controller defective

20-358 (1)

C03 (female)

Resistance value

Between (16) and (3) (13) (23)

7 – 14 Ω

Between (16) and grounding

Above 1 MΩ

PC160LC-7

TROUBLESHOOTING

E232

Related circuit diagram

PC160LC-7

20-359 (1)

E233

TROUBLESHOOTING

Error Code in Electrical System E233 (Disconnection in PC-EPC solenoid) User Code

Error Code

Failure Code

E233

DXA0KA

E02

Failure phenomenon

Disconnection in PC-EPC solenoid (in governor • pump controller system)

Failure content

• No current flows to the PC-EPC solenoid circuit.

Response from controller

• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the current returns to normalcy.

Phenomenon occurring on machine

• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled)

Relative information

• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No. 013: PC-EPC solenoid current) • If the solenoid and wiring harness are free from abnormality, the machine can be operated with the output equivalent to E-mode by setting the emergency pump driving switch in the emergency position. • Keep the emergency pump driving switch in the normal position during troubleshooting. Cause

PC-EPC solenoid 1 defective (Internal short-circuiting)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V21 (male)

Resistance value

Between (1) and (2)

7 – 14 Ω

Presumed cause and standard value in normalcy

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Emergency pump driving 2 switch defective (Internal disconnection)

S25 (male)

Emergency pump driving switch

Between (2) and (3) Between (5) and (6)

Resistance value

Normal

Below 1 Ω

Emergency

Above 1 MΩ

Normal

Below 1 Ω

Emergency

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

Short-circuiting of wiring harness 4 (Contact with 24 V circuit)

Governor • pump controller defective

20-360 (1)

Wiring harness between C03 (female) (16) and S21 (3)

Resistance value

Below 1 Ω

Wiring harness between S21 (2) and V21 (female) (1)

Resistance value

Below 1 Ω

Wiring harness between C03 (female) (3) (13) (23) and S25 (female) (6)

Resistance value

Below 1 Ω

Wiring harness between S25 (female) (5) and V21 (female) (2)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (16) and S25 (female) (3) and grounding

Voltage

Below 1 V

Between wiring harness between S25 (female) (2) and V21 (female) (1) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (16) and (3) (13) (23)

7 – 14 Ω

PC160LC-7

TROUBLESHOOTING

E233

Related circuit diagram

PC160LC-7

20-361 (1)

E238

TROUBLESHOOTING

Error Code in Electrical System E238 (Disconnection in attachment return switching relay) User Code

Error Code

Failure Code

—

E238

D196KA

Failure phenomenon

Disconnection in attachment return switching relay (in governor • pump controller system)

Failure content

• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24 V voltage is not generated.

Response from controller

• None in particular • If the failure cause disappears, the governor returns to normalcy.

Phenomenon occurring on machine

• The hydraulic circuit for attachments cannot be switched to the single operation (The selector valve is not switched to the tank circuit)

Relative information

Presumed cause and standard value in normalcy

1 Fuse No. 2 fault Attachment return 2 switching relay defective (Internal disconnection)

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

Grounding fault of wiring harness 4 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting If the fuse No. 2 has been blown, there is a big possibility that grounding fault occurred in the relay circuit. (Cause 4 reference) !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male)

Resistance value

Between (1) and (2)

100 – 500 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (8) and R20 (female) (2)

Resistance value

Below 1 Ω

Wiring harness from R20 (female) (1) to J03 to FB1-2 outlet

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) (8) and R20 (female) (2) and grounding

Resistance value

Above 1 MΩ

Between wiring harness from R20 (female) (1) to J03 to FB1-2 outlet and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5

Governor • pump controller defective

C02 Between (8) and grounding

20-362 (1)

Working mode

Voltage

Other than B mode

20 – 30 V

B mode

Below 1 V

PC160LC-7

TROUBLESHOOTING

E238

Related circuit diagram

PC160LC-7

20-363 (1)

E245

TROUBLESHOOTING

Error Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC solenoid) User Code

Error Code

Failure Code

—

E245

DXE4KB

Failure phenomenon

Short-circuiting in attachment oil flow rate adjusting EPC solenoid (in governor • pump controller system)

• Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.

Response from controller

• The controller turns OFF power to the attachment oil flow rate adjusting EPC solenoid circuit. • Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The attachments do not move. (The PPC basic pressure is not supplied to the service PPC valve)

Relative information

• It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Presumed cause and standard value in normalcy

Failure content

Cause Attachment oil flow rate adjusting EPC solenoid 1 defective (Internal short-circuiting or grounding fault) Grounding fault of wiring harness 2 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V30 (male)

Resistance value

Between (1) and (2)

7 – 14 Ω

Between (1) and grounding

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (female) (1) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3

Governor • pump controller defective

C03 (female)

Resistance value

Between (26) and (3) (13) (23)

7 – 14 Ω

Between (26) and grounding

Above 1 MΩ

Related circuit diagram

20-364 (1)

PC160LC-7

E246

TROUBLESHOOTING

Error Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC solenoid) User Code

Error Code

Failure Code

—

E246

DXE4KA

Failure phenomenon

Disconnection in attachment oil flow rate adjusting EPC solenoid (in governor • pump controller system)

• No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.

Response from controller

• None in particular (The solenoid does not work, as there is no current flowing to it) • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.

Phenomenon occurring on machine

• The attachments do not move. (The PPC basic pressure is not supplied to the service PPC valve)

Relative information

• It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Presumed cause and standard value in normalcy

Failure content

Cause

Standard value in normalcy and references for troubleshooting

Attachment oil flow rate adjusting EPC solenoid 1 defective (Internal short-circuiting or grounding fault)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)

Governor • pump controller defective

V30 (male)

Resistance value

Between (1) and (2)

7 – 14 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (male) (1) and grounding

Resistance value

Below 1 Ω

Between wiring harness between C03 (female) (3) (13) (23) and V30 (male) (2) and grounding

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (26) and V30 (female) (1) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)

Resistance value

Between (26) and (3) (13) (23)

7 – 14 Ω

Related circuit diagram

PC160LC-7

20-365 (1)

E306

TROUBLESHOOTING

Error Code in Electrical System E306 (Abnormality in governor potentiometer) User Code

Error Code

Failure Code

E306

DK54KZ

—

Failure phenomenon

Abnormality in governor potentiometer (in governor • pump controller)

Failure content

• Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.

Response from controller

• The controller exercises control by computing the motor position through voltage right before a failure occurred. • Even if the failure cause disappears of itself, the governor potentiometer does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The engine cannot attain the specified rotation at high idling. (A bit lower) • The engine cannot attain the specified rotation at low idling (A bit higher) • The auto-decelerator or automatic warming-up function does not work. • There is hunting while the engine is running. • The engine stalls. • The engine does not stop.

Relative information

• Input from the governor potentiometer (voltage) can be confirmed in the monitor function. (Code No. 031: Governor potentiometer voltage) Cause

Sensor power source defective

Standard value in normalcy and references for troubleshooting If Service Code No. [E226] is displayed, troubleshoot the failure first. !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Presumed cause and standard value in normalcy

Governor potentiometer 2 defective (Internal failure)

E10 (male)

Resistance value

Between (A) and (C)

4.0 – 6.0 kΩ

Between (B) and (A)

0.25 – 5.0 kΩ

Between (B) and (C)

0.25 – 5.0 kΩ

Grounding fault of wiring harness 4 (Contact with grounding circuit)

Short-circuiting of wiring harness 5 (Contact with 24 V circuit)

Wiring harness from C01 (female) (22) to J07 to E10 (female) (A)

Resistance value

Below 1 Ω

Wiring harness between C01 (female) (21) and E10 (female) (C)

Resistance value

Below 1 Ω

Wiring harness between C01 (female) (13) and E10 (female) (B)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (13) and E10 (female) (B) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from C01 (female) (22) to J07 to E10 (female) (A) and grounding

Voltage

Below 1 V

Between wiring harness between C01 (female) (13) and E10 (female) (B) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 6

Governor • pump controller defective

20-366 (1)

C01

Resistance value

Between (22) and (21)

Power sourse

4.5 – 5.5 V

Between (13) and (21)

Signal

0.5 – 4.5 V

PC160LC-7

TROUBLESHOOTING

E306

Related circuit diagram

PC160LC-7

20-367 (1)

E308

TROUBLESHOOTING

Error Code in Electrical System E308 (Abnormality in fuel dial) User Code

Error Code

Failure Code

E308

DK10KZ

E05

Failure phenomenon

Abnormality in fuel dial (in governor • pump controller)

Failure content

• Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.

Response from controller

• The controller exercises control by computing the fuel dial position through voltage right before a failure occurred. • If the failure cause disappears, the fuel dial returns to normalcy.

Phenomenon occurring on machine

• If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL. • If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL. • There is hunting while the engine is running. • The engine cannot attain the specified rotation at high idling and lacks power.

Relative information

• Input from the fuel dial (voltage) can be confirmed in the monitor function. (Code No. 030: Fuel dial voltage) Cause

Sensor power source defective

Presumed cause and standard value in normalcy

Fuel dial defective (Internal failure)

E06 (male)

Resistance value

Between (1) and (3)

4.0 – 6.0 kΩ

Between (2) and (1)

0.25 – 5.0 kΩ

Between (2) and (3)

0.25 – 5.0 kΩ

Grounding fault of wiring harness 4 (Contact with grounding circuit)

Short-circuiting of wiring harness 5 (Contact with 24 V circuit)

Wiring harness from C01 (female) (22) to J07 to E06 (female) (1)

Resistance value

Below 1 Ω

Wiring harness between C01 (female) (21) and E06 (female) (3)

Resistance value

Below 1 Ω

Wiring harness between C01 (female) (19) and E06 (female) (2)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (19) and E06 (female) (2) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from C01 (female) (22) to J07 to E06 (female) (1) and grounding

Voltage

Below 1 V

Between wiring harness between C01 (female) (19) and E06 (female) (2) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 6

Governor • pump controller defective

20-368 (1)

C01

Resistance value

Between (22) and (21)

Power sourse

4.5 – 5.5 V

Between (19) and (21)

Signal

0.5 – 4.5 V

PC160LC-7

TROUBLESHOOTING

E308

Related circuit diagram

PC160LC-7

20-369 (1)

E311

TROUBLESHOOTING

Error Code in Electrical System E311 (Short-circuiting in cold starting solenoid relay) User Code

Error Code

Failure Code

E311

D199KB

—

Failure phenomenon

Short-circuiting in cold starting solenoid relay (in governor•pump controller system)

• Abnormal current flowed when the cold starting solenoid relay circuit was grounded (power ON).

Response from controller

• The controller turns OFF power to the cold starting solenoid relay circuit. • Even when the failure cause disappears, the current does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The engine does not start easily or at all when temperature is low. (The fuel injection pump rack does not move in the increasing direction.)

Relative information

• This error code detects abnormality on the primary side (coil side) of the cold starting solenoid relay but does not detect abnormality on the secondary side (contact side).

Presumed cause and standard value in normalcy

Failure content

Cause Cold starting solenoid relay defective 1 (Internal short-circuiting or grounding fault) Short-circuiting of wiring harness 2 (Contact with 24 V circuit)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R22 (male)

Resistance value

Between (1) and (2)

100 – 500 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) (9) and R22 (female) (2) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and perform troubleshooting when turning it ON. 3

Governor • pump controller defective

C02

Engine water temperature

Voltage

Below 0°C

20 – 30 V (for 3 sec at max)

0°C or higher

Below 1 V

Between (9) and grounding

20-370 (1)

PC160LC-7

TROUBLESHOOTING

E311

Related circuit diagram Serial No.: 10001 – 11000

Serial No.: 11001 and up

PC160LC-7

20-371 (4)

E312

TROUBLESHOOTING

Error Code in Electrical System E312 (Disconnection in cold starting solenoid relay) User Code

Error Code

Failure Code

E312

D199KA

—

Failure phenomenon

Disconnection in cold starting solenoid relay (in governor • pump controller system)

Failure content

• When the cold starting solenoid relay is disconnected from grounding (power OFF), 24 V voltage is not generated.

Response from controller

• None in particular. • If the failure cause disappears, the voltage returns to normalcy.

Phenomenon occurring on machine

• The engine does not start easily or at all when temperature is low. (The fuel injection pump rack does not move in the increasing direction.)

Relative information

• This error code detects abnormality on the primary side (coil side) of the cold starting solenoid relay but does not detect abnormality on the secondary side (contact side). Cause

Presumed cause and standard value in normalcy

1 Fuse No. 2 defective Cold starting solenoid 2 relay defective (Disconnection)

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

Grounding fault of wiring harness 4 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting If fuse No. 2 is broken, the circuit probably has grounding fault (See cause 4). !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R22 (male)

Resistance value

Between (1) and (2)

100 – 500 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (9) and R22 (female) (2)

Resistance value

Below 1 Ω

Wiring harness between R22 (female) (1), J03, and FB1-2 outlet

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) (8) and R22 (female) (2) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between R22 (female) (1), J03, and FB1-2 outlet and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and perform troubleshooting when turning it ON. Governor • pump 5 controller defective

C02

Engine water temperature

Voltage

Below 0°C

20 – 30 V (for 3 sec at max)

0°C or higher

Below 1 V

Between (9) and grounding

20-372 (1)

PC160LC-7

TROUBLESHOOTING

E312

Related circuit diagram Serial No.: 10001 – 11000

Serial No.: 11001 and up

PC160LC-7

20-373 (4)

E315

TROUBLESHOOTING

Error Code in Electrical System E315 (Short-circuiting in battery relay) User Code

Error Code

Failure Code

—

E315

D110KB

Failure phenomenon

Short-circuiting in battery relay (in governor • pump controller)

• Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.

Response from controller

• The controller turns OFF power to the battery drive circuit. • Even when the failure cause disappears, the relay does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The engine does not stop. (The controller power cannot be maintained until the engine stops)

Relative information

• It can be confirmed in the monitor function how the battery relay works (ON or OFF). (Code No. 037: Controller output)

Presumed cause and standard value in normalcy

Failure content

Cause

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Battery relay defective (Internal failure)

Grounding fault of wiring harness 2 (Contact with grounding circuit)

Battery relay (Unit)

Resistance value

Between A21 (BR terminal) and A20 (E terminal)

Approx. 100 Ω

Between A21 (BR terminal) and grounding

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (4) to D01 to J01 to A21 (BR terminal) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3

Governor • pump controller defective

20-374 (1)

C03 (female)

Engine starting switch

Voltage

Between (4) and grounding

ON → OFF

20 – 30 V (for 4 to 7 seconds)

PC160LC-7

TROUBLESHOOTING

E315

Related circuit diagram

PC160LC-7

20-375 (1)

E316

TROUBLESHOOTING

Error Code in Electrical System E316 (Step-out in governor motor) User Code —

Error Code

Failure Code

E316

DY10K4

Failure phenomenon

Step-out in governor motor (in governor • pump controller)

Failure content

• There is a big difference between signals from the potentiometer and the set values in the controller.

Response from controller

• The controller repeats the same controlling motions (step-out). • Even when the failure cause disappears, the governor motor does not return to normalcy, unless the engine starting switch is once turned OFF.

Phenomenon occurring on machine

• The engine rotation cannot be controlled. • There is hunting in the rotation. • The engine does not stop.

Presumed cause and standard value in normalcy

Cause 1 Fuel dial defective

If Service Code [E308] is displayed, troubleshoot that failure first.

2 Governor potentiometer system defective

If Service Code [E306] is displayed, troubleshoot that failure first.

Governor motor system defective (disconnection)

If Service Code [E317] is displayed, troubleshoot that failure first.

Governor motor system defective (short-circuiting)

If Service Code [E318] is displayed, troubleshoot that failure first.

5 Governor lever adjustment improper

Refer to the section of "Inspection and Adjustment - Special Function of Monitor Panel" in this manual.

6 Engine fuel control system defective

Refer to 102 series Engine Shop Manual.

7 Governor • pump controller defective

As this is an internal failure, no troubleshooting can be carried out. (If there is none of the failures listed above, the controller is judged as defective)

20-376 (1)

Standard value in normalcy and references for troubleshooting

PC160LC-7

E317

TROUBLESHOOTING

Error Code in Electrical System E317 (Disconnection in governor motor Phase A and B) User Code

Error Code

Failure Code

E317

DY10KA

E05

Failure phenomenon

Disconnection in governor motor Phase A and B (in governor • pump controller)

Failure content

• No current flew to the governor motor, when power was supplied to the motor.

Response from controller

• None in particular. • If the failure cause disappears, the governor returns to normalcy.

Phenomenon occurring on machine

• The engine rotation drops to low idling. • There is hunting in the rotation • The engine does not stop. • The governor motor steps out.

Relative information

• Operation of the governor motor (current) can be confirmed in the monitor function. (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Presumed cause and standard value in normalcy

Cause

Governor motor defec1 tive (Internal disconnection)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E11 (male)

Resistance value

Between (1) and (2)

2.5 – 7.5 Ω

Between (3) and (4)

2.5 – 7.5 Ω

Wiring harness between C03 (female) (5) and E11 (female) (1)

Resistance value

Below 1 Ω

Wiring harness between C03 (female) (15) and E11 (female) (2)

Resistance value

Below 1 Ω

Wiring harness between C03 (female) (25) and E11 (female) (3)

Resistance value

Below 1 Ω

Wiring harness between C03 (female) (35) and E11 (female) (4)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3

Governor • pump controller defective

PC160LC-7

C03 (female)

Resistance value

Between (5) and (15)

2.5 – 7.5 Ω

Between (25) and (35)

2.5 – 7.5 Ω

20-377 (1)

TROUBLESHOOTING

E317

Related circuit diagram

20-378 (1)

PC160LC-7

E318

TROUBLESHOOTING

Error Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) User Code

Error Code

Failure Code

E05

E318

DY10KB

Failure phenomenon

Short-circuiting in governor motor Phase A and Phase B (in governor • pump controller system)

Failure content

• Abnormal current flew to the governor motor, when power is supplied to the motor.

Response from controller

• None in particular • If the failure cause disappears, the governor motor returns to normalcy.

Phenomenon occurring on machine

• The engine rotation cannot be controlled. • The engine rotation drops to low idling. • There is hunting in the rotation. • The engine does not stop.

Relative information

• Operation of the governor motor (current) can be confirmed in the monitor function. (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current) Cause

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Presumed cause and standard value in normalcy

Governor motor defective 1 (Internal short-circuiting or grounding fault)

E11 (male)

Resistance value

Between (1) and (2)

2.5 – 7.5 Ω

Between (3) and (4)

2.5 – 7.5 Ω

Between (1) and grounding

Above 1 MΩ

Between (3) and grounding

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)

Between wiring harness between C03 (female) (5) and E11 (female) (1) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between C03 (female) (15) and E11 (female) (2) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between C03 (female) (25) and E11 (female) (3) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between C03 (female) (35) and E11 (female) (4) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Governor • pump 3 controller defective

20-380 (1)

Resistance value

Between (5) and (15)

2.5 – 7.5 Ω

Between (25) and (35)

2.5 – 7.5 Ω

Between (5) and grounding

Above 1 MΩ

Between (15) and grounding

Above 1 MΩ

Between (25) and grounding

Above 1 MΩ

Between (35) and grounding

Above 1 MΩ

PC160LC-7

TROUBLESHOOTING

E318

Related circuit diagram

PC160LC-7

20-381 (1)

A000N1 / A000N2

TROUBLESHOOTING

Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling) User Code —

Error Code

Failure Code

—

A000N1

Failure phenomenon

Out-of-rate engine rotation at high idling (in mechanical system)

Failure content

• Engine rotation above 2,650 rpm was detected for more than 10 seconds, while the engine was running.

Response from controller

• None in particular • If the failure cause disappears of itself, the engine rotation returns to normalcy.

Phenomenon occurring on machine

• There is a possibility that the engine is damaged, if is used continuously without adjustment.

Relative information

• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function. (Code No. 010: Engine rotation) Cause

Presumed cause and standard value in normalcy

Standard value in normalcy and references for troubleshooting

Check if there has been an internal or external factor that would cause Failure in engine mechan1 the engine to overrun at high idling, and troubleshoot the mechanical ical system system of the engine. 2

Governor • pump controller defective

As this is an internal failure, troubleshooting cannot be conducted. (Unless there is any visible trouble found in the machine, use of the controller may be continued as it is)

Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling) User Code

Error Code

Failure Code

—

A000N2

Failure phenomenon

Out-of-rate engine rotation at low idling (in mechanical system)

Failure content

• Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.

Response from controller

• None in particular • If the failure cause disappears of itself, the rotation returns to normalcy.

Phenomenon occurring on machine

• There is a possibility that the engine is damaged, if it is used continuously without adjustment.

Relative information

• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function. (Code No. 010: Engine rotation) Cause

Presumed cause and standard value in normalcy

20-382 (1)

Standard value in normalcy and references for troubleshooting

Check if there has been an internal or external factor that would cause Failure in engine mechanthe engine to overrun at high idling, and troubleshoot the mechanical ical system system of the engine.

Governor • pump controller defective

As this is an internal failure, troubleshooting cannot be conducted. (Unless there is any visible trouble found in the machine, use of the controller may be continued as it is)

PC160LC-7

AA10NX

TROUBLESHOOTING

Failure Code in Mechanical System AA10NX (Air cleaner clogging) User Code

Error Code

Failure Code

—

AA10NX

—

Failure phenomenon

Air cleaner clogged (in mechanical system)

Failure content

• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. disconnected from grounding circuit).

Response from controller

• None in particular

Phenomenon occurring on machine

• There is a possibility that the engine is damaged, if it is used continuously without corrective action.

Relative information

• This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor panel while the engine is running. • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel. (Code No. 046: Monitor input 2)

Presumed cause and standard value in normalcy

Cause Air cleaner clogged 1 (when the system is in normal condition)

Air cleaner clogging 2 switch defective (Internal disconnection)

Standard value in normalcy and references for troubleshooting !Check the air cleaner for clogging. If it is clogged, clean or replace it with new one. !Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. A31 (male) Between (1) and (2)

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

Air cleaner

Resistance value

When in normal condition

Below 1 Ω

When clogged

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. Wiring harness between P02 (female) (5) and A31 (female) (1)

Resistance value

Below 1 Ω

Between wiring harness A31 (female) (2) and grounding

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Monitor panel defective

P02 Between (5) and grounding

Air cleaner

Voltage

When in normal condition

Below 1 V

When clogged

20 – 30 V

Related circuit diagram

PC160LC-7

20-383 (1)

AB00KE

TROUBLESHOOTING

Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage) User Code

Error Code

Failure Code

—

AB00KE

—

Failure phenomenon

Abnormally lowered charging voltage (in mechanical system)

Failure content

• Generation signal from the alternator is not inputted, while the engine is running.

Response from controller

• None in particular

Phenomenon occurring on machine

• There is a possibility that the battery may not be charged, if charging is continued without corrective action.

Relative information

• If the charge monitor of the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the alternator (voltage) can be confirmed in the monitor function. (Code No. 043: Charging voltage)

Presumed cause and standard value in normalcy

Cause

Alternator defective (short generating output)

Disconnection of wiring harness 2 (Disconnection or defective contact with connector)

Grounding fault of wiring harness 3 (Contact with grounding circuit)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. E12 (male)

Engine rotation

Voltage

Between (1) and grounding

Above medium speed

27.5 – 29.5 V

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from P02 (female) (11) to J02 to E12 (female) (1)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between each wiring harness between C02 (female) (11), J02, and E12 (female) (1), between C02 (female) (11) and A27 (female) (2), between C02 (female) (11) and D01 (female) (6), and between C02 (female) (11) and other related circuits and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Monitor panel defective

20-384 (1)

P02

Engine rotation

Voltage

Between (11) and grounding

Above medium speed

27.5 – 29.5 V

PC160LC-7

TROUBLESHOOTING

AB00KE

Related circuit diagram

PC160LC-7

20-385 (1)

B@BAZG

TROUBLESHOOTING

Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) User Code

Error Code

Failure Code

—

B@BAZG

Failure phenomenon

Abnormally lowered engine oil pressure (in mechanical system)

• The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the engine was running.

Response from controller

• None in particular

Phenomenon occurring on machine

• There is a possibility that the engine may seize, if the engine is kept running without corrective action.

Relative information

• If the engine oil pressure monitor of the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function. (Code No. 046: Monitor input 2)

Presumed cause and standard value in normalcy

Failure content

Cause

Standard value in normalcy and references for troubleshooting

Engine oil pressure low1 ered (the system in normal condition)

Check the engine oil pressure. If it is abnormal, inspect failure cause and damage of the engine, and then repair.

Engine oil pressure 2 switch defective (Internal short-circuiting)

Grounding fault of wiring harness 3 (Contact with grounding circuit)

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. E02 (Unit)

Engine oil pressure

Resistance value

Between terminal and grounding

When in normal condition

Above 1 MΩ

When lowered

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (7) and E02 (terminal) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Monitor panel defective

P02 Between (7) and grounding

Engine oil pressure

Voltage

When in normal condition

20 – 30 V

When lowered

Below 1 V

Related circuit diagram

20-386 (1)

PC160LC-7

B@BAZK

TROUBLESHOOTING

Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level) User Code

Error Code

Failure Code

—

B@BAZK

Failure phenomenon

Abnormally lowered engine oil level (in mechanical system)

Failure content

• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the engine is stopped (with the starting switch in the ON position).

Response from controller

• None in particular

Phenomenon occurring on machine

• There is a possibility that the engine seizes if it is kept running without a corrective action.

Relative information

• If the engine oil level monitor of the monitor panel lights up in red while the engine is stopped (with the starting switch in ON position), this failure code is recorded. • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No. 046: Monitor input 2)

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Engine oil level lowered !Check the oil level in the engine oil pan. If it is low, add oil. 1 (System in normal condi(If the phenomenon occurs frequently, check the cause) tion)

Engine oil level switch 2 defective (Internal disconnection)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E03 (male) Between (1) and grounding

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

Engine oil level

Resistance value

When in normal condition

Below 1 Ω

When lowered

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (8) and E03 (female) (1)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective

P02 Between (8) and grounding

Engine oil level

Voltage

When in normal condition

Below 1 V

When lowered

20 – 30 V

Related circuit diagram

PC160LC-7

20-387 (1)

B@BCNS

TROUBLESHOOTING

Failure Code in Mechanical System B@BCNS (Engine cooling water overheating) User Code

Error Code

Failure Code

—

B@BCNS

Failure phenomenon

Engine cooling water overheated (in mechanical system)

• The engine cooling water sensor inputted a signal of 102°C, while the engine was running.

Response from controller

• Response from controller

Phenomenon occurring on machine

• There is a possibility that the engine seizes, if it is kept running without a corrective action.

Relative information

• If the engine water temperature monitor of the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the engine cooling water temperature sensor (temperature) can be confirmed in the monitor function. (Code No. 041: Engine cooling water temperature)

Presumed cause and standard value in normalcy

Failure content

Cause

Standard value in normalcy and references for troubleshooting

Engine Overheating 1 (system in normal condition)

!The engine may have overheated. Inspect failure cause and damage of the engine, and then repair.

Engine cooling water temperature sensor 2 defective (Internal short-circuiting)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E05 (male) Between (1) and (2) Between (2) and grounding

Grounding fault of wiring harness 3 (Contact with grounding circuit)

Engine cooling water temperature 10 – 100 °C

Resistance value 90 – 3.5kΩ Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (1) and E05 (female) (2) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panel defective

P02 (female) Between (1) and (13) Between (1) and grounding

Engine water temperature 10 – 100 °C

Resistance value 90 – 3.5kΩ Above 1 MΩ

Related circuit diagram

20-388 (1)

PC160LC-7

B@BCZK

TROUBLESHOOTING

Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level) User Code

Error Code

Failure Code

—

B@BCZK

Failure phenomenon

Abnormally lowered radiator water level (in mechanical system)

Failure content

• The signal circuit in the radiator water level switch was opened (i.e. disconnected from grounding).

Response from controller

• None in particular

Phenomenon occurring on machine

• There is a possibility that the engine seizes, if it is kept running without a corrective action.

Relative information

• If the radiator water level monitor of the monitor panel lights up in red while the engine is stopped (with the starting switch in ON position), this failure code is recorded. • Input from the radiator water level switch (ON or OFF) can be confirmed in the monitor function. (Code No. 045: Monitor input 1)

Presumed cause and standard value in normalcy

Cause Radiator sub-tank water 1 level lowered (system in normal condition)

Radiator water level 2 switch defective (Internal disconnection)

Standard value in normalcy and references for troubleshooting !Check the water level in the radiator sub-tank. If it is low, add water. (If this phenomenon occurs frequently, check the cause) !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A33 (male) Between (1) and (2)

Disconnection of wiring harness 3 (Disconnection or defective contact with connector)

Sub-tank water level

Resistance value

When in normal condition

Below 1 Ω

When lowered

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (3) and A33 (female) (1)

Resistance value

Below 1 Ω

Wiring harness between A33 (female) (2) and grounding

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective

P02 Between (3) and grounding

Sub-tank water level

Resistance value

When in normal condition

Below 1 V

When lowered

20 – 30 V

Electrical Circuit Diagram for Radiator Water Level Switch in Monitor Panel

PC160LC-7

20-389 (1)

B@HANS

TROUBLESHOOTING

Failure Code in Mechanical System B@HANS (Hydraulic oil overheating) (Multi-monitor only) User Code

Error Code

Failure Code

—

B@HANS

Failure phenomenon

Hydraulic oil overheated (in mechanical system)

• The hydraulic oil temperature sensor inputted a signal of 102°C, while the engine was running.

Response from controller

• None in particular

Phenomenon occurring on machine

• There is a possibility that the engine seizes, if it is kept running without a corrective action.

Relative information

• If the hydraulic oil temperature monitor of the monitor panel lights up in red while the engine is running, this failure code is recorded. • Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function. (Code No. 044: Hydraulic oil temperature)

Presumed cause and standard value in normalcy

Failure content

Cause

Standard value in normalcy and references for troubleshooting

Hydraulic oil overheat1 ing (system in normal condition)

!The hydraulic oil may have overheated. Inspect failure cause and damage of the hydraulic equipment, and then repair.

Hydraulic oil temperature 2 sensor defective (Internal short-circuiting)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A61 (male) Between (1) and (2) Between (2) and grounding

Grounding fault of wiring harness 3 (Contact with grounding circuit)

Hydraulic oil temperature 10 – 100 °C

Resistance value 90 – 3.5kΩ Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (12) and A61 (female) (2) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panel defective

P02 (female) Between (12) and (13) Between (12) and grounding

Hydraulic oil temperature 10 – 100 °C

Resistance value 90 – 3.5kΩ Above 1 MΩ

Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor

20-390 (1)

PC160LC-7

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) BEFORE CONDUCTING E-MODE TROUBLESHOOTING ....................................................................... 20-402 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-403 E- 1 Engine does not start ........................................................................................................................ 20-404 E- 2 Engine stops while in operation ........................................................................................................ 20-409 E- 3 Engine rotates unstably or hunting ................................................................................................... 20-410 E- 4 Engine does not stop ........................................................................................................................ 20-412 E- 5 Auto-decelerator does not work ........................................................................................................ 20-414 E- 6 Auto engine warm-up device does not work ..................................................................................... 20-415 E- 7 Preheater does not operate .............................................................................................................. 20-416 E- 8 All work equipment, swing and travel do not move........................................................................... 20-418 E- 9 One-touch power max switch does not work .................................................................................... 20-420 E-10 Attachment circuit does not change.................................................................................................. 20-421 E-11 No display in monitor panel at all ...................................................................................................... 20-422 E-12 Monitor panel does not display partially............................................................................................ 20-423 E-13 Contents of monitor panel are different from mounted model........................................................... 20-423 E-14 Fuel level monitor lights up in red while engine is running................................................................ 20-424 E-15 Engine cooling water temperature gauge does not indicate correctly .............................................. 20-425 E-16 Hydraulic oil temperature gauge does not display correctly ............................................................. 20-426 E-17 Fuel gauge does not display correctly .............................................................................................. 20-427 E-18 Swing lock monitor does not display correctly .................................................................................. 20-428 E-19 When monitor switch is operated, nothing is displayed .................................................................... 20-430 E-20 Windshield wiper and window washer does not work....................................................................... 20-432 E-21 Alarming buzzer cannot be cancelled ............................................................................................... 20-436 E-22 "Boom RAISE" is not correctly displayed in monitor function ........................................................... 20-437 E-23 "Boom LOWER" is not correctly displayed in monitor function ......................................................... 20-438 E-24 "Arm IN" is not correctly displayed in monitor function ..................................................................... 20-439 E-25 "Arm OUT" is not correctly displayed in monitor function ................................................................. 20-440 E-26 "Bucket CURL" is not correctly displayed in monitor function........................................................... 20-441 E-27 "Bucket DUMP" is not correctly displayed in monitor function .......................................................... 20-442 E-28 "SWING" is not correctly displayed in monitor function .................................................................... 20-443 E-29 "TRAVEL" is not correctly displayed in monitor function................................................................... 20-446 E-30 "Travel differential pressure" is not correctly displayed in monitor function ...................................... 20-448 E-31 "Service" is not correctly displayed in monitor function..................................................................... 20-450 E-32 Troubleshooting for air conditioner system ....................................................................................... 20-452 E-33 Travel alarm does not sound or does not stop sounding .................................................................. 20-454

PC160LC-7

20-401 (4)

BEFORE CONDUCTING E-MODE TROUBLESHOOTING

TROUBLESHOOTING

BEFORE CONDUCTING E-MODE TROUBLESHOOTING Connection table of fuse box This connection table shows the devices to which each power supply of the fuse box (FB1) supplies power directly (A switch power supply is a device which supplies power while the engine starting switch is at the ON position and a constant power supply is a device which supplies power while the engine starting switch is at the OFF position). When conducting troubleshooting for an electric system, you should check its fuse box and fusible link to see if the power is supplied normally. Type of power supply

Fuse No.

Fuse capacity

Destination of power Governor pump controller (Controller power supply)

10A

Emergency pump drive resistor Swing holding brake release switch Governor pump controller (Solenoid power supply)

Switch power supply (Fusible link: A34)

Constant power supply (Fusible link: A35)

20-402 (4)

20A

Cold starting solenoid relay (Coil side and contact side) Attachment return switching relay (Coil side and contact side)

10A

Safety lock switch

10A

Horn switch

10A

(Spare)

10A

(Spare)

20A

Air conditioner unit

20A

Light switch

10A

Service power supply (M32 connector)

10A

Radio

20A

(Spare)

10A

Room lamp

10A

(Spare)

Cigarette lighter Windshield washer motor

Rotary lamp switch Additional relay (Coil side and contact side) Light relay (Contact side) One-touch power maximizing switch Radio

Starting motor cut-out (Personal code) relay (Coil side) Monitor panel

Travel alarm DC/DC converter

Engine starting switch / Monitor panel —

PC160LC-7

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ! The following information are edited and contained in the "Information Contained in Troubleshooting Table". You are required to proceed with troubleshooting after fully grasping the contents. Failure information

Phenomena occurring on machine

Relative information

Information on occurred failures and troubleshooting Cause

<Contents> • The standard values in normalcy by which to judge "good" or "no good" about presumed causes. • References for making judgement of "good" or "no good"

Presumed cause and standard value in normalcy

Standard value in normalcy and references for troubleshooting

Cause for presumed failure (The attached No. for filing and reference purpose only. It does not stand for any priority)

<Phenomena of wiring harness fault> • Failure due to disconnection Defective contact with connector or disconnection of wiring harness has occurred. • Grounding fault A wiring harness that is not originally connected with a grounding circuit is in contact with it. • Failure due to short-circuiting A wiring harness that is not originally connected with a power source circuit (24 V) is in contact with it. <Points to remember in troubleshooting> 1) Connector denotation method and handling of T-adapters Insert or connect T-adapters in the following manner, unless specifically otherwise instructed. • If there is no indication of (male) or (female) in the connector No., pull off a connector and insert a T-adapter into both sides of male and female. • If there is an indication of (male9 and (female) in the connection No., pull off a connector and insert a T-adapter into only one side of (male) or (female). 2) Description sequence of pin No. and handling of circuit tester leads Connect the positive lead (+) and negative lead (–) for troubleshooting in the following manner unless specifically otherwise instructed. • Connect the positive lead (+) to a pin No. marked at the front or wiring harness. • Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.

Relative Electrical Circuit Diagram

PC160LC-7

20-403 (1)

E-1

TROUBLESHOOTING

E-1 Engine does not start Failure information

• Engine does not start.

Relative information

• The engine starting circuit has the following 2 starting lock mechanisms. 1) Starting lock by password of monitor panel 2) Starting lock by safety lock lever Cause

Insufficient battery capacity

Fuses No. 3 or 18 defective

Engine starting switch defective (Internal disconnection)

Presumed cause and standard value in normalcy

Lock switch defective (Internal disconnection)

Starting motor cut-off relay R11 or R13 defective (Internal disconnection or short-circuit)

(1) Engine does not turn.

Standard value in normalcy and references for troubleshooting Battery voltage

Specific gravity of battery fluid

Above 24 V

Above 1.26

If fuse No. 3 or 18 is broken, the circuit probably has grounding fault, etc. (See cause 10.) If the fuse is not broken but the monitor panel does not light up, check the power supply circuit between the battery and fuse box. aTurn the engine starting switch OFF for the preparations. H15 (male)

Engine starting switch

Resistance value

OFF

Above 1 Mz

START

Below 1 z

Between (1) and (4)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female)

Lock lever

Resistance value

Reset

Above 1 Mz

Lock

Below 1 z

Between (1) and (3)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R11 (female), R13 (female)

Resistance value

Between (1) and (2)

100 – 500 z

Between (3) and (5)

Above 1 Mz

Between (3) and (6)

Below 1 z

aTurn the engine starting switch OFF for the preparations (and disconnect only terminal C), and hold it in the START position during the troubleshooting. Engine starting switch

Relay terminal A27

Starting motor safety relay defective (Internal failure)

Voltage/Resistance value

Between B and grounding

Power source

20 – 30 V

Between E and grounding

GND

Below 1 z

Between A27 (2) and grounding

Generation signal

Between A27 (1) and grounding

Starting input

20 – 30 V

Starting output

20 – 30 V

Between C and grounding

START

Below 1 V

If the power source, grounding, generation signal, and starting input are normal but the starting output is abnormal, the starting motor safety relay is defective. aTurn the engine starting switch OFF for the preparations, and hold it in the START position during the troubleshooting. Engine starting switch

Starting motor 7

Starting motor defective (Internal failure)

Between B and grounding Between C and grounding

Power source Starting signal

Voltage 20 – 30 V

START 20 – 30 V

If the power source and starting signal are normal but the starting motor does not rotate, the starting motor is defective.

20-404 (4)

PC160LC-7

E-1

TROUBLESHOOTING

Cause

Alternator defective (Internal failure)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the ON or START position during the troubleshooting. E12 (male)

Voltage

Between (1) and grounding

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Presumed cause and standard value in normalcy

Disconnection of wiring harness (Disconnection or defective contact with connector)

Wiring harness between FB1-18 outlet and H15 (female) (1)

Resistance value

Below 1 Ω

Wiring harness from H15 (female) (4) to J01 and R11 (female) (5)

Resistance value

Below 1 Ω

Wiring harness between R11 (female) (3) and A27 (female) (1)

Resistance value

Below 1 Ω

Wiring harness between starting safety relay C and starting motor C

Resistance value

Below 1 Ω

Wiring harness between FB1-3 outlet and S14 (male) (1)

Resistance value

Below 1 Ω

Wiring harness between S14 (male) (3) and R11 (female) (1)

Resistance value

Below 1 Ω

Wiring harness between R11 (female) (2) and R13 (female) (6)

Resistance value

Below 1 Ω

Wiring harness between R13 (female) (3) and J04 and grounding

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness 10 (Contact with grounding circuit)

Short-circuit of wiring harness 11 (Contact with 24 V circuit)

PC160LC-7

Between wiring harness between FB1-18 outlet and H15 (female) (1) and grounding

Resistance value

Above 1 MΩ

Between wiring harness from H15 (female) (4) to J01 and R11 (female) (5), or H15 (female) (4) and P01 (female) (4), or H15 (female) (4) and C01 (female) (17), or H15 (female) (4) to other relative circuits and grounding

Resistance value

Above 1 MΩ

Between wiring harness between R11 (female) (3) and A27 (female) (1) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between starting motor safety relay C and starting motor C and grounding

Resistance value

Above 1 MΩ

Between wiring harness between FB1-3 outlet and S14 (male) (1) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between S14 (male) (3) and R11 (female) (1) and grounding

Resistance value

Above 1 MΩ

Between wiring harness from P02 (female) (14) to J05 and R13 (female) (2) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from A27 (female) (2) and E12 (female) (1), or A27 (female) (2) to J02 and D01 (female) (6), or A27 (female) (2) and P02 (female) (11), or A27 (female) (2) to other relative circuits and grounding

Voltage

Below 1 V

20-405 (1)

TROUBLESHOOTING

E-1

Related circuit diagram

20-406 (1)

PC160LC-7

E-1

TROUBLESHOOTING

(2) Engine does not start easily or at all at low temperature.

Failure information

• Engine does not start.

Relative information

• If the engine starting switch is turned ON when temperature is low (Engine water temperature: Below 0°C), the cold start solenoid is turned ON to increase the fuel injection rate. • If the primary side (coil side) of the cold start solenoid relay has a fault (short-circuit or disconnection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected, however. Cause

Fuse No. 2 defective Engine water temperature sensor (for controller) defective (Internal short-circuit)

Standard value in normalcy and references for troubleshooting If fuse No. 2 is broken, the circuit probably has grounding fault, etc. (See cause 6.) !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E12 (male)

Presumed cause and standard value in normalcy

Cold start solenoid defective (Internal disconnection or short-circuit)

Resistance value

- 30 – 0°C

57 k – 10 kΩ

5 – 100°C

10 k – 0.3 kΩ

- 30 – 100°C

Above 1 MΩ

Between (A) and (B) Between (B) and grounding

Cold start solenoid relay R22 defective (Internal disconnection)

Engine water temperature

When relay R22 is replaced with another relay, if the condition becomes normal, relay R22 is defective. !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V07 (Unit)

Resistance value

Between terminal and solenoid body

7.7 ± 0.3 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance Wiring harness from FB1-2 outlet to J03 and R22 (female) (3) Below 1 Ω (Disconnection or value defective contact Resistance with connector) Below 1 Ω Wiring harness between R22 (female) (5) and V07 value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding circuit)

Between wiring harness between C01 (female) (20) and E12 (female) (B) and grounding

Resistance value

Above 1 MΩ

Between wiring harness from FB1-2 outlet to J03, to R22 (female) (3), and to other relative circuits and grounding

Resistance value

Above 1 MΩ

Between wiring harness between R22 (female) (5) and V07 and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting (Troubleshooting on the input side). C01 (female) P02 (female) Between C01 (20) and P02 (13)

Governor • pump controller defective

Between C01 (20) and grounding

Engine water temperature

Resistance value

- 30 – 0°C

57 k – 10 kΩ

5 – 100°C

10 k – 0.3 kΩ

- 30 – 100°C

57 k – 0.3 kΩ

!Turn the engine starting switch OFF for the preparations, and conduct troubleshooting when it is turned from the OFF position to the ON position (Troubleshooting on the output side). C02

Engine water temperature

Voltage

Between (9) and grounding

Below 0°C (or disconnect E12)

20 – 30 V (Max. 3 sec)

Above 0°C

Below 1V

If the troubleshooting result on the input side is normal but that on the output side is abnormal, the controller is defective.

PC160LC-7

20-407 (1)

TROUBLESHOOTING

E-1

Related circuit diagram Serial No.: 10001 – 11000

Serial No.: 11001 and up

20-408 (4)

PC160LC-7

E-2

TROUBLESHOOTING

E-2 Engine stops while in operation Failure information

• Engine stops while in operation.

Relative information

• Input from the governor potentiometer (voltage) can be confirmed in the monitor function. (Code No. 031: governor potentiometer voltage) Cause

Engine stops while in operation.

Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 1

Governor potentiometer fault (Internal failure)

E10 (male)

Resistance value

Between (A) and (C)

4.0 – 6.0 kΩ

Between (B) and (A)

0.25 – 5.0 kΩ

Between (B) and (C)

0.25 – 5.0 kΩ

Disconnection of wir- !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position ing harness during the troubleshooting. (Disconnection or Wiring harness between C01 (female) (13) and E10 (female) Resistance defective contact Below 1 Ω (B) value with connector)

Grounding fault of wiring harness (Contact with grounding circuit)

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4

Governor • pump controller defective

C01

Voltage

Between (22) and (21)

4.5 – 5.5 V

Between (13) and (21)

0.5 – 4.5 V

Related circuit diagram

PC160LC-7

20-409 (1)

E-3

TROUBLESHOOTING

E-3 Engine rotates unstably or hunting (1) Engine rotates unstably at low idling. (2) Engine hunting. (3) High idling speed is low.

Failure information

• Engine rotates unstably or hunting

Relative information

• The governor • pump controller carries out the following controls normally. Consequently, the set opening angle of the fuel control dial and the control angle of the governor motor may not precisely conform to each other. 1) Control of governor by selection of working mode 2) Control of governor by setting of auto deceleration function 3) Control of governor by operating condition of control lever 4) Control of governor by automatic warm-up function in cold state 5) Control of governor by turbocharger protection function at starting of engine Accordingly, be sure to select the "Governor lever stroke adjustment mode" when checking the operation of the fuel control dial and governor motor (Since the governor control function does not work in this mode, the set opening angle of the fuel control dial always conforms to the control angle of the governor motor). • The engine speed can be confirmed in the monitor function. (Code No. 010: Engine speed) Cause

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch ON for the troubleshooting (Monitoring). Monitoring code

Model code signal fault

002

Presumed cause and standard value in normalcy

003

Item

Normal display

Controller model code

150

If the monitoring display is abnormal, conduct troubleshooting for error code [E217]. 2

Defective adjustment See TESTING AND ADJUSTING "Special function of monitor panel". of governor lever !Turn the engine starting switch ON or start the engine for the troubleshooting.

Malfunction of gover- When the following operation is conducted, if the governor motor lever moves smoothly, governor motor is normal. nor motor • Operate the fuel control dial between low idling and high idling. • Stop the engine by turning the starting switch OFF.

Engine fuel control system defective

Disconnection of wir- !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position ing harness during the troubleshooting. (Disconnection or Wiring harness from C01 (female) (23) to J07 and H15 Resistance defective contact Below 1 Ω (female) (5) value with connector)

Grounding fault of wiring harness (Contact with grounding circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Governor • pump controller defective

As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the causes listed in Item 1 through 6, the controller is judged as defective.)

20-410 (1)

See Shop Manual for 102 Series Engine.

Between wiring harness from C01 (female) (23) to J07 and H15 (female) (5) and to other relative circuits and grounding

Resistance value

Above 1 MΩ

PC160LC-7

TROUBLESHOOTING

E-3

Related circuit diagram

PC160LC-7

20-411 (1)

E-4

TROUBLESHOOTING

E-4 Engine does not stop Failure information

• Engine does not stop.

Relative information

• The governor • pump controller holds the battery relay for 4 seconds at shortest and 7 seconds at longest to secure the drive power for the governor motor after the starting switch is turned to the OFF position until the engine stops. • It can be confirmed in the monitor function how the battery relay works (ON or OFF) (Code No. 037: Controller output) Cause

Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

!Operate the starting switch for the troubleshooting. 1

Battery relay fault (Internal failure)

Assembled-type diode D01 fault (Internal disconnection)

When the starting switch is operated as follows, if the battery relay contacts make operating sounds, the battery relay is normal. • Starting switch OFF→ON→OFF !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)

Digital type circuit tester

Continuity

Between (5) and (1)

Diode mode

Continued

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Disconnection of wirWiring harness between C03 (female) (4) and D01 (female) (5) ing harness (Disconnection or defective contact Wiring harness from D01 (female) (1) to J01 and A21 (BR) with connector) Wiring harness between A20 (E1) and grounding

Resistance value

Below 1 Ω

Resistance value

Below 1 Ω

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4

Governor • pump controller defective

20-412 (1)

C03

Engine starting switch

Voltage

Between (4) and grounding

ON→OFF

20 – 30 V (for 4 to 7 seconds)

PC160LC-7

TROUBLESHOOTING

E-4

Related circuit diagram

PC160LC-7

20-413 (1)

E-5

TROUBLESHOOTING

E-5 Auto-decelerator does not work Failure information

• Auto-decelerator does not work.

Relative information

• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the auto-decelerator does not work. • Confirm the display on the monitor panel, when the engine is running. Cause

Boom RAISE signal fault

Standard value in normalcy and references for troubleshooting Monitoring code

Item

Normal display

019

Boom RAISE

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-22 Troubleshooting.

Boom LOWER signal fault

Monitoring code

Item

Normal display

019

Boom LOWER

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-23 Troubleshooting.

Presumed cause and standard value in normalcy

Arm IN signal fault

Monitoring code

Item

Normal display

019

Arm IN

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-24 Troubleshooting.

Arm OUT signal fault

Monitoring code

Item

Normal display

019

Arm OUT

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-25 Troubleshooting.

Bucket CURL signal fault

Monitoring code

Item

Normal display

021

Bucket CURL

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-26 Troubleshooting.

Bucket DUMP signal fault

Monitoring code

Item

Normal display

021

Bucket DUMP

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-27 Troubleshooting.

Swing signal fault

Monitoring code

Item

Normal display

019

Swing

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-28 Troubleshooting.

Travel signal fault

Monitoring code

Item

Normal display

019

Travel

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-29 Troubleshooting.

Attachment signal fault (When attachments is installed)

Governor • pump 10 controller defective

20-414 (1)

Monitoring code

Item

Normal display

021

Service

Lever operation: ON Lever NEUTRAL: OFF

If the display on the monitor panel is not normal, proceed to No. E-31 Troubleshooting. As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the causes listed in Item 1 through 9, the controller is judged as defective.

PC160LC-7

E-6

TROUBLESHOOTING

E-6 Auto engine warm-up device does not work • The auto engine warm-up device does not work.

Relative information

• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C, and raise the engine rotation up to 1,200 rpm. • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch ON for the troubleshooting (Monitoring).

Engine cooling water temperature signal fault

Monitoring code

Item

Normal display

041

Engine cooling water temperature

Compare with the actual engine cooling water temperature.

If the display on the monitor panel is not normal, proceed to No. E-15 Troubleshooting. 2

Governor • pump controller defective

PC160LC-7

As this is an internal failure, troubleshooting cannot be conducted. (If the fault mentioned in the above item is not found, the Governor • pump controller is judged as defective)

20-415 (1)

E-7

TROUBLESHOOTING

E-7 Preheater does not operate • Preheater does not operate.

Relative information

• The preheater monitor lights up when the starting switch is turned to the HEAT position and starts flashing about 30 seconds later to notify the operator of completion of preheating (It stops flashing about 10 seconds after). • Input state (ON • OFF) of the preheating signal can be confirmed in the monitor function. (Code No. 045: Monitor input 1)

Presumed cause and standard value in normalcy

Failure information

(1) When starting switch is turned to HEAT position, preheater monitor does not light up.

Cause

Standard value in normalcy and references for troubleshooting

Starting switch system defective

If the preheater does not operate (If the heating unit does not become hot), conduct troubleshooting (2).

Disconnection of wir- !Turn the engine starting switch OFF for the preparations, and hold it in the OFF posiing harness tion during the troubleshooting. (Disconnection or Wiring harness between P02 (female) (18) and J02 (male) Resistance defective contact Below 1 Ω (7) value with connector) !Turn the engine starting switch OFF for the preparation.

Monitor panel defective

P02 Between (18) and grounding

Starting switch

Voltage

OFF

Below 1 V

HEAT

20 – 30 V

Failure information

• Preheater does not operate.

Relative information

• When the temperature is low (When the water temperature is below 30°C), the governor • pump controller drives the heater relay for 100 seconds after the engine is started to heat the engine automatically. Cause

Starting switch defective (Internal disconnection)

(2) When starting switch is turned to HEAT position, preheater unit does not become hot.

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparation. H15 (male) Between (1) and (3)

Starting switch

Resistance value

OFF

Above 1 MΩ

HEAT

Below 1 Ω

Presumed cause and standard value in normalcy

!Turn the engine starting switch OFF for the preparation. 2

Heater relay defective (Internal disconnection) Intake air heater defective (Internal disconnection)

Heater relay

Starting switch

Continuity • Resistance value

Between A25 and grounding

OFF

There is continuity

Between contact terminals

HEAT

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Intake air heater

Continuity

Between E01 and grounding

There is continuity

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Disconnection of wirWiring harness from H15 (female) (3) to J02 and A25 ing harness (Disconnection or defective contact Wiring harness between A22 and heater relay with connector) Between A26 and E01

20-416 (1)

Resistance value

Below 1 Ω

Resistance value

Below 1 Ω

Resistance value

Below 1 Ω

PC160LC-7

TROUBLESHOOTING

E-7

Related circuit diagram

PC160LC-7

20-417 (1)

E-8

TROUBLESHOOTING

E-8 All work equipment, swing and travel do not move • All work equipment, swing and travel do not move.

Relative information

—

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Fuse No. 3 fault

If the fuse No. 3 is blown, there is a big possibility that grounding fault occurred in the circuit. (cause 6 reference)

Lock switch defective (Internal disconnection)

PPC lock solenoid fault (Internal disconnection or short-circuiting) Assembled-type diode D01 fault (Internal short-circuiting)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female) Between (1) and (2)

Lock lever

Resistance value

Lock

Above 1 Mz

Release

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V01 (male)

Resistance value

Between (1) and (2)

20 – 60 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)

Resistance value

Between (4) and (8)

Above 1 Mz (no continuity)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Disconnection of wirWiring harness between FB1-3 outlet and S14 (male) (1) ing harness (Disconnection or defective contact Wiring harness from S14 (male) (2) to J02 and V01 (female) (1) with connector) Wiring harness between V01 (female) (2) and grounding

Grounding fault of wiring harness (Contact with grounding (GND) circuit)

20-418 (4)

Resistance value

Below 1 z

Resistance value

Below 1 z

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-3 outlet and S14 (male) (1) and grounding

Resistance value

Above 1 Mz

Wiring harness from S14 (male) (2) to J02 and V01 (female) (1), or between wiring harness between S14 (male) (2) and D01 (female) (4) and grounding

Resistance value

Above 1 Mz

PC160LC-7

TROUBLESHOOTING

E-8

Related circuit diagram

PC160LC-7

20-419 (4)

E-9

TROUBLESHOOTING

E-9 One-touch power max switch does not work • One-touch power max. switch does not work.

Relative information

• If the one-touch power max switch is pressed while the engine is running in mode A or E, the one-touch power max monitor is displayed on the monitor panel. • Input from the one-touch power max. switch (left knob switch) can be confirmed in the monitor function. (Code No. 022: Switch input 1)

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Fuse No. 9 fault

If the fuse No. 9 is blown, there is a big possibility that grounding fault occurred in the circuit. (cause 4 reference)

One-touch power max. switch fault (Internal disconnection)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. M23 (male) Between (1) and (2)

One-touch power max. switch

Resistance value

Release

Above 1 MΩ

Depress

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance Below 1 Ω (Disconnection or Wiring harness between FB1-9 outlet and M23 (female) (1) value defective contact Resistance with connector) Wiring harness between M23 (female) (2) and C01 (female) (11) Below 1 Ω value

Grounding fault of wiring harness (Contact with grounding (GND) circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-9 outlet and M23 (female) (1) and grounding

Resistance value

Above 1 MΩ

Between wiring harness between M23 (female) (2) and C01 (female) (11) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5

Governor • pump controller defective

C01 Between (11) and grounding

One-touch power max. switch

Voltage

Release

Below 1 V

Depress

20 – 30 V

Related circuit diagram

20-420 (1)

PC160LC-7

E-10

TROUBLESHOOTING

E-10 Attachment circuit does not change (1) When working mode A or E is selected, attachment circuit is not switched to crusher circuit (reciprocation circuit). (2) When working mode B is selected, attachment circuit is not switched to breaker circuit (one-way circuit).

Failure information

• Attachment circuit does not change.

Relative information

• If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or disconnection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected, however. Cause

Presumed cause and standard value in normalcy

Attachment return selector solenoid defective (Internal disconnection or short-circuit) Attachment return selector relay defective (Internal disconnection or short-circuit)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V12 (male)

Resistance value

Between (1) and (2)

20 – 60 Ω

Between (1) and grounding

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male)

Resistance value

Between (3) and (5)

Below 1 Ω

Between (3) and (6)

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Disconnection of wirWiring harness between J03 (male) (8) and R20 (female) (3) ing harness (Disconnection or defective contact Wiring harness between R20 (female) (5) and V12 (female) (1) with connector) Wiring harness between V12 (female) (2) and grounding

Short-circuit of wiring harness (Contact with 24 V circuit)

Resistance value

Below 1 Ω

Resistance value

Below 1 Ω

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness and R20 (female) (5) and V12 (female) (1) and grounding

Voltage

Below 1 V

Related circuit diagram

PC160LC-7

20-421 (1)

E-11

TROUBLESHOOTING

E-11 No display in monitor panel at all Failure information

Presumed cause and standard value in normalcy

Relative information

• No display in monitor panel at all

• When the engine starting switch is turned ON, there appears no display at all in the monitor panel.

— Cause

Standard value in normalcy and references for troubleshooting

Fuse No. 12 fault

If the fuse No. 12 is blown, there is a big possibility that grounding fault occurred in the circuit. (cause 3 reference)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance Wiring harness from P01 (female) (1) (2) to J07 to FB1-12 Below 1 z (Disconnection or value defect contact with Resistance connector) Wiring harness between P01 (female) (6) (7) and grounding Below 1 z value

Grounding fault of wiring harness (Contact with grounding (GND) circuit)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from P01 (female) (1) (2) to J07 to FB1-12 outlet and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations.

Monitor panel defective

20-422 (4)

P01 (female)

Engine starting switch

Voltage and resistance value

Between (1) (2) and grounding

Voltage: 20 – 30 V

Between (6) (7) and grounding

OFF

Resistance value: Below 1 z

PC160LC-7

E-11

TROUBLESHOOTING

Related circuit diagram Serial No.: 10001 – 11000

Serial No.: 11001 and up

PC160LC-7

20-422-1 (4)

E-12, E-13

TROUBLESHOOTING

E-12 Monitor panel does not display partially • Monitor panel does not display partially.

Relative information

—

Presumed cause and standard value in normalcy

Failure information

Cause

When starting switch is turned ON, monitor panel does not display partially.

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch ON for the troubleshooting.

Monitor panel LCD defective

When the switch is operated as follows, if the all panel LCD goes off (if the all screen becomes white), the monitor panel LCD is normal. • Press switches [ ] + [ A ] simultaneously.

Monitor panel defective

As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the causes listed above, the monitor panel is judged as defective.)

E-13 Contents of monitor panel are different from mounted model Failure information

• Contents of monitor panel are different from mounted model.

Relative information

—

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch ON for the troubleshooting (Monitoring). Monitoring code

Model code signal fault

002 003

Item

Normal display

Controller model code

150

If the display of the monitor is abnormal, conduct the troubleshooting for error code [E217]. 2

Monitor panel defective

PC160LC-7

As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the causes listed above, the monitor panel is judged as defective.)

20-423 (1)

E-14

TROUBLESHOOTING

E-14 Fuel level monitor lights up in red while engine is running Failure information

• Fuel level monitor lights up in red while engine is running.

Relative information

• If the fuel level gauge of the monitor panel enters the red range, the fuel level monitor lights up in red. • Input (Voltage) from the fuel level sensor can be confirmed in the monitor function. (Code No. 042: Fuel level sensor voltage)

Presumed cause and standard value in normalcy

Cause 1

Fuel level low (System is normal)

Fuel level sensor defective (Internal disconnection)

Disconnection of wiring harness (Disconnection or defective contact with connector)

Standard value in normalcy and references for troubleshooting Check the fuel level in the fuel tank and add fuel, if necessary. !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A60 (male) Between (1) and grounding

Fuel level

Resistance value

FULL (Upper limit)

Approx. 12 Ω

EMPTY (Lower limit)

85 – 110 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (2) and A60 (female) (1)

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4

Monitor panel defective

P02 (female) Between (2) and grounding

Fuel level

Resistance value

FULL (Upper limit)

Approx. 12 Ω

EMPTY (Lower limit)

85 – 110 Ω

Related circuit diagram

20-424 (1)

PC160LC-7

E-15

TROUBLESHOOTING

E-15 Engine cooling water temperature gauge does not indicate correctly

Failure information

(1) The engine cooling water rises normally, but the • Engine cooling water temperature gauge does display does not exceed the white range (C). not indicate correctly. (2) The engine cooling water temperature remains stable, but the display rises to the red range (H).

Relative information

• Input from the engine cooling water temperature sensor can be confirmed in the monitor function. (Code No. 041: Engine cooling water temperature) Cause

Presumed cause and standard value in normalcy

Engine cooling water temperature sensor fault (Internal disconnection or short-circuiting)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E05 (male) Between (1) and (2) Between (2) and grounding

Engine cooling water temperature 10 – 100 °C

Resistance value 90 – 3.5 kΩ Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between P02 (female) (1) and E05 (female) (2) Below 1 Ω value defective contact Resistance with connector) Wiring harness between P02 (female) (13) and E05 (female) (1) Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between P02 (female) (1) and E05 (female) (2) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5

Monitor panel defective

P02 (female) Between (1) and (13) Between (1) and grounding

Engine cooling water temperature 10 – 100 °C

Resistance value 90 – 3.5 kΩ 90 – 3.5 kΩ

Related circuit diagram

PC160LC-7

20-425 (1)

E-16

TROUBLESHOOTING

E-16 Hydraulic oil temperature gauge does not display correctly

Failure information

(1) Hydraulic oil temperature rises normally, but the • Hydraulic oil temperature gauge does not disdisplay does not exceed the white range (C). play correctly. (2) Hydraulic oil temperature remains stable, but the display rises up the red range (H).

Relative information

• Input from the hydraulic oil temperature sensor can be confirmed in the monitor function. (Code No. 044: Hydraulic oil temperature) Cause

Presumed cause and standard value in normalcy

Hydraulic oil temperature sensor fault (Internal disconnection or short-circuiting)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A61 (male) Between (1) and (2) Between (2) and grounding

Hydraulic oil temperature 10 – 100 °C

Resistance value 90 – 3.5 kΩ Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between P02 (female) (12) and A61 (female) (2) Below 1 Ω value defective contact Resistance with connector) Wiring harness between P02 (female) (13) and A61 (female) (1) Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between P02 (female) (12) and A61 (female) (2) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5

Monitor panel defective

P02 (female) Between (12) and (13) Between (12) and grounding

Engine cooling water temperature 10 – 100 °C

Resistance value 90 – 3.5 kΩ 90 – 3.5 kΩ

Related circuit diagram

20-426 (1)

PC160LC-7

E-17

TROUBLESHOOTING

E-17 Fuel gauge does not display correctly (1) Though fuel was refilled, the display does not exceed the red range (E). (2) Though the remaining fuel level is low, the display does not drop below the green range (F).

Failure information

• Fuel gauge does not display correctly.

Relative information

• Input from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No. 042: Fuel sensor voltage) Cause

Presumed cause and standard value in normalcy

Fuel level sensor fault (Internal disconnection or short-circuiting)

Fuel level

Resistance value

FULL (Upper limit)

Approx. 12 Ω

EMPTY (Lower limit)

85 – 110 Ω

Disconnection of wir- !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position ing harness during the troubleshooting. (Disconnection or Resistance defective contact Wiring harness between P02 (female) (2) and A60 (female) (1) Below 1 Ω value with connector) !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between P02 (female) (2) and A60 (female) (1) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5

Monitor panel defective

P02 (female) Between (2) and grounding

Fuel level

Resistance value

FULL (Upper limit)

Approx. 12 Ω

EMPTY (Lower limit)

85 – 110 Ω

Related circuit diagram

PC160LC-7

20-427 (1)

E-18

TROUBLESHOOTING

E-18 Swing lock monitor does not display correctly (1) Though the swing lock switch was turned ON, the swing lock monitor does not light up. (2) Though the swing lock switch was turned OFF, the swing lock monitor lights up.

Failure information

• Swing lock monitor does not display correctly.

Relative information

• Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function. (Code No. 049: Monitor input 3) Cause

Presumed cause and standard value in normalcy

Swing lock switch fault (Internal disconnection or short-circuiting)

Swing lock switch

Resistance value

OFF

Above 1 MΩ

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness from P02 (female) (17) to J02 to X05 (male) (1) Below 1 Ω value defective contact Resistance with connector) Wiring harness from X05 (male) (2) to J05 to grounding Below 1 Ω value

Grounding fault of wiring harness (Contact with grounding (GND) circuit)

Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from P02 (female) (17) to J02 and X05 (male) (1), or P02 (female) (17) to C02 (female) (38) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from P02 (female) (17) to J02 and X05 (male) (1), or P02 (female) (17) to C02 (female) (38) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5

Monitor panel defective

P02 Between (17) and grounding

20-428 (1)

Swing lock switch

Voltage

OFF

20 – 30 V

Below 1 V

PC160LC-7

TROUBLESHOOTING

E-18

Related circuit diagram

PC160LC-7

20-429 (1)

E-19

TROUBLESHOOTING

E-19 When monitor switch is operated, nothing is displayed Failure information

• When monitor switch is operated, nothing is dis- (1) When mode selector switch is operated, working played. mode monitor is not displayed.

Relative information

—

Presumed cause and standard value in normalcy

Cause 1

Monitor panel defective

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information

• When monitor switch is operated, nothing is dis- (2) When LCD monitor adjustment switch is operplayed. ated, mode selection screen is not displayed.

Relative information

—

Presumed cause and standard value in normalcy

Cause 1

Monitor panel defective

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information

• When monitor switch is operated, nothing is displayed.

Relative information

—

Presumed cause and standard value in normalcy

Cause 1

Monitor panel defective

(3) When selector switch is operated, flow rate adjustment screen or flow rate selection screen is not displayed.

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information

• When monitor switch is operated, nothing is dis- (4) When maintenance switch is operated, item played. selection screen is not displayed.

Relative information

—

Presumed cause and standard value in normalcy

Cause 1

Monitor panel defective

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information

• When monitor switch is operated, nothing is dis- (5) When automatic deceleration switch is operated, played. automatic deceleration monitor is not displayed.

Relative information

• When the automatic decelerator does not operate either, conduct the troubleshooting for E-5.

Presumed cause and standard value in normalcy

20-430 (1)

Cause 1

Monitor panel defective

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

PC160LC-7

E-19

TROUBLESHOOTING

Failure information

• When monitor switch is operated, nothing is dis- (6) When travel speed selector switch is operated, played. travel speed monitor is not displayed.

Relative information

• When the travel speed does not change either, conduct the troubleshooting for H-2.

Presumed cause and standard value in normalcy

Cause 1

Monitor panel defective

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

Failure information

• When monitor switch is operated, nothing is dis- (7) When wiper switch is operated, wiper monitor is played. not displayed.

Relative information

• When the wiper does not operate either, conduct the troubleshooting for E-20.

Presumed cause and standard value in normalcy

PC160LC-7

Cause 1

Monitor panel defective

Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.

20-431 (1)

E-20

TROUBLESHOOTING

E-20 Windshield wiper and window washer does not work Failure information

• Windshield wiper and window washer does not (1) The windshield wiper does not work. work

Relative information

• Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function. (Code No. 049: Monitor input 3) Cause

Presumed cause and standard value in normalcy

Window rear limit switch fault (Internal disconnection or short-circuiting) Windshield wiper motor fault (Internal disconnection or short-circuiting)

Front window

Resistance value

When installed at front

Above 1 MΩ

When retracted at rear

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (female)

Continuity

Between (3) and (1)

There is continuity

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Wiring harness between P01 (female) (9) and W04 (female) Resistance (Disconnection or Below 1 Ω (3) value defective contact Wiring harness between P01 (female) (10) and W04 (female) Resistance with connector) Below 1 Ω (1) value

Grounding fault of !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position wiring harness during the troubleshooting. (Contact with Resistance grounding (GND) cir- Between wiring harness between P02 (female) (15) and W03 Above 1 MΩ (female) (1) value cuit)

Monitor panel fault (window rear limit switch system)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02 Between (15) and grounding

Voltage

When installed at front

20 – 30 V

When retracted at rear

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Monitor panel fault (Windshield wiper motor system)

20-432 (1)

Front window

P01 Between (9) and grounding Between (10) and grounding

Windshield wiper switch

Resistance value

OFF

Below 3 V

Below 3 V ⇔ 20 – 30 V (Constant cycle)

PC160LC-7

TROUBLESHOOTING

E-20

Related circuit diagram

PC160LC-7

20-433 (1)

E-20

TROUBLESHOOTING

Serial No.: 10001 – 11000 Failure information

• Windshield wiper or windshield washer does not (2) Windshield washer does not operate. operate.

Relative information

—

Presumed cause and standard value in normalcy

Cause 1

Fuse No. 4 defective

Washer motor defective (Internal disconnection or grounding fault)

Standard value in normalcy and references for troubleshooting If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 4.) aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A50 (male)

Resistance value

Between (1) and (2)

5 – 20 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance Wiring harness from FB1-4 to J03 to J06 and A50 (female) (1) Below 1 z (Disconnection or value defective contact Wiring harness from A50 (female) (2) to J04 and P01 Resistance with connector) Below 1 z (female) (3) value aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding circuit)

Between wiring harness from FB1-4 to J03 to J06 and A50 (female) (1), or FB1-4 to D04 (female) (4), and to other relative circuits and grounding

Resistance value

Above 1 Mz

Between wiring harness from A50 (female) (2) to J04 and P01 (female) (3), or A50 (female) (2) to D04 (female) (8) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5

Monitor panel defective

P01 Between (3) and grounding

20-434 (4)

Windshield washer switch

Voltage

OFF

20 – 30 V

Below 1 V

PC160LC-7

TROUBLESHOOTING

E-20

Related circuit diagram

PC160LC-7

20-435 (1)

E-20

TROUBLESHOOTING

Serial No.: 11001 and up Failure information

• Windshield wiper or windshield washer does not (2) Windshield washer does not operate. operate.

Relative information

—

Presumed cause and standard value in normalcy

Cause 1

Fuse No. 4 defective

Washer motor defective (Internal disconnection or grounding fault)

Resistance value

Between (1) and (2)

5 – 20 z

Between (1) and grounding

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance Wiring harness from FB1-4 to J03 to J06 and A50 (female) (1) Below 1 z (Disconnection or value defective contact Wiring harness from A50 (female) (2) to J04 and P01 Resistance with connector) Below 1 z (female) (3) value aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding circuit)

Between wiring harness from FB1-4 to J03 to J06 and A50 (female) (1), or FB1-4 to D02 (female) (3), and to other relative circuits and grounding

Resistance value

Above 1 Mz

Between wiring harness from A50 (female) (2) to J04 and P01 (female) (3), or A50 (female) (2) to D02 (female) (7) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5

Monitor panel defective

P01 Between (3) and grounding

20-435-1 (4)

Windshield washer switch

Voltage

OFF

20 – 30 V

Below 1 V

PC160LC-7

E-20

TROUBLESHOOTING

Related circuit diagram

PC160LC-7

20-435-2 (4)

E-21

TROUBLESHOOTING

E-21 Alarming buzzer cannot be cancelled Failure information

• Alarming buzzer cannot be cancelled.

Relative information

• Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function. (Code No. 049: Monitor input 3)

Presumed cause and standard value in normalcy

Cause

Alarming buzzer cancellation switch fault (Internal disconnection)

Alarming buzzer cancellation switch

Resistance value

Release

Above 1 MΩ

Depress

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between P02 (female) (16) and P03 (male) (1) Below 1 Ω value defective contact Resistance with connector) Wiring harness from P03 (male) (2) to J05 and grounding Below 1 Ω value

Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between P02 (female) (16) and P03 (male) (1) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4

Monitor panel fault

P02 Between (16) and grounding

Alarming buzzer cancellation switch

Voltage

Release

20 – 30 V

Depress

Below 1 V

Related circuit diagram

20-436 (1)

PC160LC-7

E-22

TROUBLESHOOTING

E-22 "Boom RAISE" is not correctly displayed in monitor function Failure information

• "Boom RAISE" is not correctly displayed in mon- • "Boom RAISE" is not correctly displayed in the itor function. monitor function on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Boom RAISE PPC hydraulic switch fault (Internal disconnection or short-circuiting)

Standard value in normalcy and references for troubleshooting !Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S06 (male) Between (1) and (2)

Right work equipment control lever

Resistance value

NEUTRAL

Above 1 MΩ

RAISE

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between C03 (female) (10) and S06 (female) (1) Below 1 Ω value defective contact Resistance with connector) Wiring harness between S06 (female) (2) and grounding Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between C03 (female) (10) and S06 (female) (1) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5

Governor • pump controller defective

C03 Between (10) and grounding

Right work equipment control lever

Voltage

NEUTRAL

20 – 30 V

RAISE

Below 1 V

Related circuit diagram

PC160LC-7

20-437 (1)

E-23

TROUBLESHOOTING

E-23 "Boom LOWER" is not correctly displayed in monitor function Failure information

• "Boom LOWER" is not correctly displayed in • "Boom LOWER" is not correctly displayed in the monitor function. monitor function on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Boom LOWER PPC hydraulic switch fault (Internal disconnection or short-circuiting)

Right work equipment control lever

Resistance value

NEUTRAL

Above 1 MΩ

LOWER

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between C03 (female) (20) and S02 (female) (1) Below 1 Ω value defective contact Resistance with connector) Wiring harness between S02 (female) (2) and grounding Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between C03 (female) (20) and S02 (female) (1) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5

Governor • pump controller defective

C03 Between (20) and grounding

Right work equipment control lever

Voltage

NEUTRAL

20 – 30 V

LOWER

Below 1 V

Related circuit diagram

20-438 (1)

PC160LC-7

E-24

TROUBLESHOOTING

E-24 "Arm IN" is not correctly displayed in monitor function Failure information

• "Arm IN" is not correctly displayed in monitor • "Arm IN" is not correctly displayed in the monitor function. function (special function) on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Arm IN PPC hydraulic switch fault (Internal disconnection or short-circuiting)

Left work equipment control lever

Resistance value

NEUTRAL

Above 1 MΩ

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between C03 (female) (30) and S04 (female) (1) Below 1 Ω value defective contact Resistance with connector) Wiring harness between S04 (female) (2) and grounding Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between C03 (female) (30) and S04 (female) (1) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5

Governor • pump controller defective

C03 Between (30) and grounding

Left work equipment control lever

Voltage

NEUTRAL

20 – 30 V

Below 1 V

Related circuit diagram

PC160LC-7

20-439 (1)

E-25

TROUBLESHOOTING

E-25 "Arm OUT" is not correctly displayed in monitor function Failure information

• "Arm OUT" is not correctly displayed in monitor • "Arm OUT" is not correctly displayed in the monitor function. function (special function) on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Arm OUT PPC hydraulic switch defect (Internal disconnection and short-circuiting)

Left work equipment control lever

Resistance value

NEUTRAL

Above 1 MΩ

OUT

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between C03 (female) (40) and S08 (female) (1) Below 1 Ω value defective contact Resistance with connector) Wiring harness between S08 (female) (2) and grounding Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between C03 (female) (40) and S08 (female) (1) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5

Governor • pump controller defective

C03 Between (40) and grounding

Left work equipment control lever

Voltage

NEUTRAL

20 – 30 V

OUT

Below 1 V

Related circuit diagram

20-440 (1)

PC160LC-7

E-26

TROUBLESHOOTING

E-26 "Bucket CURL" is not correctly displayed in monitor function Failure information

• "Bucket CURL" is not correctly displayed in moni- • "Bucket CURL" is not correctly displayed in the montor function. itor function (special function) on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Bucket CURL PPC hydraulic switch fault (Internal disconnection and short-circuiting)

Right work equipment control lever

Resistance value

NEUTRAL

Above 1 MΩ

CURL

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between C03 (female) (9) and S01 (female) (1) Below 1 Ω value defective contact Resistance with connector) Wiring harness between S01 (female) (2) and grounding Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between C03 (female) (9) and S01 (female) (1) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5

Governor • pump controller defective

C03 Between (9) and grounding

Right work equipment control lever

Voltage

NEUTRAL

20 – 30 V

CURL

Below 1 V

Related circuit diagram

PC160LC-7

20-441 (1)

E-27

TROUBLESHOOTING

E-27 "Bucket DUMP" is not correctly displayed in monitor function Failure information

• "Bucket DUMP" is not correctly displayed in moni- • "Bucket DUMP" is not correctly displayed in the montor function. itor function (special function) on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Bucket DUMP PPC hydraulic switch fault (Internal disconnection and short-circuiting)

Right work equipment control lever

Resistance value

NEUTRAL

Above 1 MΩ

DUMP

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between C03 (female) (19) and S05 (female) (1) Below 1 Ω value defective contact Resistance with connector) Wiring harness between S05 (female) (2) and grounding Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between C03 (female) (19) and S05 (female) (1) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5

Governor • pump controller defective

C03 Between (19) and grounding

Right work equipment control lever

Voltage

NEUTRAL

20 – 30 V

DUMP

Below 1 V

Related circuit diagram

20-442 (1)

PC160LC-7

E-28

TROUBLESHOOTING

E-28 "SWING" is not correctly displayed in monitor function Failure information

• "SWING" is not correctly displayed in monitor • "SWING" is not correctly displayed in the monitor function. function (special function) on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Swing PPC hydraulic switch, left, fault (Internal disconnection or short-circuiting)

Swing PPC hydraulic switch, right, fault (Internal disconnection or short-circuiting)

Standard value in normalcy and references for troubleshooting aTurn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S03 (male) Between (1) and (2)

Left work equipment control lever

Resistance value

NEUTRAL

Above 1 Mz

Left

Below 1 z

aTurn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S07 (male) Between (1) and (2)

Left work equipment control lever

Resistance value

NEUTRAL

Above 1 Mz

Right

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Disconnection of wiring harness (Disconnection or defective contact with connector)

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

Wiring harness between C03 (female) (29) and S03 (female) (1), or wiring harness between C03 (female) (29) and S07 (female) (1)

Resistance value

Below 1 z

Wiring harness between S03 (female) (2) and grounding

Resistance value

Below 1 z

Wiring harness between S07 (female) (2) and grounding

Resistance value

Below 1 z

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (29) and S03 (female) (1), or wiring harness between C03 (female) (29) and S07 (female) (1) and grounding

Resistance value

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness between C03 (female) (29) and S03 (female) (1), or wiring harness between C03 (female) (29) and S07 (female) (1) and grounding

Voltage

Below 1 V

aTurn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6

Governor • pump controller defective

C03 Between (29) and grounding

PC160LC-7

Swing lever

Voltage

NEUTRAL

20 – 30 V

Right or left

Below 1 V

20-443 (4)

TROUBLESHOOTING

E-28

Related circuit diagram

20-444 (1)

PC160LC-7

E-29

TROUBLESHOOTING

E-29 "TRAVEL" is not correctly displayed in monitor function Failure information

• "TRAVEL" is not correctly displayed in monitor • "TRAVEL" is not correctly displayed in the monitor function. function (special function) on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Travel PPC hydraulic switch fault (Internal disconnection or short-circuiting)

Travel control lever

Resistance value

NEUTRAL

Above 1 MΩ

Forward or reverse

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Wiring harness from C03 (female) (39) to J01 and S30 Resistance (Disconnection or Below 1 Ω (female) (2) value defective contact Resistance with connector) Wiring harness from S30 (female) (1) to J05 and grounding Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Wiring harness from C03 (female) (39) to J01 to S30 (female) (2) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5

Governor • pump controller defective

C03 Between (39) and grounding

20-446 (1)

Travel control lever

Voltage

NEUTRAL

20 – 30 V

Forward or reverse

Below 1 V

PC160LC-7

TROUBLESHOOTING

E-29

Related circuit diagram

PC160LC-7

20-447 (1)

E-30

TROUBLESHOOTING

E-30 "Travel differential pressure" is not correctly displayed in monitor function • "Travel differential pressure" is not correctly displayed in the monitor function (special function) on the monitor panel.

Failure information

• "Travel differential pressure" is not correctly displayed in monitor function.

Relative information

• When pressure difference is created between the right and left travel PPC circuits (in steering), the travel differential mechanism is turned ON. Cause

Presumed cause and standard value in normalcy

Travel steering PPC hydraulic switch fault (Internal disconnection or short-circuiting)

Travel control lever

Resistance value

NEUTRAL

Above 1 MΩ

One side of right or left only

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Wiring harness between C02 (female) (16) and S31 (female) (2) Below 1 Ω value defective contact Resistance with connector) Wiring harness from S31 (female) (2) to J05 and grounding Below 1 Ω value !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.

Between wiring harness between C02 (female) (16) and S31 (female) (2) and grounding

Resistance value

Voltage

Above 1 MΩ

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 5

Governor • pump controller defective

C02 Between (16) and grounding

20-448 (1)

Travel control lever

Voltage

NEUTRAL

20 – 30 V

One side of right or left only

Below 1 V

PC160LC-7

TROUBLESHOOTING

E-30

Related circuit diagram

PC160LC-7

20-449 (1)

E-31

TROUBLESHOOTING

E-31 "Service" is not correctly displayed in monitor function Failure information

• "Service" is not correctly displayed in monitor func- • "Service" is not correctly displayed in the monitor tion. function (special function) on the monitor panel.

Relative information

— Cause

Presumed cause and standard value in normalcy

Service (front) PPC hydraulic switch fault (Internal disconnection or short-circuiting) Service (rear) PPC hydraulic switch fault (Internal disconnection or short-circuiting)

Service pedal

Resistance value

NEUTRAL

Above 1 MΩ

Front

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S11 (male) Between (1) and (2)

Service pedal

Resistance value

NEUTRAL

Above 1 MΩ

Rear

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.

Disconnection of wiring harness (Disconnection or defective contact with connector)

Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)

Wiring harness between C02 (female) (35) and S10 (female) (1), or wiring harness between C02 (female) (35) and S11 (female) (1)

Resistance value

Below 1 Ω

Wiring harness between S10 (female) (2) and grounding

Resistance value

Below 1 Ω

Wiring harness between S11 (female) (2) and grounding

Resistance value

Below 1 Ω

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (35) and S10 (female) (1), or between wiring harness between C02 (female) (35) and S11 (female) (1) and grounding

Resistance value

Above 1 MΩ

!Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness between C02 (female) (35) and S10 (female) (1), or between wiring harness between C02 (female) (35) and S11 (female) (1) and grounding

Voltage

Below 1 V

!Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6

Governor • pump controller defective

C02 Between (35) and grounding

20-450 (1)

Service pedal

Voltage

NEUTRAL

20 – 30 V

Front or rear

Below 1 V

PC160LC-7

TROUBLESHOOTING

E-31

Related circuit diagram

PC160LC-7

20-451 (1)

E-32

TROUBLESHOOTING

E-32 Troubleshooting for air conditioner system Serial No.: 10001 – 11000 • Air conditioner does not work.

Relative information

• For the electric circuit diagram inside air conditioner unit, see "Electric circuit diagram of air conditioner" in the collected circuit diagrams.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Fuse No. 11 fault

When the fuse No. 11 is blown, there is a big possibility that grounding fault occurred in the circuit. (cause 3 reference)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance Wiring harness between FB1-11 outlet and M26 (male) (4) (5) Below 1 z (Disconnection or value defective contact Resistance with connector) Wiring harness between M26 (male) (8) and grounding Below 1 z value

Grounding fault of wiring harness (Contact with grounding (GND) circuit)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-11 outlet and M26 (male) (4) (5) and grounding

Voltage

Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4

Air conditioner unit defective

M26

Voltage

Between (4) (5) and (8)

20 – 30 V

If the result is as above, the air conditioner unit is defective.

20-452 (4)

PC160LC-7

TROUBLESHOOTING

E-32

Related circuit diagram

PC160LC-7

20-453 (1)

E-32

TROUBLESHOOTING

Serial No.: 11001 and up Troubleshooting procedure for air conditioner system a The control panel of the air conditioner constantly monitors the sensors and other devices in the system . When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially. a If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to the procedure for “Troubleshooting by self-diagnosis notice”, and then; • If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”. • If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.

Troubleshooting by self-diagnosis notice a Check the “Self-diagnosis notice” on the control panel according to the following procedure. •

How to display “Self-diagnosis notice” 1) Turn the starting switch ON. 2) Press OFF switch (1) and check that anything is not displayed on display monitor (2). 3) Hold the UP switch ( ) and DOWN switch ( ) of temperature setting switch (3) simultaneously for 3 seconds or more. 4) Check the “Self-diagnosis notice” displayed on display monitor (2).

•

How to select “Self-diagnosis notice” If multiple “Self-diagnosis notices” are recorded, press the UP switch ( ) or DOWN switch ( ) of temperature setting switch (3) to select another notice.

•

How to delete “Self-diagnosis notice” When reproducing the “Self-diagnosis notices” or after removing the cause of a failure, press the switches on both sides of recirc/fresh air selector switch (4) simultaneously for 3 seconds or more, and all the “Self-diagnosis notices” are deleted.

•

Finishing display of “Self-diagnosis notice” To finish display of the “Self-diagnosis notice”, press OFF switch (1) or turn the starting switch OFF.

20-453-1 (4)

Self-diagnosis notice E-E11 E12 E15 E16 E18 E43 E44 E45

PC160LC-7

E-32

TROUBLESHOOTING

Self-diagnosis notice

Trouble

Disconnection in recirculated air sensor

E11 Contents of trouble

• Disconnection in the recirculated air sensor system is detected.

Action of control panel

• Fixes the recirculated air temperature for control. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Related information

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

Defective recirculated 1 air sensor (Internal disconnection)

Disconnection of wiring harness (Disconnection 2 or defective contact with connector)

Defective air conditioner system

Self-diagnosis notice

Trouble

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male)

Resistance

Between (1) and (2)

300 z – 430 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (12) and TH I (female) (2)

Resistance

Max. 1 z

Wiring harness between M29 (female) (11) and TH I (female) (1)

Resistance

Max. 1 z

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

Short circuit in recirculated air sensor

E12 Contents of trouble

• Short circuit in the recirculated air sensor system is detected.

Action of control panel

Related information

Possible causes and standard value in normal state

Cause Defective recirculated air 1 sensor (Internal short circuit)

Disconnection of wiring harness (Disconnection 2 or defective contact with connector)

Defective air conditioner system

PC160LC-7

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male)

Resistance

Between (1) and (2)

300 z – 430 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (12) and TH I (female) (2)

Resistance

Max. 1 z

Wiring harness between M29 (female) (11) and TH I (female) (1)

Resistance

Max. 1 z

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

20-453-2 (4)

E-32

TROUBLESHOOTING

Self-diagnosis notice

Trouble

Disconnection in water temperature sensor

E15 Contents of trouble

• Disconnection in the water temperature sensor system is detected.

Action of control panel

• Ignores the warm-up control and fixes the engine water temperature at 60°C for control. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Related information

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning Defective water temperastarting switch ON. 1 ture sensor (Internal disResistance THW (male) connection) Between (1) and (2) 95 z – 455 kz Disconnection of wiring harness (Disconnection 2 or defective contact with connector)

Defective air conditioner system

Self-diagnosis notice

Trouble

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (14) and THW (female) (2)

Resistance

Max. 1 z

Wiring harness between M29 (female) (11) and THW (female) (1)

Resistance

Max. 1 z

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

Short circuit in water temperature sensor

E16 Contents of trouble

• Short circuit in the water temperature sensor system is detected.

Action of control panel

Related information

Possible causes and standard value in normal state

Cause Defective water tempera1 ture sensor (Internal short circuit)

Disconnection of wiring harness (Disconnection 2 or defective contact with connector)

Defective air conditioner system

20-453-3 (4)

Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THW (male)

Resistance

Between (1) and (2)

95 z – 455 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (14) and THW (female) (2)

Resistance

Max. 1 z

Wiring harness between M29 (female) (11) and THW (female) (1)

Resistance

Max. 1 z

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

PC160LC-7

E-32

TROUBLESHOOTING

Self-diagnosis notice

Trouble

Short circuit in daylight sensor

E18 Contents of trouble

• Short circuit in the daylight sensor system is detected.

Action of control panel

• Assumes that the daylight sensor is not installed for control. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Related information

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

Defective daylight sen1 The daylight sensor may be defective. Check it directly. sor (Internal short circuit) Disconnection of wiring harness (Disconnection 2 or defective contact with connector)

Defective air conditioner system

Self-diagnosis notice

Trouble

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (16) and P15 (female) (2)

Resistance

Max. 1 z

Wiring harness between M30 (female) (3) and P15 (female) (1)

Resistance

Max. 1 z

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

Abnormality in air outlet damper

E43 Contents of trouble

• Abnormality in air outlet servomotor system is detected.

Action of control panel

• Stops the air outlet servomotor. • When the following condition is satisfied, the operation returns to normalcy. • <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Related information

a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause

Standard value in normalcy and references for troubleshooting

Possible causes and standard value in normal state

Defective air outlet servo1 The air outlet servomotor may be defective. Check it directly. motor (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)

Defective air conditioner system

PC160LC-7

Wiring harness between MV1 (female) (1) and M30 (female) (3)

Resistance

Max. 1 z

Wiring harness between MV1 (female) (3) and M29 (female) (11)

Resistance

Max. 1 z

Wiring harness between MV1 (female) (5) and M30 (female) (9)

Resistance

Max. 1 z

Wiring harness between MV1 (female) (6) and M29 (female) (8)

Resistance

Max. 1 z

Wiring harness between MV1 (female) (7) and M29 (female) (9)

Resistance

Max. 1 z

If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

20-453-4 (4)

E-32

TROUBLESHOOTING

Self-diagnosis notice

Trouble

Abnormality in air mix damper

E44 Contents of trouble

• Abnormality in air mix servomotor system is detected.

Action of control panel

• Stops the air mix servomotor. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Related information

a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause

Possible causes and standard value in normal state

Defective air mix servo1 motor (Internal defect)

Standard value in normal state/Remarks on troubleshooting The air mix servomotor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)

Defective air conditioner system

20-453-5 (4)

Wiring harness between MAM (female) (1) and M29 (female) (11)

Resistance

Max. 1 z

Wiring harness between MAM (female) (3) and M30 (female) (3)

Resistance

Max. 1 z

Wiring harness between MAM (female) (5) and M30 (female) (2)

Resistance

Max. 1 z

Wiring harness between MAM (female) (6) and M29 (female) (4)

Resistance

Max. 1 z

Wiring harness between MAM (female) (7) and M29 (female) (5)

Resistance

Max. 1 z

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

PC160LC-7

E-32

TROUBLESHOOTING

Self-diagnosis notice

Trouble

Abnormality in recirculated and fresh air damper

E45 Contents of trouble

• Abnormality in recirculated and fresh air servomotor system is detected.

Action of control panel

• Stops the recirculated and fresh air servomotor. • When the following condition is satisfied, the operation returns to normalcy. <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> + <Starting air conditioner>

Related information

a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils.

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

Defective recirculated 1 and fresh air servomotor (Internal defect)

The recirculated and fresh air servomotor may be defective. Check it directly.

2 Defective fuse (in unit)

If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection 3 in wiring harness or defective contact in connector)

Defective air conditioner system

PC160LC-7

Wiring harness between MRF (female) (1) and M29 (female) (6)

Resistance

Max. 1 z

Wiring harness between MRF (female) (3) and M29 (female) (7)

Resistance

Max. 1 z

Wiring harness between MRF (female) (7), fuse in unit, and M33 (female) (3)

Resistance

Max. 1 z

If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

20-453-6 (4)

TROUBLESHOOTING

E-32

Electrical Circuit Diagram for Air Conditioner

20-453-7 (4)

PC160LC-7

E-32

TROUBLESHOOTING

Troubleshooting by failure phenomenon Trouble

• The air conditioner does not operate.

(1) The air conditioner does not operate at all.

Related information Cause 1 Defective fuse No. 11

Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.) a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes and standard value in normal state

Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)

Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)

Wiring harness between fuse 11 outlet and M33 (male) (3)

Resistance

Max. 1z

Wiring harness between M27 (female) (14) and M30 (female) (6)

Resistance

Max. 1z

Wiring harness between M33 (male) (2) and chassis ground

Resistance

Max. 1z

Wiring harness between M29 (female) (12) and chassis ground

Resistance

Max. 1z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between circuit breaker fuse 11 outlet and M33 (male) (3) and chassis ground

Resistance

Min. 1 Mz

Between wiring harness between M27 (female) (14) and M30 (female) (6) and chassis ground

Resistance

Min. 1 Mz

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4

Defective air conditioner unit

M33

Voltage

Between (2) and (3)

20 V – 30 V

If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective control panel

M30, M29

Voltage

Between M30 (6) and M29 (12)

20 V – 30 V

If the above voltage is normal and the air conditioner does not operate, the control panel is defective.

PC160LC-7

20-453-8 (4)

E-32

TROUBLESHOOTING

Trouble

• The air conditioner does not operate.

(2) Air does not come out (Air flow is insufficient).

Related information Cause 1 Defective fuse (in unit)

Defective blower relay (on coil side)

Defective blower relay (on contact side)

Possible causes and standard value in normal state

Defective power transis4 tor (Internal defect)

Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R30 (male)

Resistance

Between (1) and (3)

140 – 340 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. R30

Fan switch

Voltage

Between (4) and chassis ground

ON (Operated)

20 – 30 V

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fan switch

If air flow can be changed with fan switch, Operate in range of Low, Medium, and High power transistor is normal. a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective blower motor (Internal defect)

MB (female)

Fan switch

Voltage

Between (1) and (2)

ON (Operated)

20 – 30 V

If the above voltage is normal and the blower motor does not rotate, the blower motor is defective. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection 6 in wiring harness or defective contact in connector)

Defective air conditioner system

20-453-9 (4)

Wiring harness between fuse 11 outlet, fuse in unit, R30 (3), R31 (female) (1), and M30 (female) (6)

Resistance

Max. 1 z

Wiring harness between M29 (female) (3) and R30 (female) (1)

Resistance

Max. 1 z

Wiring harness between M29 (female) (12) and chassis ground

Resistance

Max. 1 z

Wiring harness between MB (female) (1) and R30 (female) (4)

Resistance

Max. 1 z

Wiring harness between MB (female) (2) and PTR (female) (3)

Resistance

Max. 1 z

Wiring harness between PTR (female) (1) and chassis ground

Resistance

Max. 1 z

Wiring harness between PTR (female) (2) and M30 (female) (7)

Resistance

Max. 1 z

Wiring harness between PTR (female) (4) and M30 (female) (8)

Resistance

Max. 1 z

If none of causes 1 – 6 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

PC160LC-7

E-32

TROUBLESHOOTING

Trouble

• The air conditioner does not operate.

(3) Air is not cooled (Cooling capacity is low).

Related information Cause 1 Defective fuse (in unit)

Possible causes and standard value in normal state

Defective compressor relay (on coil side)

Defective compressor relay (on contact side)

Defective thermostat (Internal defect)

Defective high/low pres5 sure switch (Internal disconnection)

Resistance

Between (1) and (2)

140 – 340 z

a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position). R31

Fan switch

Voltage

Between (4) and chassis ground

ON (Operated)

20 – 30 V

The thermostat may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P17 (male)

Resistance

Between (1) and (2)

Max. 1 z

Defective compressor clutch (Internal defect)

The compressor clutch may be defective. Check it directly.

Defective compressor (Internal defect)

The compressor may be defective. Check it directly. a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection 8 in wiring harness or defective contact in connector)

Defective air conditioner system

PC160LC-7

Wiring harness between M30 (female) (4) and P17 (female) (1)

Resistance

Max. 1 z

Wiring harness between P17 (female) (2) and chassis ground

Resistance

Max. 1 z

Wiring harness between fuse 11 outlet, R31 (female) (2), fuse in unit, R31 (female) (1), and M30 (female) (6)

Resistance

Max. 1 z

Wiring harness between ST1 (female) (1) and R31 (female) (3)

Resistance

Max. 1 z

Wiring harness between M29 (female) (2) and ST1 (female) (2)

Resistance

Max. 1 z

Wiring harness between M29 (female) (12) and chassis ground

Resistance

Max. 1 z

Wiring harness between R31 (female) (4) and E06 (female) (1)

Resistance

Max. 1 z

If none of causes 1 – 8 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

20-453-10 (4)

TROUBLESHOOTING

E-32

Electrical Circuit Diagram for Air Conditioner

20-453-11 (4)

PC160LC-7

E-33

TROUBLESHOOTING

E-33 Travel alarm does not sound or does not stop sounding

Failure information

(1) The travel alarm does not sound while the • Travel alarm does not sound or does not stop machine is traveling. sounding. (2) The alarm begins to sound when the machine is at a standstill.

Relative information

—

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Fuse No. 15 fault

When the fuse No. 15 is blown, there is a big possibility that grounding fault occurred in the circuit. (cause 4 reference) !Start the engine for the troubleshooting (Monitoring).

Travel signal fault

Monitoring code

Item

Normal display

019

Travel

Control lever operation: ON Control lever NEUTRAL: OFF

If the monitor display is not correct, proceed to No. E-29 Troubleshooting.

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Wiring harness between FB1-15 outlet to J03 and A43 Resistance (Disconnection or Below 1 Ω (female) (1) value defective contact Resistance with connector) Wiring harness between A43 (female) (2) and J01 (19) Below 1 Ω value

Grounding fault of wiring harness (Contact with grounding (GND) circuit)

Travel alarm fault

20-454 (1)

!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-15 outlet to J03 and A43 (female) (1) and grounding

Resistance value

Above 1 MΩ

As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes listed in Item 1 through 4 above is found, the travel alarm is judged as defective)

PC160LC-7

TROUBLESHOOTING

E-33

Related circuit diagram

PC160LC-7

20-455 (1)

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-503 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS ...................................................... 20-504 H- 1 Speed or power of all work equipment, swing, and travel are low .................................................... 20-506 H- 2 Engine speed sharply drops or engine stalls .................................................................................... 20-507 H- 3 No work equipment, travel and swing move ..................................................................................... 20-508 H- 4 Abnormal noise is heard from around hydraulic pump ..................................................................... 20-508 H- 5 Auto-decelerator does not work ........................................................................................................ 20-509 H- 6 Fine control mode does not function................................................................................................. 20-509 H- 7 Speed or power of boom is low......................................................................................................... 20-510 H- 8 Speed or power of arm is low ............................................................................................................20-511 H- 9 Speed or power of bucket is low ....................................................................................................... 20-512 H-10 Work equipment does not move in its single operation .................................................................... 20-513 H-11 Hydraulic drift of work equipment is large......................................................................................... 20-514 H-12 Time lag of work equipment is large ................................................................................................. 20-515 H-13 One-touch power max system does not operate .............................................................................. 20-515 H-14 Work equipment loaded more is slower during compound operation ............................................... 20-516 H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE ................................... 20-516 H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel ............ 20-517 H-17 Machine deviates during travel ......................................................................................................... 20-518 H-18 Travel speed is low ........................................................................................................................... 20-519 H-19 Machine cannot be steered easily or steering power is low ............................................................. 20-520 H-20 Travel speed does not change or it is kept low or high..................................................................... 20-521 H-21 Track does not move (only either side)............................................................................................. 20-521 H-22 Machine does not swing ................................................................................................................... 20-522 H-23 Swing acceleration or swing speed is low ........................................................................................ 20-523 H-24 Excessive overrun when stopping swing .......................................................................................... 20-524 H-25 When upper structure stops swinging, it makes large shock ............................................................ 20-525 H-26 When upper structure stops swinging, it makes large sound............................................................ 20-525 H-27 Hydraulic drift of swing is large ......................................................................................................... 20-526 H-28 Attachment circuit does not change.................................................................................................. 20-527 H-29 Flow rate in attachment circuit cannot be adjusted........................................................................... 20-527

PC160LC-7

20-501 (1)

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ! Troubleshooting Table collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Phenomena occurring on machine

Relative information

Information on occurred failures and troubleshooting

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Cause for presumed failure (The attached No. for filing and reference purpose only. It does not stand for any priority)

<Contents> • The standard values in normalcy by which to judge "good" or "no good" about presumed causes. • References for making judgement of "good" or "no good"

PC160LC-7

20-503 (1)

TROUBLESHOOTING

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS

20-504 (1)

PC160LC-7

TROUBLESHOOTING

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS

! This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems.

PC160LC-7

20-505 (1)

H-1

TROUBLESHOOTING

H-1 Speed or power of all work equipment, swing, and travel are low Failure information

• Speed or power of all work equipment, swing, and travel are low.

Relative information

• Conduct the troubleshooting in working mode A.

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. Control levers

Hydraulic oil temperature

Unload pressure

Approx. 50°C

Below 5.9 MPa {Below 60 kg/cm2}

Approx. 80°C

Below 7.4 MPa {Below 75 kg/cm2}

Malfunction of unload valve All levers in NEUTRAL

Presumed cause and standard value in normalcy

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Defective adjustment or operation of main relief valve

Control lever

Main relief pressure

Arm relieved in IN direction

33.6 – 37.0 MPa {343 – 378 kg/cm2}

If the oil pressure cannot be set normally by adjustment, the main relief valve may be malfunctioning or may have an internal defect. Check the main relief valve directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 3

Malfunction of self-pressure reducing valve

Control levers

Control circuit basic pressure

All levers in NEUTRAL

2.84 – 3.43 MPa {29 – 35 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Defective adjustment or operation of PC valve

Measured oil pressure

Measurement conditions

Oil pressure ratio

Pump discharge pressure

Swing lock: ON Arm: Relieved in IN direction

PC valve output pressure

Approx. 0.6(Approx. 3/5)

If the oil pressure cannot be set normally by adjustment, the PC valve may be malfunctioning or may have an internal defect. Check the PC valve directly. Oil pressure ratio Measured oil pressure 5

Defective adjustment or operation of LS valve

Pump discharge pressure LS valve output pressure

Bucket curled (Lever at stroke end)

All levers in NEUTRAL Almost same pressure

1 Approx. 0.6(Approx. 3/5)

If the oil pressure cannot be set normally by adjustment, the LS valve may be malfunctioning or may have an internal defect. Check the LS valve directly. 6

Malfunction of servo piston

The servo piston may have malfunction. Check it directly.

Piston pump defective

If there is none of the causes listed above, the piston pump may have problems of lowering of performance, malfunction, internal defect, etc.

20-506 (1)

PC160LC-7

H-2

TROUBLESHOOTING

H-2 Engine speed sharply drops or engine stalls Failure information

• Engine speed sharply drops or the engine stalls.

Relative information

• Conduct the troubleshooting in working mode A.

Cause

Standard value in normalcy and references for troubleshooting !Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normalcy

Improper adjustment or malfunctioning of main relief valve

Control lever

Main relief pressure

Arm IN relief

33.6 – 37.0 MPa {343 – 378 kg/cm2}

If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the main relief valve or its internal failure is suspected. In that case, check the valve itself. !Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure to be measured 2

Improper adjustment or malfunctioning of PC valve

Pump delivery pressure PC valve output pressure

Measurement condition

Oil pressure ratio

Swing lock: ON Arm IN relief

1 Approx. 0.6(Approx. 3/5)

If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the PC valve or its internal failure is suspected. In that case, check the valve itself. Oil pressure to be measured 3

Improper adjustment or malfunctioning of LS valve

Pump delivery pressure LS valve output pressure

Oil pressure ratio All control levers in NEUTRAL Nearly equal pressure

Bucket curled (control lever full stroke) 1 Approx. 0.6(Approx. 3/5)

If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve itself. 4

Orifice or filter in servo equipment clogged

The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself.

Malfunction of servo piston

The servo piston is suspected of malfunction. Check the piston itself.

PC160LC-7

20-507 (1)

H-3, H-4

TROUBLESHOOTING

H-3 No work equipment, travel and swing move Failure information

• No work equipment, travel and swing move.

Relative information

• Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting !Stop engine for preparations. Start troubleshooting at engine high idling.

Malfunctioning of PPC lock solenoid valve

Safety lock lever

Main relief pressure

Locked

0 MPa {0 kg/cm2}

Released

2.84 – 3.43 MPa {29 – 35 kg/cm2}

!Stop engine for preparations. Start troubleshooting at engine high idling. 2

Malfunctioning of self reducing pressure valve

Control lever

Control circuit source pressure

All control levers in NEUTRAL position

2.84 – 3.43 MPa {29 – 35 kg/cm2}

Piston pump defective

The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in the following manner. • Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal condition.

Damper defective

It is presumed that the pump shaft does not rotate due to some internal failure of the dumper. Check the damper itself.

H-4 Abnormal noise is heard from around hydraulic pump • An abnormal noise is heard from around the hydraulic pump.

Relative information

—

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Hydraulic oil level lowered

Make a visual check.

Quality of hydraulic oil bad

Air may have get mixed with the oil. Make a visual check.

Hydraulic tank cap breather clogged

It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside the tank. Make a visual check.

Hydraulic tank strainer clogged

It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative pressure in the suction circuit. Make a visual check.

Piston pump defective

The piston pump is suspected of an internal failure. Check the pump itself.

20-508 (1)

PC160LC-7

H-5, H-6

TROUBLESHOOTING

H-5 Auto-decelerator does not work • Auto-decelerator does not work.

Relative information

• This troubleshooting mode is applied when the auto-decelerator does not work, while operating the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch only in the travel circuit -actually located inside PPC valve) • Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting !Stop engine for preparations. Start troubleshooting at engine high idling.

Malfunctioning of travel PPC valve (shuttle valve)

Travel control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kg/cm2}

Operation

Above 2.7 MPa {Above 28 kg/cm2}

H-6 Fine control mode does not function Failure information

• Fine control mode does not function.

Relative information

• Set the working mode at A mode for the troubleshooting.

Cause

Presumed cause and standard value in normalcy

Orifice in LS circuit clogged

Standard value in normalcy and references for troubleshooting The orifice in the LS circuit is presumed to be clogged. Check the orifice itself. !Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured

Improper adjustment or malfunctioning of LS valve

Pump delivery pressure LS valve output pressure

All control levers in NEUTRAL Nearly equal oil pressure

At bucket CURL (control lever full stroke) 1 Approx. 0.6 (Approx. 3/5)

If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve itself. 3

PC160LC-7

Malfunctioning of servo piston

Malfunctioning of the servo piston is suspected. Check the piston itself.

20-509 (1)

H-7

TROUBLESHOOTING

H-7 Speed or power of boom is low Failure information

• Speed or power of boom is low.

Relative information

• Conduct the troubleshooting in working mode A.

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of right PPC valve (boom circuit)

Right work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kg/cm2}

Boom RAISE position Boom LOWER position

Above 2.7 MPa {Above 28 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Presumed cause and standard value in normalcy

Malfunction of pump mergedivider solenoid valve

Control levers

Solenoid output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only (on either or both sides)

2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunction of pump mergedivider valve

The pump merge-divider valve of the control valve may have a malfunction. Check it directly.

Malfunction of boom control valve (spool)

The spool of the boom control valve may have a malfunction. Check it directly (including stroke limiting mechanism on RAISE side).

Malfunction of boom control valve (pressure compensation valve)

The pressure compensation valve of the boom control valve may have a malfunction. Check it directly.

Malfunction or defective sealing of boom control valve (regeneration valve)

The regeneration valve of the boom control valve may have a malfunction or its sealing may be defective. Check it directly.

Malfunction of boom control valve (lock valve)

The lock valve of the boom control valve may have a malfunction. Check it directly.

Malfunction or defective sealing of boom control valve (safety-suction valve)

The safety-suction valve of the boom control valve (on the head side) may have a malfunction or its sealing may be defective. Check it directly.

Malfunction or defective sealThe suction valve of the boom control valve (on the bottom side) may have a maling of boom control valve (sucfunction or its sealing may be defective. Check it directly. tion valve)

Malfunction or defective seal10 ing of centralized safety-suction valve

The centralized safety-suction valve of the control valve may have a malfunction or its sealing may be defective. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

11 Boom cylinder defective

20-510 (1)

Boom cylinder

Leakage from cylinder

Relieved in RAISE direction

20 cc/min

PC160LC-7

H-8

TROUBLESHOOTING

H-8 Speed or power of arm is low Failure information

• Speed or power of arm is low.

Relative information

• Conduct the troubleshooting in working mode A.

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of left PPC valve (arm circuit)

Left work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kg/cm2}

Arm IN position Arm OUT position

Above 2.7 MPa {Above 28 kg/cm2}

Presumed cause and standard value in normalcy

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 2

Malfunction of pump mergedivider solenoid valve

Control levers

Solenoid output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only (on either or both sides)

2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunction of pump mergedivider valve

The pump merge-divider valve of the control valve may have a malfunction. Check it directly.

Malfunction of arm control valve (spool)

The spool of the arm control valve may have a malfunction. Check it directly (including stroke limiting mechanisms on IN side and OUT side).

Malfunction of arm control valve (pressure compensation valve)

The pressure compensation valve of the arm control valve may have a malfunction. Check it directly.

Malfunction of arm control valve (lock valve) (when lock valve is installed)

The lock valve of the arm control valve may have a malfunction. Check it directly.

Malfunction or defective sealing of arm control valve (safety-suction valves)

The safety-suction valves of the arm control valve (on the bottom side and head side) may have a malfunction or their sealing may be defective. Check them directly.

Malfunction or defective sealing of centralized safety-suction valve

Arm cylinder defective

PC160LC-7

Arm cylinder

Leakage from cylinder

Relieved in IN direction

20 cc/min

20-511 (1)

H-9

TROUBLESHOOTING

H-9 Speed or power of bucket is low Failure information

• Speed or power of bucket is low.

Relative information

• Conduct the troubleshooting in working mode A. Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of right PPC valve (bucket circuit)

Right work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kg/cm2}

Bucket CURL position Bucket DUMP position

Above 2.7 MPa {Above 28 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Presumed cause and standard value in normalcy

Malfunction of pump mergedivider solenoid valve

Control levers

Solenoid output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only (on either or both sides)

2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunction of pump mergedivider valve

The pump merge-divider valve of the control valve may have a malfunction. Check it directly.

Malfunction of bucket control valve (spool)

The spool of the bucket control valve may have a malfunction. Check it directly.

Malfunction of bucket control valve (pressure compensation valve)

The pressure compensation valve of the bucket control valve may have a malfunction. Check it directly.

Malfunction or defective sealing of bucket control valve (safety-suction valves)

The safety-suction valves of the bucket control valve (on the bottom side and head side) may have a malfunction or their sealing may be defective. Check them directly.

Malfunction or defective sealing of centralized safety-suction valve

20-512 (1)

Bucket cylinder defective

Bucket cylinder

Leakage from cylinder

Relieved in CURL direction

20 cc/min

PC160LC-7

H-10

TROUBLESHOOTING

Failure information

• The boom does not move when operated independently. • Work equipment does not move in its single • The arm does not move when operated indeoperation pendently. • The bucket does not move when operated independently.

Relative information

• Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

H-10 Work equipment does not move in its single operation

Cause

Standard value in normalcy and references for troubleshooting !Stop engine for preparations. Start troubleshooting at engine high idling.

PC160LC-7

Malfunctioning of PPC valve

Malfunctioning of work equipment control valve (spool)

Work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kg/cm2}

Operation

Above 2.7 MPa {Above 28 kg/cm2}

The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.

20-513 (1)

H-11

TROUBLESHOOTING

Failure information

• Hydraulic drift of work equipment is large.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

H-11 Hydraulic drift of work equipment is large (1) Hydraulic drift of boom is large.

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Boom cylinder defective

Boom cylinder

Leakage from cylinder

Relieved in RAISE direction

20 cc/min

Defective sealing of boom control valve (lock valve)

Sealing of the lock valve of the boom control valve may be defective. Check it directly.

Defective sealing of centralized safety-suction valve

Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly.

Failure information

• Hydraulic drift of work equipment is large.

Relative information

• Conduct the troubleshooting in working mode A. Cause

(2) Hydraulic drift of arm is large.

Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 1

Arm cylinder defective

Arm cylinder

Leakage from cylinder

Relieved in IN direction

20 cc/min

Defective sealing of arm control valve (spool)

Sealing of the spool of the arm control valve may be defective. Check it directly.

Defective sealing of arm control valve (suction valve)

Sealing of the suction valve of the arm control valve (on the bottom side) may be defective. Check it directly.

Defective sealing of arm control valve (lock valve) (when lock valve is installed)

Sealing of the lock valve of the arm control valve may be defective. Check it directly.

Defective sealing of centralized safety-suction valve

Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly.

Failure information

• Hydraulic drift of work equipment is large.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Bucket cylinder defective

Bucket cylinder

Leakage from cylinder

Relieved in CURL direction

20 cc/min

Defective sealing of bucket control valve (spool)

Sealing of the spool of the bucket control valve may be defective. Check it directly.

Defective sealing of bucket control valve (suction valve)

Sealing of the suction valve of the bucket control valve (on the bottom side) may be defective. Check it directly.

Defective sealing of centralized safety-suction valve

Sealing of the centralized safety-suction valve of the control valve may be defective. Check it directly.

20-514 (1)

(3) Hydraulic drift of bucket is large.

PC160LC-7

H-12, H-13

TROUBLESHOOTING

Failure information

• Time lag of work equipment is large.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

H-12 Time lag of work equipment is large

Cause

Standard value in normalcy and references for troubleshooting

Malfunction of control valve (regeneration valve) [Only boom]

The regeneration valve of the control valve may have a malfunction. Check it directly.

Malfunction of control valve (suction valve).

The suction valve of the control valve (on the head side) may have a malfunction. Check it directly.

H-13 One-touch power max system does not operate Failure information

• One-touch power max system does not operate.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

PC160LC-7

Malfunction of 2-stage relief solenoid valve

Malfunction of main relief valve

Swing lock switch

Solenoid output pressure

OFF

0 MPa {0 kg/cm2}

2.84 – 3.43 MPa {29 – 35kg/cm2}

The main relief valve of the control valve may have a malfunction. Check it directly.

20-515 (1)

H-14, H-15

TROUBLESHOOTING

H-14 Work equipment loaded more is slower during compound operation • Work equipment loaded more is slower during compound operation.

Relative information

—

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting The pressure compensation valve of the work equipment loaded less may have a malfunction. Check it directly. Compound operation

Malfunction of pressure compensation valve of work equipment loaded less

More loaded side Less loaded side

Boom RAISE + Arm IN

Boom

Arm

Boom RAISE + Arm OUT

Arm

Boom

Boom RAISE + Bucket CURL

Boom

Bucket

Arm IN + Bucket CURL

Arm

Bucket

Boom LOWER + Arm OUT

Arm

Boom

H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE • Boom RAISE speed is low in compound operation of swing + boom RAISE.

Relative information

• If the speed of single operation of the boom RAISE speed is slow, conduct troubleshooting for H7 first.

Presumed cause and standard value in normalcy

Failure information

Cause

20-516 (1)

Malfunction or defective sealing of LS selector valve

Standard value in normalcy and references for troubleshooting

The LS selector valve of the control valve may have a malfunction or its sealing may be defective. Check it directly.

PC160LC-7

H-16

TROUBLESHOOTING

H-16 Travel speed lowers largely during compound operation of work equipment/ swing + travel Failure information

• Travel speed lowers largely during compound operation of work equipment/swing + travel.

Relative information

• Conduct the troubleshooting in working mode A. Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Presumed cause and standard value in normalcy

Malfunction of pump mergedivider solenoid valve

Control levers

Solenoid output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only (on either or both sides)

2.84 – 3.43 MPa {29 – 35kg/cm2}

Malfunction of pump mergedivider valve

The pump merge-divider valve may have a malfunction. Check it directly.

Malfunction of work equipment control valve (pressure compensation valve)

The pressure compensation valve of the work equipment control valve may have a malfunction. Check it directly.

Malfunction of swing control valve (pressure compensation valve)

The pressure compensation valve of the swing control valve may have a malfunction. Check it directly.

Malfunction of travel control valve (pressure compensation valve)

The pressure compensation valve of the travel control valve may have a malfunction. Check it directly.

PC160LC-7

20-517 (1)

H-17

TROUBLESHOOTING

H-17 Machine deviates during travel Failure information

• Machine deviates during travel.

Relative information

• Conduct the troubleshooting in working mode A.

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of self-pressure reducing valve

Control levers

Control circuit basic pressure

All levers in NEUTRAL

2.84 – 3.43 MPa {29 – 35 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 2

Malfunction of travel PPC valve

Travel lever

PPC valve output pressure

Forward or reverse position

Above 2.7 MPa {Above 28 kg/cm2}

Difference in above output between both sides

Below 0.4 MPa {Below 4 kg/cm2}

Presumed cause and standard value in normalcy

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 3

Malfunction of pump mergedivider valve

Travel lever

Solenoid valve output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only (on either or both sides)

2.84 – 3.43 MPa {29 – 35 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 4

Malfunction of travel junction solenoid valve

Travel lever

Solenoid valve output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only on either side

2.84 – 3.43 MPa {29 – 35 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. Control levers 5

Hydraulic oil temperature

Unload pressure

Approx. 50°C

Below 5.9 MPa {Below 60 kg/cm2}

Approx. 80°C

Below 7.4 MPa {Below 75 kg/cm2}

Malfunction of unload valve All levers in NEUTRAL

Malfunction of pump mergedivider valve

The pump merge-divider valve may have a malfunction. Check it directly.

Malfunction of travel junction valve

The travel junction valve may have a malfunction. Check it directly.

Malfunction of travel control lever (spool)

The spool of the travel control lever may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Travel motor defective

10 Final drive defective

20-518 (1)

Travel lever

Leakage from travel motor

Travel circuit relieved

27.2 /min

The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)

PC160LC-7

H-18

TROUBLESHOOTING

H-18 Travel speed is low Failure information

• Travel speed is low.

Relative information

• Conduct the troubleshooting in working mode A.

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of self-pressure reducing valve

Control levers

Control circuit basic pressure

All levers in NEUTRAL

2.84 – 3.43 MPa {29 – 35 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Presumed cause and standard value in normalcy

Malfunction of travel PPC valve

Travel lever

PPC valve output pressure

Forward or reverse position

Above 2.7 MPa {Above 28 kg/cm2}

Difference in above output between both sides

Below 0.4 MPa {Below 4 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 3

Malfunction of pump mergedivider valve

Travel lever

Solenoid valve output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only (on either or both sides)

2.84 – 3.43 MPa {29 – 35 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. Control levers 4

Hydraulic oil temperature

Unload pressure

Approx. 50°C

Below 5.9 MPa {Below 60 kg/cm2}

Approx. 80°C

Below 7.4 MPa {Below 75 kg/cm2}

Malfunction of unload valve All levers in NEUTRAL

Malfunction of pump mergedivider valve

The pump merge-divider valve may have a malfunction. Check it directly.

Malfunction of travel control lever (spool)

The spool of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel control lever (pressure compensation valve)

The pressure compensation valve of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel control lever (suction valve)

The suction valve of the travel control lever may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Travel motor defective

10 Final drive defective

PC160LC-7

Travel lever

Leakage from travel motor

Travel circuit relieved

27.2 /min

The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)

20-519 (1)

H-19

TROUBLESHOOTING

H-19

Machine cannot be steered easily or steering power is low

Failure information

• Machine cannot be steered easily or steering power is low.

Relative information

• Conduct the troubleshooting in working mode A.

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of travel PPC valve (steering spool)

Travel lever

PPC valve output pressure (at starting switch)

In NEUTRAL on both sides

0 MPa {0 kg/cm2}

Operated on either side

Above 2.7 MPa {Above 28 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Presumed cause and standard value in normalcy

Malfunction of pump mergedivider valve

Travel lever

Solenoid valve output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only (on either or both sides)

2.84 – 3.43 MPa {29 – 35 kg/cm2}

!Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting. 3

Malfunction of travel junction solenoid valve

Travel lever

Solenoid valve output pressure

All levers in NEUTRAL

0 MPa {0 kg/cm2}

Position for travel only on either side

2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunction of hydraulic pump (check valve)

The check valve of the hydraulic pump may have a malfunction or its sealing may be defective. Check it directly.

Malfunction of hydraulic pump (shuttle valve)

The shuttle valve of the hydraulic pump may have a malfunction or its sealing may be defective. Check it directly.

Malfunction of pump mergedivider valve

The pump merge-divider valve may have a malfunction. Check it directly.

Malfunction of travel junction valve

The travel junction valve may have a malfunction. Check it directly.

Malfunction of travel control lever (spool)

The spool of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel control lever (pressure compensation valve)

The pressure compensation valve of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel control lever (suction valve)

The suction valve of the travel control lever may have a malfunction. Check it directly.

Malfunction of travel motor (Safety and check valve)

The safety and check valve of the travel motor may have a malfunction. Check it directly. (It may be checked by exchanging the front and rear motors or the right and left motors and checking change of the phenomenon.)

20-520 (1)

PC160LC-7

H-20, H-21

TROUBLESHOOTING

H-20 Travel speed does not change or it is kept low or high Failure information

• Travel speed does not change or it is kept low or high.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of travel speed selector solenoid valve

Malfunction of travel motor (speed-changer unit)

Travel speed

Travel lever

Solenoid valve output pressure

In NEUTRAL

0 MPa {0 kg/cm2}

Operated

2.84 – 3.43 MPa {29 – 35 kg/cm2}

The speed-changer unit of the travel motor may have a malfunction. Check it directly.

H-21 Track does not move (only either side) Failure information

• Track does not move (only either side).

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Defective seat of travel control valve (suction valve)

The suction valve seat of the travel control lever may be defective. Check it directly.

Defective seat of travel control The safety and check valve seat of the travel control lever may be defective. valve (Safety and check valve) Check it directly.

Malfunction of travel motor (counterbalance valve)

The counterbalance valve of the travel motor may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

PC160LC-7

Travel motor defective

Final drive defective

Travel lever

Leakage from travel motor

Travel circuit relieved

27.2 /min

The final drive may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)

20-521 (1)

H-22

TROUBLESHOOTING

H-22 Machine does not swing • Machine does not swing.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Failure information

Cause

(1) Machine does not swing in either direction.

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of swing holding brake solenoid valve

Malfunction of swing motor (holding brake)

Right work equipment control lever

Solenoid valve output pressure

In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing

2.84 – 3.43 MPa {29 – 35 kg/cm2}

The holding brake of the swing motor may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Swing motor defective

Swing machinery defective

Left work equipment control lever

Leakage from swing motor

Swing circuit relieved

10 /min

The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)

Failure information

• Machine does not swing.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

(2) Machine does not swing in only one direction.

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of swing PPC valve

Malfunction of swing control valve (spool)

Left work equipment control lever

PPC valve output pressure

In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing

Above 2.7 MPa {Above 28 kg/cm2}

The spool of the swing control valve may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Defective adjustment or malfunction of swing motor (safety valve)

Defective sealing of swing motor (suction valve)

20-522 (1)

Swing lock switch

Left work equipment control lever

Swing relief pressure

Swing circuits relieved (separately on both sides)

28.9 – 32.9 MPa {295 – 335 kg/cm2}

Sealing of the suction valve of the swing motor may be defective. Check it directly.

PC160LC-7

H-23

TROUBLESHOOTING

H-23 Swing acceleration or swing speed is low (1) Swing acceleration or swing speed is low in both directions.

Failure information

• Swing acceleration or swing speed is low.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Malfunction of swing control valve (pressure compensation valve)

The pressure compensation valve of the swing control valve may have a malfunction. Check it directly.

Malfunction of swing motor (holding brake)

The holding brake of the swing motor may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Swing motor defective

Swing machinery defective

Left work equipment control lever

Leakage from swing motor

Swing circuit relieved

10 /min

The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)

(2) Swing acceleration or swing speed is low in only one direction.

Failure information

• Swing acceleration or swing speed is low.

Relative information

• Conduct the troubleshooting in working mode A. Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Presumed cause and standard value in normalcy

Malfunction of swing PPC valve

Malfunction of swing control valve (spool)

Left work equipment control lever

PPC valve output pressure

In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing

Above 2.7 MPa {Above 28 kg/cm2}

The spool of the swing control valve may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

PC160LC-7

Defective adjustment or malfunction of swing motor (safety valve)

Defective sealing of swing motor (suction valve)

Swing lock switch

Left work equipment control lever

Swing relief pressure

Swing circuits relieved (separately on both sides)

28.9 – 32.9 MPa {295 – 335 kg/cm2}

Sealing of the suction valve of the swing motor may be defective. Check it directly.

20-523 (1)

H-24

TROUBLESHOOTING

H-24 Excessive overrun when stopping swing • Excessive overrun when stopping swing.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and stan-dard value in normalcy

(1) Overrun of upper structure is large in both directions.

Failure information

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Swing motor defective

Left work equipment control lever

Leakage from swing motor

Swing circuit relieved

10 /min

(2) Overrun of upper structure is large in only one direction.

Failure information

• Excessive overrun when stopping swing.

Relative information

• Conduct the troubleshooting in working mode A. Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Presumed cause and standard value in normalcy

Left work equipment control lever

PPC valve output pressure

In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing

Above 2.7 MPa {Above 28 kg/cm2}

Clogging of swing PPC slow return valves

The swing PPC slow return valves may be clogged. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

Malfunction of swing control valve (spool)

The spool of the swing control valve may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

20-524 (1)

Malfunction of swing PPC valve

Defective adjustment or malfunction of swing motor (safety valve)

Defective sealing of swing motor (suction valve)

Swing lock switch

Left work equipment control lever

Swing relief pressure

Swing circuits relieved (separately on both sides)

28.9 – 32.9 MPa {295 – 335 kg/cm2}

Sealing of the suction valve of the swing motor may be defective. Check it directly.

PC160LC-7

H-25, H-26

TROUBLESHOOTING

H-25 When upper structure stops swinging, it makes large shock Failure information

• When upper structure stops swinging, it makes large shock.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of swing PPC valve

Left work equipment control lever

PPC valve output pressure

In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing

Above 2.7 MPa {Above 28 kg/cm2}

Malfunction of swing PPC slow return valves

The swing PPC slow return valves may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

Malfunction of swing motor (shockless valve)

The shockless valve of the swing motor may have malfunction. Check it directly.

H-26 When upper structure stops swinging, it makes large sound • When upper structure stops swinging, it makes large sound.

Relative information

• Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Malfunction of back pressure check valve

The back pressure check valve may have a malfunction. Check it directly.

Malfunction of swing motor (safety valve)

The swing motor (safety valves) may have a malfunction. Check the valves directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

Malfunction of swing motor (suction valves)

The swing motor (suction valves) may have a malfunction. Check the valves directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

Swing machinery defective

The swing machinery may have a defect in it. Check it directly. (It may be checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)

PC160LC-7

20-525 (1)

H-27

TROUBLESHOOTING

H-27 Hydraulic drift of swing is large Failure information

• Hydraulic drift of swing is large.

Relative information

• If the swing lock switch is turned ON or the swing holding brake release switch is in the normal position, the swing brake operates and the disc brake holds the upper structure. • Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

(1) When swing holding brake is operated

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of swing holding brake solenoid valve

Malfunction or internal defect of swing motor (holding brake)

Right work equipment control lever

Solenoid valve output pressure

In NEUTRAL

0 MPa {0 kg/cm2}

Operated for swing

2.84 – 3.43 MPa {29 – 35 kg/cm2}

The holding brake of the swing motor may have a malfunction or an internal defect. Check it directly.

Failure information

• Hydraulic drift of swing is large.

Relative information

• If the swing holding brake release is in the emergency position, the swing holding brake is released and the upper structure is held with only hydraulic pressure. • Conduct the troubleshooting in working mode A.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Defective sealing of swing control valve (spool)

Sealing of the spool of the swing control valve may have a malfunction. Check it directly.

Defective sealing of swing motor (safety valve)

The safety valves of the swing motor may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

Defective sealing of swing motor (suction valve)

The suction valves of the swing motor may have a malfunction. Check them directly. (They may be checked by exchanging with each other and checking change of the phenomenon.)

Malfunction or defective sealing of swing motor (shockless valve)

The shockless valve of the swing motor may have a malfunction or its sealing may be defective. Check it directly.

20-526 (1)

(2) When swing holding brake is released

PC160LC-7

H-28, H-29

TROUBLESHOOTING

H-28 Attachment circuit does not change When attachment is installed Failure information

• The return circuit of the attachment circuit does not change.

Relative information

• If an attachment is installed, the service circuit changes according to the selected working mode as shown below. 1) In mode A or E: The double acting circuit is selected and the safety valve is set to the low pressure. 2) In mode B: The single acting circuit is selected and the safety valve is set to the high pressure. * Setting of the safety valve on only port B side is changed. Port A is always set to the low pressure.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

Malfunction of attachment return selector solenoid valve

Working mode

Solenoid valve output pressure

Mode E or A

0 MPa {0 kg/cm2}

Mode B

2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunction of attachment return selector valve

The attachment return selector valve may have a malfunction. Check it directly.

Malfunction of service control valve (safety valve)

The safety valve of the service control valve (on port B side) may have a malfunction. Check it directly.

H-29 Flow rate in attachment circuit cannot be adjusted When attachment is installed Failure information

• Flow rate in attachment circuit cannot be adjusted.

Relative information

• If an attachment is installed, the flow rate in the service circuit changes according to the selected working mode. • How to adjust the flow rate in modes A and E is different from that in mode B. For details, see OPERATION MANUAL.

Presumed cause and standard value in normalcy

Cause 1

Malfunction of attachment flow rate adjustment EPC valve

Standard value in normalcy and references for troubleshooting The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly. !Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.

PC160LC-7

Malfunction of service PPC valve

Wiring harness connector

Service pedal

PPC valve output pressure

Disconnect connector V30 of attachment flow rate adjustment EPC valve.

In NEUTRAL

0 MPa {0 kg/cm2}

Operated

Above 2.7 MPa {Above 28 kg/cm2}

20-527 (1)

TROUBLESHOOTING OF ENGINE (S-MODE) METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-602 S- 1 Starting performance is poor (Starting always takes time)................................................................ 20-606 S- 2 Engine does not start ........................................................................................................................ 20-608 (1) Engine does not turn .................................................................................................................. 20-608 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) .............................. 20-609 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)............................ 20-610 S- 3 Engine does not pick up smoothly (Follow-up is poor) ..................................................................... 20- 611 S- 4 Engine stops during operations ........................................................................................................ 20-612 S- 5 Engine does not rotate smoothly (Hunting)....................................................................................... 20-613 S- 6 Engine lacks output (or lacks power) ................................................................................................ 20-614 S- 7 Exhaust smoke is black (Incomplete combustion) ............................................................................ 20-615 S- 8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-616 S- 9 Oil becomes contaminated quickly ................................................................................................... 20-617 S-10 Fuel consumption is excessive ......................................................................................................... 20-618 S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-619 S-12 Oil pressure monitor lights up (Drop in oil pressure)......................................................................... 20-620 S-13 Oil level rises (Water, fuel in oil)........................................................................................................ 20-621 S-14 Water temperature becomes too high (Overheating)........................................................................ 20-622 S-15 Abnormal noise is made ................................................................................................................... 20-623 S-16 Vibration is excessive ....................................................................................................................... 20-624

PC160LC-7

20-601 (4)

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections [A] + [B] in the chart on the right corresponds to the items where answers can be obtained from the user. The items in [B] are items that can be obtained from the user, depending on the user’s level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under [C] in the chart on the right correspond to this. The serviceman narrows down the causes from information [A] that he has obtained from the user and the results of [C] that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].

20-602 (4)

PC160LC-7

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with Q, and of these, causes that have a high probability are marked with w. Check each of the [Questions] and [Check items] in turn, and marked the Q or w in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. 1. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with E to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. 2. Use the E in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.

PC160LC-7

20-603 (4)

TROUBLESHOOTING

•

METHOD OF USING TROUBLESHOOTING CHARTS

Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. S-7

Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel

20-604 (4)

PC160LC-7

TROUBLESHOOTING

PC160LC-7

METHOD OF USING TROUBLESHOOTING CHARTS

20-605 (4)

S-1

TROUBLESHOOTING

S-1 Starting performance is poor (Starting always takes time) General causes why exhaust smoke comes out but engine takes time to start • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel (At ambient temperature of –10°C or below, ASTM D975 No. 2 diesel fuel is used) a Battery charging rate Charging rate Ambient temperature

• •

100 %

90 %

80 %

75 %

70 %

20°C

1.28

1.26

1.24

1.23

1.22

0°C

1.29

1.27

1.25

1.24

1.23

–10°C

1.30

1.28

1.26

1.25

1.24

The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.

20-606 (4)

PC160LC-7

TROUBLESHOOTING

PC160LC-7

S-1

20-607 (4)

TROUBLESHOOTING

S-2

S-2 Engine does not start (1) Engine does not turn General causes why engine does not turn

20-608 (4)

•

Internal parts of engine seized a If internal parts of the engine are seized, carry out troubleshooting for "Engine stops during operations".

• •

Failure in hydraulic pump system Defective electrical system

PC160LC-7

TROUBLESHOOTING

S-2

(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) General causes why engine turns but no exhaust smoke comes out • • •

Supply of fuel impossible Supply of fuel is extremely small Improper selection of fuel (particularly in winter)

a Standards for use of fuel

PC160LC-7

20-609 (4)

TROUBLESHOOTING

S-2

(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) General causes why exhaust smoke comes out but engine does not start • • • •

20-610 (4)

Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel

PC160LC-7

TROUBLESHOOTING

S-3

S-3 Engine does not pick up smoothly (Follow-up is poor) General causes why engine does not pick up smoothly • • • •

Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injction Improper fuel used

PC160LC-7

20-611 (4)

TROUBLESHOOTING

S-4

S-4 Engine stops during operations General causes why engine stops during operations • • •

Seized parts inside engine Insufficient supply of fuel Overheating a If there is overheating and the engine stops, carry out troubleshooting for overheating.

•

Failure in hydraulic pump a If the engine stops because of a failure in the hydraulic pump, carry out troubleshooting for H mode.

20-612 (4)

PC160LC-7

TROUBLESHOOTING

S-5

S-5 Engine does not rotate smoothly (Hunting) Ge neral c auses why engine does not r otate smoothly • • •

Air in fuel system Defective governor mechanism Defective governor motor mechanism a If hunting stops when governor spring is disconnected, carry out troubleshooting for E mode.

PC160LC-7

20-613 (4)

TROUBLESHOOTING

S-6

S-6 Engine lacks output (or lacks power) General causes why engine lacks output • • • • •

20-614 (4)

Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used (if non-specified fuel is used, output drops) Lack of output due to overtaking a If there is overheating and lack of output, carry out troubleshooting for overheating.

PC160LC-7

TROUBLESHOOTING

S-7

S-7 Exhaust smoke is black (Incomplete combustion) General causes why exhaust smoke is black • • •

Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel

PC160LC-7

20-615 (4)

TROUBLESHOOTING

S-8

S-8 Oil consumption is excessive (or exhaust smoke is blue) a Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling) General causes why oil consumption is excessive • • •

20-616 (4)

Abnormal combustion of oil External leakage of oil Wear of lubrication system

PC160LC-7

TROUBLESHOOTING

S-9

S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly • • • • •

Entry of exhaust gas due to internal wear Clogging of lubrication passage Improper fuel Improper oil used Operation under excessive load

PC160LC-7

20-617 (4)

TROUBLESHOOTING

S-10

S-10 Fuel consumption is excessive General causes why fuel consumption is excessive • • •

20-618 (4)

Leakage of fuel Improper condition of fuel injection Excessive injection of fuel

PC160LC-7

TROUBLESHOOTING

S-11

S-11 Oil is in cooling water, or water spurts back, or water level goes down General causes why oil is in cooling water • •

Internal leakage in lubrication system Internal leakage in cooling system

PC160LC-7

20-619 (4)

TROUBLESHOOTING

S-12

S-12 Oil pressure monitor lights up (Drop in oil pressure) General causes why oil pressure monitor lights up • • • •

Leakage, clogging, wear of lubricating system Defective oil pressure control Improper oil used (improper viscosity) Deterioration of oil due to overheating

a Standards for engine oil selection

20-620 (4)

PC160LC-7

TROUBLESHOOTING

S-13

S-13 Oil level rises (Water, fuel in oil) a If there is oil in the cooling water, carry out troubleshooting for "Oil is in cooling water". General causes why oil level rises • • •

Water in oil (milky white) Fuel in oil (diluted, and smells of diesel fuel) Entry of oil from other component

PC160LC-7

20-621 (4)

TROUBLESHOOTING

S-14

S-14 Water temperature becomes too high (Overheating) General causes why water temperature becomes too high • • • •

20-622 (4)

Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Defective cooling circulation system Rise in oil temperature in hydraulic pump system a Carry out troubleshooting for H mode.

PC160LC-7

TROUBLESHOOTING

S-15

S-15 Abnormal noise is made a Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made • • •

Abnormality due to defective parts Abnormal combustion Air sucked in from intake system

PC160LC-7

20-623 (4)

TROUBLESHOOTING

S-16

S-16 Vibration is excessive a If there is abnormal noise together with the vibration, carry out troubleshooting also for "Abnormal noise is made". General causes why vibration is excessive • • •

20-624 (4)

Defective parts (abnormal wear, breakage) Improper alignment Abnormal combustion

PC160LC-7

30 DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL ..................30- 3 PRECAUTIONS WHEN PERFORMING OPERATION.............................................30- 5 SPECIAL TOOL LIST...................................30- 7 SKETCHES OF SPECIAL TOOLS ..............30-10 STARTING MOTOR Removal and Installation ..........................30-11 FUEL INJECTION PUMP Special tools..............................................30-12 Removal....................................................30-12 Installation.................................................30-14 ENGINE FRONT SEAL Removal....................................................30-16 Installation............................................. 30-17-1 ENGINE REAR SEAL Removal....................................................30-18 Installation.................................................30-19 CYLINDER HEAD Special tools..............................................30-20 Removal....................................................30-20 Installation.................................................30-23 RADIATOR Removal and Installation ..........................30-26 AFTER COOLER Removal and Installation ..........................30-27 HYDRAULIC OIL COOLER Removal and Installation ..........................30-28 ENGINE AND HYDRAULIC PUMP Special tools..............................................30-29 Removal....................................................30-29 Installation.................................................30-32 TRUCK SHOE Special tools..............................................30-34 Expansion .................................................30-34 Installation.................................................30-35 SPROCKET Removal and Installation ..........................30-36 FINAL DRIVE Removal and Installation ..........................30-37 Special tools..............................................30-38 Disassembly .............................................30-38 Assembly ..................................................30-40 PC160LC-7

IDLER Special tools ............................................. 30-45 Disassembly............................................. 30-45 Assembly.................................................. 30-46 RECOIL SPRING Special tools ............................................. 30-48 Disassembly............................................. 30-48 Assembly.................................................. 30-49 TRACK ROLLER Special tools ............................................. 30-50 Disassembly and Assembly ..................... 30-50 CARRIER ROLLER Special tools ............................................. 30-51 Disassembly and Assembly ..................... 30-51 SWING MOTOR AND SWING MACHINERY Removal and Installation.......................... 30-52 Special tools ............................................. 30-53 Disassembly............................................. 30-53 Assembly.................................................. 30-56 SWING MOTOR Special tools ............................................. 30-61 Disassembly............................................. 30-61 Assembly.................................................. 30-64 CENTER SWIVEL JOINT Removal ................................................... 30-69 Installation ................................................ 30-70 Special tools ............................................. 30-71 Disassembly and Assembly ..................... 30-71 WORK EQUIPMENT Special tools ............................................. 30-72 Removal ................................................... 30-72 Installation ................................................ 30-74 REVOLVING FRAME Removal ................................................... 30-75 Installation ................................................ 30-76 SWING CIRCLE Removal and Installation.......................... 30-77 HYDRAULIC TANK Removal ................................................... 30-78 Installation ................................................ 30-80

30-1 (4)

CONTROL VALVE Removal ................................................. 30- 81 Installation .............................................. 30- 84 Disassembly and Assembly ................... 30- 85 HYDRAULIC PUMP Special tools ........................................... 30- 87 Removal ................................................. 30- 87 Installation .............................................. 30- 88 HYDRAULIC PUMP INPUT SHAFT OIL SEAL Special tools ........................................... 30- 89 Removal and Installation........................ 30- 89 WORK EQUIPMENT PPC VALVE Disassembly and Assembly ................... 30- 90 TRAVEL PPC VALVE Disassembly and Assembly ................... 30- 91 HYDRAULIC CYLINDER Special tools ........................................... 30- 92 Disassembly........................................... 30- 92 Assembly................................................ 30- 94 COUNTERWEIGHT Removal and Installation........................ 30- 98 AIR CONDITIONER UNIT Special tools ........................................... 30- 99 Removal ................................................. 30- 99 Installation .............................................. 30-101 OPERATOR'S CAB Removal ................................................. 30-102 Installation .............................................. 30-104 OPERATOR'S CAB GLASS (STUCK GLASS) ..................................... 30-105 Special tools ........................................... 30-106 Removal ................................................. 30-106 Installation .............................................. 30-107 FRONT WINDOW Removal ................................................. 30-116 Installation .............................................. 30-118 MONITOR Removal and Installation........................ 30-121 GOVERNOR, PUMP CONTROLLER Removal and Installation........................ 30-122

30-2 (4)

PC160LC-7

HOW TO READ THIS MANUAL

DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL REMOVAL AND INSTALLATION OF ASSEMBLIES SPECIAL TOOLS

INSTALLATION OF PARTS

•

Special tools that are deemed necessary for removal or installation of parts are listed. List of the special tools contains the following kind of information 1) Necessity t: Special tools which cannot be substituted, should always be used. q: Speciall tools which are very useful if available, can be substituted with commercially available tools.

2) Distinction of new and existing special tools. N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark (Q) in sketch column. A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. a Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T---×××---××××.

•

Except where otherwise instructed, install parts is the reverse order of removal. Instructions and precautions for installing part are shown with [*1] mark in the INSTALLATION Section, identifying which step the instructions are intended for. Marks shown in the INSTALLATION Section stand for the following. k a

This mark indicates safety-related precautions, which must be followed when doing the work. This marks gives guidance or precautions when doing the procedure.

2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5

This mark indicates an amount of oil or water to be added.

SKETCHES OF SPECIAL TOOLS •

Various special tools are illustrated for the convenience of local manufacture.

REMOVAL OF PARTS •

•

The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. Various symbols used in the REMOVAL Section are explained and listed below. k a [*1]

This mark indicates safety-related precautions, which must be followed when doing the work. This mark gives guidance or precautions when doing the procedure. This mark shows that there are instructions or precautions for installing parts.

6 This mark shows oil or water be drained.

4 This mark shows the weight of a part or a device.

PC160LC-7

30-3 (2)

HOW TO READ THIS MANUAL

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES SPECIAL TOOLS •

•

Special tools which are deemed necessary for disassembly and assembly are listed in this section. List of the special tools contains the following kind of information. 1) Necessity t: Special tools which cannot be substituted, should always be used. q: Speciall tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools. N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark (Q) in sketch column. A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. 4) Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T---×××--××××.

ASSEMBLY •

•

Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil or water to be added. Various symbols used in the ASSEMBLY Section are explained and listed below. k a

This mark indicates safety-related precautions, which must be followed when doing the work. This marks gives guidance or precautions when doing the procedure.

2 This mark stands for a specific coating agent to be used. 3 This mark indicates the specified torque. 5

This mark indicates an amount of oil or water to be added.

SKETCHES OF SPECIAL TOOLS 1) Vartious special tools are illustrated for the convenience of local manufacture.

DISASSEMBLY •

•

The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained. Various symbols used in the DISASSEMBLY Section are explained and listed below. k

This mark indicates safety-related precautions which must be followed when doing the work. This mark gives guidance or precautions when doing the procedure.

6 This mark shows oil or water to be drained.

30-4 (2)

PC160LC-7

PRECAUTIONS WHEN PERFORMING OPERATION

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN PERFORMING OPERATION Be sure to follow the general precautions given below when performing removal or installation (disassmbly or assembly) of units. 1. Precautions when performing removal work • If the engine coolant water contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wiring, hold onto the connectors when disconnecting them. • Fasten tags to wires and hoses to identify and show their installation position and help to prevent any mistakes when re-installing. • Count and check the number and thickness of the shims, and keep them in a safe place. • When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering after removal. a Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting it during disassembly operations. A.

Face seal type hoses and tubes Nominal number 02 03 04 05 06

Plug (nut end)

Nut (elbow end)

07376-70210 07376-70315 07376-70422 07376-70522 07376-70628

02789-00210 02789-00315 02789-00422 02789-00522 02789-00628

Split flange type hoses and tubes Nominal number 04 05

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

C. If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06 08 10 12 14 16 18 20 22 24 27

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734

PC160LC-7

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34

30-5 (2)

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN PERFORMING OPERATION

2. Precautions when carrying out installation work • Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. • Install the hoses without twisting or interference. • Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. • Bend the cotter pins or lock plate securely. • When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with tow or three drops of adhesive. • When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. • Clean all parts, and correct any damage, dents, burrs, or rust. • Coat rotating parts and sliding parts with engine oil. • When press fitting parts, coat the surface with anti-friction compound (LM-P). • After installing snap rings, check that the snap ring is installed securely in the ring groove. • When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. • When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. • When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run it at low idle. 2. Operate the work equipment control lever to operate the hydraulic cylinders, 4 – 5 times, stopping the cylinder 100 mm from the end of their stroke. 3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operations • If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified level. Run the engine to circulate the coolant water through the system. Then check the coolant water level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed for repair, Bleed the air from the system after reassembling the parts. a For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

30-6 (2)

PC160LC-7

SPECIAL TOOL LIST

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

Q’ty

Fuel injection pump assembly

795-799-1390

Puller

A 2

795-799-1171

Puller

790-331-1110

Wrench

795-799-2610

Installer

Installation of front seal

795-799-2620

Installer

Installation of dust seal

795-931-1100

Seal puller

Installation of rear seal

796-460-1210

Oil stopper

796-770-1320

Adapter

790-101-2501

Push puller

• 790-101-2510

• Block

• 790-101-2520

• Screw

• 791-112-1180

• Nut

• 790-101-2540

• Washer

• 790-101-2630

• Leg

• 790-101-2570

• Plate

• 790-101-2560

• Nut

• 790-101-2650

• Adapter

796-427-1200

Wrench

796T-427-1220

Push tool

790-101-2510

Block

792-104-3940

Bolt

01580-11613

Nut

01613-31645

Washer

790-105-2100

Jack

790-101-1102

Pump

791-545-1510

Installer

Part No.

Part Name

Cylinder head assembly

Engine front seal, dust seal

Engine rear seal Engine and hydraulic pump assembly

Center swivel joint assembly

C D

Final drive assembly

F 2

PC160LC-7

Sketch

Symbol

New/ Remodel

Component

Necessity

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured). a Necessity: t.........Cannot be substituted, must always be installed (used) q.........Extremely useful if available or, can be substituted with commercially available part. a New/Remodel: N .........Tools with new part numbers, newly developed for this model. : R .........Tools with upgraded part numbers, remodeled from items already available for other models. :Blank:...Tools already available for other models, can be used without any modification a Tools marked Q in the Sketch column are tools introduced in the sketches of the special (See SKETCHES OF SPECIAL TOOLS). Nature of work, remarks Removal, installation of fuel injection pump assembly Removal of nozzle holder assembly Tightening of cylinder head bolt

Oil stopper

Disassembly of center swivel joint assembly

Removal, installation of nut

Installation of bearing

Installation of floating seal

30-7 (4)

SPECIAL TOOL LIST

KBATZ080080

Wrench

G 2

KBATZ030190

Adapter

KBATZ060400

Stopper

790-101-5201

Push tool KIT

• 790-101-5221

• Grip

• 01010-51225

• Bolt

• 790-101-5271

• Plate

790-434-1630

Installer

Installation of floating seal

791-601-1000

Oil pump

Filling with oil

791-685-8006

Compressor

790-201-2780

Spacer

791-635-3160

Extension

790-101-1600

Cylinder (686 kN {70t})

790-101-1102

Pump

791-640-2180

Guide bolt

790-201-1500

Push tool KIT

• 790-201-1620

• Plate

• 790-101-5021

• Grip

• 01010-50816

• Bolt

790-101-5001

Push tool KIT

• 790-101-5081

• Plate

• 790-101-5021

• Grip

• 01010-50816

• Bolt

790-434-1660

Installer

Installation of floating seal

791-601-1000

Oil pump

Filling with oil

790-101-5201

Push tool KIT

• 790-101-5221

• Grip

• 01010-51225

• Bolt

• 790-101-5261

• Plate

790-434-1640

Installer

Installation of floating seal

791-601-1000

Oil pump

Filling with oil

Symbol

Part No.

Part Name

Press fitting of bushing

1 Track roller assembly

30-8 (4)

Disassembly, assembly of recoil spring assembly

Installation of dust seal

Carrier roller assembly

Removal, installation of ring nut

Recoil spring assembly

Nature of work, remarks

Press fitting of bushing

1 Idler assembly

Sketch

Q’ty

Swing motor and swing machinery assembly

New/ Remodel

Component

Necessity

DISASSEMBLY AND ASSEMBLY

PC160LC-7

SPECIAL TOOL LIST

Hydraulic pump input shaft oil seal

791-630-3000

Remover and installer

790-101-1300

Cylinder

790-101-1102

Pump

790-331-1110

Wrench

791-463-1350

Push tool

790-201-2740

Spacer

790-502-1003

Cylinder repair stand

790-102-4300

Wrench assembly

790-102-4310

790-720-1000

Expander

796-720-1660

Ring (for boom and bucket) q Clamp (for boom q and bucket)

Part No.

N 1 2 3

07281-01159 4

Hydraulic cylinder assembly

07281-01279

Clamp (for arm)

790-201-1702

Push tool KIT

• 790-201-1821

• Push tool (for boom) • Push tool (for arm) • Push tool (for bucket)

• 790-101-5021

• Grip

• 01010-50816

• Bolt

790-201-1500

Push tool KIT

790-201-5021

• Grip

• 01010-50816

• Bolt

• 790-201-1630

• Plate (for boom)

• 790-201-1620

• Plate (for bucket)

790-201-1980

Plate (for arm)

790-201-5021

Grip

01010-50816

Bolt

796-900-1200

Remover

790-101-4000

Puller (490 kN {50 t}, long) t Pump t (294 kN {30})

• 790-201-1811

1 1

790-101-1102

PC160LC-7

Disassembly, assembly of hydraulic cylinder assembly

Installation of piston ring

Press fitting of cylinder head bushing

Work equipment assembly

Expansion and installation of track shoe assembly

Removal, installation of piston

Ring (for arm)

• 790-201-1940

Nature of work, remarks

Press fitting of oil seal

796-720-1670

Q 5

Sketch

Part Name

Q’ty

Track shoe assembly

Symbol

New/ Remodel

Component

Necessity

DISASSEMBLY AND ASSEMBLY

Installation of dust seal

Removal of foot pin

30-9 (4)

SPECIAL TOOL LIST

Part Name

Q’ty

799-703-1200

Service tool KIT

799-703-1100

Vacuum pump (100 V) Vacuum pump (220 V) Vacuum pump (240 V)

Air conditioner unit assembly

799-703-1401

Gas leak detector

793-498-1210

Lifter (Suction cup)

20Y-54-13180

Adapter

799-703-1111 799-703-1121

Operator's cab glass (Stuck glass)

30-9-1 (4)

Sketch

Part No.

Symbol

New/ Remodel

Component

Necessity

DISASSEMBLY AND ASSEMBLY

Nature of work, remarks

Collection of and refilling with refrigerant

Fixing of window glass

PC160LC-7

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches F2 PUSH TOOL

30-10 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

STARTING MOTOR

REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery. 1. Open the engine hood. 2. Disconnect connector T13 (1) and terminal B (2). [*1] 3. Remove the mounting bolts and starting motor assembly (3). [*2]

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

3 Mounting nut of terminal B: 17.7 – 24.5 Nm {1.8 – 2.5 kgm}

[*2]

a Apply gasket sealant (LG-1) to the starting motor gasket. a Apply the gasket sealant in the form of a continuous string 1 mm thick around the area 4 mm from the inside edge of the starting motor gasket. a Apply the gasket sealant to both sides of the starting motor gasket. 3 Mounting bolt: 43 ± 6 Nm {4.38 ± 0.61 kgm}

PC160LC-7

30-11 (2)

FUEL INJECTION PUMP

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

Puller

Sketch

795-799-1390

New/Remodel

A 1

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery.

8. Remove 4 delivery tubes (7).

1. Close the fuel stop valve.

9. Remove fuel tubes (8) and (9) between the fuel filter and fuel injection pump.

2. Open the engine hood.

10. Remove lubrication tubes (10) and (11).

3. Remove plate (1).

11. Remove governor spring (12) from the governor lever. [*1]

4. Remove fan guard (2).

5. Move oil level gauge guide (3). 6. Disconnect connector V07 (4). 7. Disconnect fuel inlet hose (5) and fuel outlet hose (6). a Insert a wooden plug, etc. in the disconnected hose to prevent the fuel from flowing out.

30-12 (2)

12. Set No. 1 cylinder piston to the compression top dead center and fix the drive gear of the fuel injection pump to the injection timing. a For details, see TESTING AND ADJUSTING, Inspection and adjustment of fuel injection timing.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

13. Turn and remove cap (14). a Use a filter wrench, etc. to remove the cap.

14. Remove nut (15) and washer (16) of the fuel injection pump. [*2] a Take care not to drop the nut and washer in the case.

FUEL INJECTION PUMP

16. Remove fuel injection pump lower bracket (17) and mounting bolts and nuts (18).

17. Remove 4 mounting nuts (19) and fuel injection pump assembly (20). [*3]

15. Using tool A1, disconnect the shaft and drive gear of the fuel injection pump.

PC160LC-7

30-13 (2)

DISASSEMBLY AND ASSEMBLY

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

FUEL INJECTION PUMP

4. Install fuel injection pump assembly (20) and tighten 4 mounting nuts (19). 3 Mounting nut: 43 ± 6 Nm {4.4 ± 0.6 kgm}

a Adjust the governor lever stroke. For details, see TESTING AND ADJUSTING, Special functions of monitor panel.

[*2] [*3] a Install the fuel injection pump assembly according to the following procedure. 1. Using timing pin (13), check that the injection timing of the drive gear is fixed.

5. Fit washer (16) and tighten nut (15) temporarily. a Take care not to drop the nut and washer in the case.

k Tighten the nut to the following torque temporarily so that it will not damage the timing pin. 3 Temporary tightening torque of nut: 12.5 ± 2.5 Nm {1.25 ± 0.25 kgm}

2. Remove plug (21) of the fuel injection pump. 3. Turn over and insert timing pin (22) of the fuel injection pump and check that its cut is fitted to projection (a) in the pump. a If you can insert the timing pin smoothly, the injection timing is normal. a If you cannot insert the timing pin, the injection timing is abnormal. In this case, adjust the injection timing. (See TESTING AND ADJUSTING, Inspection and adjustment of fuel injection timing.)

6. Return the timing pin of the fuel injection pump and that of the drive gear to their original positions. 7. Tighten nut (15) of the fuel injection pump permanently.

3 Permanent tightening torque of nut: 95 ± 10 Nm {9.7 ± 1.02 kgm}

k Before starting the engine, check that timing pin (13) of the drive gear and timing pin (22) of the fuel injection pump are returned.

30-14 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP

Bleeding air • Bleed air from the fuel piping according to the following procedure. 1. Fill the fuel tank with fuel (until the float reaches the highest level). 2. Loosen eyebolt (23). 3. Remove cap (24). Loosen the knob of the feed pump and move it up and down to let fuel flow out of the mounting part of eyebolt (23) until bubbles do not come out any more. 4. Tighten eyebolt (23).

5. Start the engine and check that fuel does not leak from the fuel system.

PC160LC-7

30-15 (2)

ENGINE FRONT SEAL

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

9. Remove fan pulley (9).

795-799-2610

Installer

795-799-2620

Installer

t t

Sketch

New/Remodel

Q'ty

Part name

Necessity

Symbol

SPECIAL TOOLS

Part No.

k Take care not to catch your hands between the tensioner and pulley.

1 1

REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery. 1. Drain the coolant. a Drain the coolant to a degree that it will not leak when hose (1) is disconnected. 2. Remove hoses (1) and (2). 3. Remove fan guards (3) and (4). 4. Remove air conditioner compressor belt.

[*1]

10. Remove 4 mounting bolts (10) and crank pulley (11). [*2] a Remove the crank pulley with its timing mark (a) matched to pointer (12) or make match marks on the crank pulley and front cover so that you can position the crank pulley correctly when installing it. 11. Remove 20 mounting bolts (13) and front cover (14). [*3]

5. Disconnect connector E06 (16) and remove air conditioner compressor (5) and bracket and move them toward the counterweight. a Do not separate the air conditioner piping. 6. Remove fan shroud (6). a Take care that the fan shroud will not interfere with the other parts. 7. Remove the cooling fan.

8. Install lever [1] to tensioner (7) and move the lever in the direction of the arrow to remove fan belt (8).

30-16 (4)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

ENGINE FRONT SEAL

12. Remove engine front seal (15) from front cover (14). [*4] a If the dust seal is installed, remove it, too.

PC160LC-7

30-17 (4)

DISASSEMBLY AND ASSEMBLY

INSTALLATION • [*1]

Carry out installation in the reverse order to removal. a Install the air conditioner compressor belt. For details, see TESTING AND ADJUSTING, Inspection and adjustment of air compressor belt tension.

ENGINE FRONT SEAL

3. Dust seal a Even if a dust seal has not been installed, install the dust seal contained in the front seal kit. 1) Using tool B2, press fit dust seal (16) to the end of the crankshaft. a Press fit the dust seal until the inside end of tool B2 touches the end of the crankshaft.

[*2]

a Install the belt to the position from which it was removed. a Install the crank pulley temporarily and fan belt, and then tighten the mounting bolts to the specified torque. 3 Mounting bolt: 125 ± 5 Nm {12.75 ± 0.51 kgm} [*3] [*4] 1. Front oil seal 1) Set front oil seal (15) to tool B1. a Since plastic part [2] on the inside of the front oil seal is used to guide the front cover to the crankshaft, do not remove it from the front oil seal. 2) Press fit front oil seal (15) to front cover (14). a Press fit the front oil seal until the shoulder of tool B1 touches the inside end of the front cover. 2. Front cover 1) Apply ThreeBond 1207D or equivalent in the form of a string 1 – 2 mm thick to the gasket fitting face of the front cover. 2) Install the gasket to the front cover, and then install them to the engine. 3) Tighten the 20 mounting bolts in the following order. 3 Front cover mounting bolt: 24 ± 4 Nm {2.45 ± 0.4 kgm} 4) Remove plastic part [2] (front oil seal guide) on the inside of the front cover.

30-17-1 (4)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

PC160LC-7

ENGINE FRONT SEAL

30-17-2 (4)

ENGINE REAR SEAL

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

Seal puller

Sketch

795-931-1100

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

4. Remove rear oil seal (3). [*2] a Method of removing with seal puller: 1) Make a hole about 3 mm in diameter on the seal carrier of rear oil seal (3) with a drill.

REMOVAL 1. Remove the hydraulic pump assembly. For details, see Removal and installation of hydraulic pump assembly. 2. Remove damper assembly (1).

3. Set guide bolts [1] and lift off flywheel assembly (2). [*1] 4 Flywheel assembly: 25 kg

30-18 (4)

2) Screw the tip of seal puller C into the drilled hole and slide the hammer to remove rear oil seal (3).

a Method of removing with screwdriver: • When removing rear oil seal (3) by breaking the seal carrier with a screwdriver, take care not to damage the seal mounting part of the flywheel housing and the seal contact surface ot the crankshaft.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

ENGINE REAR SEAL

INSTALLATION • [*1]

[*2]

2) Insert rear oil seal (4) and pilot [2] together in the crankshaft and push the seal carrier of rear oil seal (4) into the flywheel housing. a Before inserting the rear oil seal, clean, degrease, and dry the seal contact surface of the crankshaft. 3) Pull out pilot [2] and push in rear oil seal (4) further.

Carry out installation in the reverse order to removal. a Tighten the mounting bolts of the flywheel assembly in the following numerical order. 3 Mounting bolt of flywheel assembly: 137 ± 7 Nm {13.97 ± 0.71 kgm}

4) Using aligning tool [3], insert the oil seal to the proper depth. a Lightly hit the top, bottom, right, and left of the aligning tool with a hammer to push in the seal, taking care that the seal carrier will not be bent.

a Install the rear oil seal according to the following procedure. 1) Insert pilot [2] in new rear oil seal (4). a Before inserting the pilot, clean, degrease, and dry the lip surface of the rear oil seal.

•

PC160LC-7

Refilling with oil

5 Damper case oil: approx. 0.75 l

30-19 (4)

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

8. Disconnect terminal E01 (4). 9. Remove the bracket mounting bolts of engine oil level gauge guide (5) and move the level gauge guide.

SPECIAL TOOLS

795-799-1171

Puller

790-331-1110

Wrench

t t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

10. Remove 4 delivery tubes (6). 11. Remove tubes (7) and (8) between fuel filter and fuel injection pump. 12. Remove bracket (9) and fuel filter as a unit. [*3]

1 1

REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery.

13. Remove air intake connector (10) and ribbon heater (11). [*4] a Cover the openings with adhesive tapes, etc. to prevent foreign matter from entering the engine.

1. Drain the coolant.

6 Coolant: 18.6 l

2. Close the fuel stop valve. 3. Open the engine hood. 4. Disconnect hose (1) from the engine.

[*1]

5. Remove fan guard (2). 6. Remove the air conditioner compressor belt. [*2] 7. Disconnect connector E06 (35), and then remove air conditioner compressor (3) and bracket and move them toward the counterweight. a Do not separate the air conditioner piping.

30-20 (2)

14. Remove heat insulation covers (12) and (13). 15. Remove muffler (14).

[*5]

PC160LC-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

16. Disconnect hoses (15) and (16).

[*6]

17. Disconnect tubes (17) and (18).

[*7]

18. Remove turbocharger assembly (19).

[*8]

25. Disconnect connector E05 (26) in the rear of the left of the engine.

19. Remove exhaust manifold (20).

[*9]

26. Disconnect spill tube (28). 27. Remove 4 nozzle holder assemblies (27). 20. Referring to REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL, Removal procedure steps 2 – 9, remove the cooling fan pulley. 21. Remove the tensioner. 22. Disconnect hoses (21) and (22).

[*10]

23. Disconnect terminal B (23) and connector E12 (24). 24. Remove alternator (25) and bracket.

a If it is difficult to pull the nozzle holder assemblies out of the cylinder head, use tool A2.

PC160LC-7

30-21 (2)

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

a Cover the nozzle holder assembly mounting parts to prevent foreign matter from entering the engine.

28. Remove head cover (29).

[*11]

30. Remove push rods (31).

[*13]

31. Lift off cylinder head assembly (32).

[*14]

4 Cylinder head assembly: 40 kg

32. Remove cylinder head gasket (33).

29. Remove rocker arm assemblies (30). [*12] a Loosen the locknut and loosen the adjustment screw of each rocker arm 2 – 3 turns.

30-22 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD 3 Tube (17): Turbocharger side: 10.3 ± 1.2 Nm {1.1 ± 0.1 kgm} Cylinder block side: 35 ± 5 Nm {3.6 ± 0.5 kgm} 3 Tube (18):10 ± 2 Nm {1.0 ± 0.2 kgm}

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

3 Hose clamp 1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm} 2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*2]

[*3]

[*4]

a Install the air conditioner compressor belt. For details, see TESTING AND ADJUSTING, Inspection and adjustment of air compressor belt tension. a Apply gasket sealant to the threads of the bolt (only 1 piece) on the head cover side among the 3 fuel filter bracket mounting bolts.

[*8]

[*9]

3 Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm} a Tighten the mounting bolts in the following numerical order. 3 Mounting bolt: 1st time : Tighten all the bolts to 43 ± 6 Nm {4.38 ± 0.61 kgm}. 2nd time: Tighten only bolts 1 – 4 to 43 ± 6 Nm {4.38 ± 0.61 kgm}.

a Apply gasket sealant to the threads of only the 2 of the air intake connector mounting bolts indicated by the arrows in the following figure

[*10] 3 Clamp of hose (22): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*11] 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} [*5]

[*6]

a When connecting the exhaust pipe to under the muffler, apply thermosetting sealant (Firegum manufactured by Nihon Holts Co., Ltd. or equivalent) all round the pipe end. 3 Clamp nut of muffler U-bolt: 9.8 – 14.7 Nm {1.0 – 1.5 kgm} 3 Clamp of hose (15): 10.0 – 11.0 Nm {1.02 – 1.12 kgm} Clamp of hose (16): 1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm} 2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

PC160LC-7

[*12] [*13] [*14] a Install the rocker arm assembly and cylinder head assembly according to the following procedure. a Check that there is not foreign matter on the cylinder head mounting face and in the cylinder. 1) Set cylinder head gasket (33) to the cylinder block. a Check that the gasket is matched to the holes of the block.

30-23 (2)

DISASSEMBLY AND ASSEMBLY

2) Sling cylinder head assembly (32) and set it to the cylinder block.

CYLINDER HEAD 3 Cylinder head bolt: 1st time : Tighten all the bolts to 90 ± 5 Nm {9.18 ± 0.51 kgm} in the numerical order shown in the figure. 2nd time: Tighten bolts 3, 6, 11, and 14 to 120 ± 5 Nm {12.24 ± 0.51 kgm} in order. 3rd time : Using tool A3, tighten all the bolts by 90° ± 5° in the numerical order shown in the figure. (Angle tightening) a When not using tool A3, make marks on the bolts and cylinder head, and then tighten each bolt by the above angle.

3) Install push rods (31). 4) Install rocker arm assemblies (30) and tighten mounting bolts (34) with the fingers. a Check that the balls of adjustment screws (35) are fitted to the sockets of push rods (31).

5) Tighten the cylinder head bolts in the following numerical order in 3 times.

2 Threads and seat of mounting bolt: Engine oil (SAE15W-40)

6) Tighten rocker arm assembly mounting bolts (34) permanently. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}

30-24 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

7) Adjust the valve clearance. For details, see TESTING AND ADJUSTING, Adjustment of valve clearance. •

Refilling with water Add water to the specified level. Run the engine to circulate the water through the system. Then, check the water level again. 5 Cooling water: 18.6 l

•

Bleeding air Bleed air from the fuel piping. For details, see REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.

PC160LC-7

30-25 (2)

RADIATOR

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

5. Remove the 2 mounting bolts and lift off radiator assembly (6). a You can lift up and remove the radiator assembly with the hands. 4 Radiator assembly: 11 kg

REMOVAL 1. Drain the coolant.

6 Cooling water: 18.6 l

2. Disconnect hoses (1) and (2).

[*1]

INSTALLATION •

3. Open the engine hood and disconnect hoses (3) and (4). [*2]

[*1]

Carry out installation in the reverse order to removal. a Tighten the clamp of hose (2) with the bolt right down. 3 Clamp of hose (2): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

4. Remove the mounting bolts of cover (5) and move the cover toward the engine. [*2]

3 Clamp of hose (4): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

• Refilling with water a Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then, check the water level again. 5 Cooling water: 18.6 l

30-26 (2)

PC160LC-7

AFTERCOOLER

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY REMOVAL 1. Disconnect hose (1).

[*1]

INSTALLATION •

[*1] 2. Open the engine hood, remove clamp (2), and disconnect hose (3). [*2] 3. Remove the mounting bolts of cover (4) and move the cover toward the engine. [*2]

Carry out installation in the reverse order to removal. a Tighten the hose clamp with the bolt right down. 3 Hose clamp: 1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm} 2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm} 3 Clamp of hose (3): 1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm} 2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

4. Remove the 2 mounting bolts and lift off aftercooler assembly (5). a You can lift up and remove the aftercooler assembly with the hands. 4 Aftercooler assembly: 9 kg

PC160LC-7

30-27 (2)

HYDRAULIC OIL COOLER

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY REMOVAL 1. Loosen plug (1) on the bottom of the hydraulic oil cooler to drain the hydraulic oil from the cooler and piping. a Before draining the oil, open the hydraulic tank cap to release the internal pressure of the tank. 6 Hydraulic oil cooler: 5.4 l

5. Remove the 3 mounting bolts and lift off hydraulic oil cooler assembly (5). 4 Hydraulic oil cooler assembly: 20 kg

2. Open the side cover and remove tube (2).

NSTALLATION •

Carry out installation in the reverse order to removal.

• Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5 Hydraulic oil cooler: 5.4 l (EO10-CD)

3. Open the engine hood and remove tube (3). 4. Remove the mounting bolts of cover (4) and move the cover toward the engine.

30-28 (2)

PC160LC-7

ENGINE AND HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY

796-460-1210

Oil stopper

796-770-1320

Adapter

q q

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

1 1

REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery. k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank.

a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1. Drain the coolant.

6 Coolant: 18.6 l

5. Remove hoses (2) and (3).

[*2]

6. Disconnect hoses (4), (5), and (6) from the engine. [*3] 7. Remove fan guards (7) and (8). 8. Remove the air conditioner compressor belt and disconnect connector E06 (9). Remove air conditioner compressor (10) and bracket and move them toward the counterweight. [*4] a Do not disconnect the air conditioner piping. 9. Remove the cooling fan. 10. Remove plate (11).

2. Remove the hydraulic tank strainer. Using tool D, stop the oil. a When not using tool D, remove the drain plug to drain the oil from the hydraulic tank. [*1] 6 Hydraulic tank: 121 l

3. Close the fuel stop valve. 4. Lift off engine hood (1).

4 Engine hood: 40 kg

PC160LC-7

30-29 (2)

ENGINE AND HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

11. Remove plates (12) and (13) and covers (14) and (15).

15. Disconnect fuel hoses (21) and 22. a Plug the hoses to prevent fuel from leaking. 16. Disconnect terminal V07 (23).

12. Disconnect connector E12 (16), terminal B (17), and connector E12 (18). 17. Disconnect terminal E02 (24). 13. Disconnect hose (19).

[*5]

18. Disconnect connector E03 (25). 14. Disconnect connector T13 (20) and terminal B under the starting motor.

30-30 (2)

19. Remove bracket (26).

PC160LC-7

DISASSEMBLY AND ASSEMBLY

20. Disconnect connectors E01 (27) and E05 (28) and remove the wiring harness clamp.

ENGINE AND HYDRAULIC PUMP

23. Disconnect connectors V21 (33) and A61 (34) and remove the wiring harness clamp. 24. Disconnect hoses (35) and (36) and tube (37). a Prepare a container to receive oil flowing out through tube (37).

21. Disconnect hose (29).

25. Disconnect hoses (38), (39), (40), and (41). 26. Disconnect ground wire (42). 27. Remove the 4 mounting bolts of oil filter bracket (43) and move the oil filter toward the engine.

22. Disconnect connectors E04 (30), E11 (31), and E10 (32).

28. Remove 4 engine mounting bolts (44).

PC160LC-7

[*6]

30-31 (2)

ENGINE AND HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

29. Lift off engine and hydraulic pump assembly (45). a Check that all the wires and pipes are disconnected. 4 Engine and oil pump assembly: 600 kg

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

3 Hydraulic tank drain plug: 58.5 – 78.5 Nm {5.97 – 8.0 kgm}

[*2]

3 Clamp of hose (2): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 3 Clamp of hose (3): 1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm} 2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*3]

3 Clamp of hose (5): 10.0 – 11.0 Nm {1.02 – 1.12 kgm} 3 Clamp of hose (6): 1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm} 2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*4]

a Install the air conditioner compressor belt. For details, see TESTING AND ADJUSTING, Inspection and adjustment of air compressor belt tension.

[*5]

3 Clamp of hose (19): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*6]

3 Engine mounting bolt: 245 – 308.7 Nm {25 – 31.5 kgm} a If the engine mounting bracket was removed from the engine, tighten its mounting bolts to the following torque. a When tightening the mounting bolts of both mounting brackets on the engine front side, put the top of the projection on the back side of the brackets to the underside of the engine.

3 Mounting bolt of engine mounting bracket: 98 – 122.5 Nm {10 – 12.5 kgm} •

Refilling with water Add water to the specified level. Run the engine to circulate the water through the system. Then, check the water level again. 5 Cooling water: 18.6 l

30-32 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

• Bleeding air a Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

PC160LC-7

30-33 (2)

TRACK SHOE

DISASSEMBLY AND ASSEMBLY

EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY

3. Using tool M, pull out master pin (2).

[*2]

790-101-1300

Cylinder Pump

790-331-1110

Wrench

t t t

790-101-1102

791-630-3000 M

Part name

Sketch

Q'ty

Remover and installer

Part No.

New/Remodel

Necessity

Symbol

SPECIAL TOOLS

1 1

EXPANSION 1. Stop the machine so that the master pin will be between the idler and carrier roller and the track shoe can be expanded in the forward and backward directions.

4. Remove tool M and move the machine forward so that temporary pin [1] will be in front of the idler, then set block [2]. 5. Pull out temporary pin [1] and remove the dust seal. Move the machine in reverse to expand track shoe (3). [*3]

2. Lower the work equipment to the ground and loosen lubricator (1) to slacken the track shoe. [*1]

k Since the internal pressure of the adjustment cylinder is very high, do not loosen the lubricator more than 1 turn. If the grease does not come out sufficiently, move the machine forward and in reverse.

30-34 (4)

PC160LC-7

TRACK SHOE

DISASSEMBLY AND ASSEMBLY

INSTALLATION •

[*1]

[*2]

Carry out installation in the reverse order to removal.

a Using tool M, press fit the master pin so that its projection a will be as follows. • Dimension a: 2.5 ± 1 mm

a Adjust the tension of the track shoe. For detail, see TESTING AND ADJUSTING, Inspection and adjustment of track shoe tension.

• Procedure for tightening shoe bolts and nuts 1. Install each shoe nut (4) so that its rounded side (R) will be fitted to the seat on the link side. a If the shoe nut is installed reversely, its corner will interfere with the seat on the link side and it will not be fitted to the seat, and that can loosen the bolt. 2. Tighten the bolt. a Check that the mating faces are fitted and retighten the bolt. 3 1st time : 490 ± 50 Nm {50 ± 5 kgm} 2nd time: 120° ± 10° Nm (Angle tightening)

PC160LC-7

[*3]

a When fitting the dust seal, apply grease (G2LI) to its contact face against the bushing.

30-35 (2)

SPROCKET

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF SPROCKET

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

2 Threads of sprocket mounting bolt: Adhesive (LT-2) 3 Sprocket mounting bolt: 441 – 490 Nm {45 – 50 kgm}

REMOVAL 1. Expand the track shoe assembly. For details, see EXPANSION OF TRACK SHOE ASSEMBLY. 2. Swing the work equipment by 90° and push up the machine with it, and then set blocks [1] between the track frame and track shoe.

3. Remove the 20 mounting bolts and lift off sprocket (1). [*1] 4 Sprocket: 40 kg

30-36 (2)

PC160LC-7

FIANAL DRIVE

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY REMOVAL

4. Remove the 18 mounting bolts from final drive assembly (6) and lift if off to remove. [*1] a Be careful. Do not damage the face of the fitting seal at the base of the hose. a When lifting off the final drive assembly, do not use a tapped hole for lifting the cover. 4 Final drive assembly: 330kg

1. Remove the sprocket, refer to the removing sprocket section in this manual.

k Lower the work equipment to the ground for safety. Stop the engine and loosen the oil filler cap on the hydraulic tank to release pressure inside. 2. Remove cover (1).

INSTALLATION •

Install in reverse order to removal.

[*1]

3 Final drive assembly mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}

•

Reflling hydraulic oil Refill hydraulic oil through the oil filler port to the specified level, and left the oil circulate in the hydraulic system by starting the engine. Then check the oil level again.

3. Disconnect four travel motor hoses (2), (3), (4) and (5).

• Bleeding air a Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

PC160LC-7

30-37 (2)

FINAL DRIVE

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

F 2

796-427-1200

Wrench

796T-427-1220

Push tool

790-101-2510

Block

792-104-3940

Bolt

01580-11613

Nut

01613-31645

Washer

790-105-2100

Jack

790-101-1102

Pump

791-545-1510

Installer

t t t t t t t t t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

1 1

1 2 2

4. No. 1 carrier assembly 1) Remove No. 1 carrier assembly (3).

2 1 1 1

DISASSEMBLY 1. Draining oil Remove the drain plug to drain the oil from the final drive case. 6 Final drive case: 3.5 l

2. Cover Remove the mounting bolts. Using eyebolts [1], remove cover (1).

2) Push in pin (4) to drive shaft (5) out of carrier (6). a After removing the shaft, remove pin (4). 3) Remove thrust washer (7), gear (8), bearing (9), and thrust washer (10).

3. Washer Remove washer (2). 5. No. 1 sun gear shaft Remove No. 1 sun gear shaft (11).

30-38 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

3) Remove thrust washer (20), gear (21), bearing (22), and thrust washer (23). 4) Remove thrust washer (15).

6. Thrust washer Remove thrust washer (13). 7. No. 2 sun gear Remove No. 2 sun gear (14).

8. No. 2 carrier assembly 1) Remove No. 2 carrier assembly (16).

9. Nut 1) Remove lock plate (24). 2) Using tool F1, remove nut (25).

10. Hub assembly 1) Using eyebolts [2], remove hub assembly (26) from the travel motor.

2) Push in pin (17) to drive shaft (18) out of carrier (19). a After removing the shaft, remove pin (17).

PC160LC-7

30-39 (2)

FINAL DRIVE

DISASSEMBLY AND ASSEMBLY

2) Remove floating seal (27). 3) Remove bearings (28) and (29) from hub (30). a When removing bearing (28), do not hit the bearing plastic retainer.

ASSEMBLY a Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil (EO30-CD) before installing. 1. Hub assembly 1) Using the push tool, press fit bearings (28) and (29) to hub (30). 2) Using tool F3, install floating seal (27). a Thoroughly degrease and dry the O-ring and O-ring fitting surface of the floating seal before installing. a After installing the floating seal, check that its slant is less than 1 mm. a After installing the floating seal, thinly apply engine oil (EO30-CD) to the sliding surfaces.

4) Remove floating seal (31) from travel motor (32).

30-40 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

3) Using tool F3, install floating seal (31) to travel motor (32). a For the procedure for installation, see 2).

4) Using eyebolts [2], set hub assembly (26) to the travel motor. 5) Using and lightly hitting the push tool, press fit the bearing.

2. Nut 1) Using tool F2, press the bearing inner race. a Do not heat the bearing or press or hit the plastic retainer directly. a Pressing force: 8.8 – 12.7 kN {0.9 – 1.3 tons} a Before pressing the bearing inner race, revolve the hub 2 – 3 turns. 2) Under the above condition, measure dimension a.

PC160LC-7

3) Measure thickness b of the nut. 4) Obtain a – b = c. 5) Using tool F1, tighten nut (25) until dimension d is c 0/-0.1.

6) Using push-pull gauge [3], measure the starting tangential force of the hub in its revolving direction on the motor case. a Starting tangential force: Max. 294 N {Max. 30 kg}

30-41 (2)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

7) Install lock plate (24). a Install the lock plate around cut e of the travel motor, fitting it to the spline thoroughly (under condition f).

2 Threads of mounting bolt: Adhesive (LT-2) a Do not apply adhesive (LT-2) to the threads of the mating nut.

3) Aligning the pin holes of shaft (18) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. a When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. 4) Insert pin (17). a Replace the pin with new one. a After inserting the pin, caulk the carrier by the part where the pin is inserted. a After assembling the carrier, check that gear (21) revolves smoothly.

3. No. 2 carrier assembly 1) Install thrust washer (15). 2) Install bearing (22) to gear (21). Fit upper and lower thrust washers (20) and (23) and set the gear assembly to carrier (19). a Replace thrust washers (20) and (23) with new ones. a There is a caulking mark made when the pin was inserted at the end of carrier side hole g and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance.

30-42 (2)

5) Install No. 2 carrier assembly (16). a Install No. 2 carrier assembly (16) so that the 3 gear shaft ends will be in the 3 hollows at the motor case end.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

a Replace thrust washers (7) and (10) with new ones. a There is a caulking mark made when the pin was inserted at the end of carrier side hole h and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance.

4. No. 2 sun gear Install No. 2 sun gear (14). 5. Thrust washer Install thrust washer (13). 2) Aligning the pin holes of shaft (5) and carrier, lightly hit the shaft with a plastic hammer, etc. to install. a When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. 3) Insert pin (4). a Replace the pin with new one. a After inserting the pin, caulk the carrier by the part where the pin is inserted. a After assembling the carrier, check that gear (8) revolves smoothly. 6. No. 1 sun gear shaft Install No. 1 sun gear shaft (11).

7. No. 1 carrier assembly 1) Install bearing (9) to gear (8). Fit upper and lower thrust washers (7) and (10) and set the gear assembly to carrier (6).

PC160LC-7

30-43 (2)

DISASSEMBLY AND ASSEMBLY

4) Install No. 1 carrier assembly (3).

FINAL DRIVE

10. Refilling with oil Tighten the drain plug and add engine oil through the oil filler. 5 Final drive case: Approx. 3.5 l (EO30-CD)

a After installing the final drive assembly to the chassis, check the oil level again at the specified position.

8. Washer Install washer (2).

9. Cover Using eyebolts [1], install cover (1) and tighten the mounting bolts.

2 Cover mounting face: Gasket sealant (LG-6) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

30-44 (2)

PC160LC-7

IDLER

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

3. Detach idler (4) from shaft (5) and support asembly (7). a The idler contains 70 – 80 cc of oil. Drain the oil at this stage if disassembly. Take care and spread a cloth on the floor to prevent smearing the floor with flushing oil.

790-101-5201

Push tool KIT

• 790-101-5221 • 01010-51225 • 790-101-5271

• Grip • Bolt • Plate

790-434-1630

Installer

790-601-1000

Oil pump

t q

4. Remove floating seal (6) on the opposite side from idler (4), shaft (5) and support assembly (7). Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

1 1

DISASSEMBLY 5. Remove dowel pin (8) to detach support (7) from shaft (5). 6. Remove bushings (9) and (10) from idler (4).

1. Remove dowel pin (1) and then support (2). 2. Remove floating seal (3) from support (2) and idler (4).

PC160LC-7

30-45 (2)

DISASSEMBLY AND ASSEMBLY

ASSEMBLY 1. Using tool H1, press fit bushings (9) and (10) to idler (4). a Press fitting load: 43 – 108 kN {4.4 – 11 ton}

2. Fit O-ring and install support (7) to shaft (5) with dowel pin (8).

IDLER

a After inserting the floating seal, check that inclination of the seal is less than 1mm and that protrusion a of the of the seal remains within the range of 5 – 7mm.

4. Assemble shaft (5) and support (7) assembly to idler (4).

3. Using tool H2, install floating seal (6) to idler (4), shaft (5) and support (7) assembly.

a Floating seal Before installing the floating seal, completely degrease both contact surfaces of an O-ring and the floating seal (hatched area in the illustration). Furthermore, take care so that no dust will stick to the contact surface of the floating seal.

30-46 (2)

PC160LC-7

IDLER

DISASSEMBLY AND ASSEMBLY

5. Using tool H2 install floating seal (3) to idler (4) and support (2). a Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. a Remove all grease and oil from the contact surface of the O-ring and the floating seal.

PC160LC-7

6. Install O-ring then install support (2) with dowel pin (1). 7. Using tool H3, add oil and tighten the plug. 5 Oil: Applox. 70 – 80 cc (SAE30)

3 Plug: 157 – 255 Nm {16 – 26 kgm}

30-47 (2)

RECOIL SPRING

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY

1. Piston assembly Remove piston assembly (2) from recoil spring assembly (1). 2.

Extension

t t t

790-101-1600

Cylinder (686 kN {70t})

790-101-1102

Pump

t t q

791-685-8006

Compressor

790-201-2780

Spacer

791-635-3160

791-640-2180

Guide bolt

790-201-1500

Push tool KIT

• 790-201-1620 • 790-101-5021 • 01010-50816

• Plate • Grip • Bolt

DISASSEMBLY

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

Disassembly of recoil spring assembly 1) Set recoil spring assembly (1) to tool J1.

k The recoil spring is under large installed load, so be very sure to set the tool properly. Failure to do this is dangerous. a Installed load of spring: 108.8 kN {11,100 kg}

1 1

1 1 1 1 1

2) Apply haidraulic pressure slowly to compress spring and remove lock plate (3). Then remove nut (4). a Compress the spring to a point where the nut becomes loose. a Release the hydraulic pressure slowly and release the tension of the spring. a Free length of spring: 558.5 mm. 3) Remove yoke (6), cylinder (7), and dust seal (8) from spring (5). 3. Disassembly of piston assembly 1) Remove lock plate (10) from piston (9), then remove valve (11). 2) Remove snap ring (12), then remove Upacking (13) and ring (14).

30-48 (6)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

ASSEMBLY

RECOIL SPRING

2) Assemble cylinder (7) and yoke (6) to spring (5), and set in tool J1.

2 Sliding portion of cylinder: Grease (G2-LI)

3) Apply hydraulic pressure slowly to compress the spring and tighten nut (4) so that the installed length of the spring is dimension a, then secure it with lock plate (3). a Installed length a of spring: 437 mm

1. Assembly of piston assembly 1) Assemble ring (14) and U-packing (13) to piston (9) and secure with snap ring (12). 2) Tighten valve (11) temporarily, and secure with lock plate (10). 2. Assembly of recoil spring assembly 1) Using tool J2, install dust seal (8) to cylinder (7).

4) Remove recoil spring assembly (1) from tool J1. 3. Asswmble piston assembly (2) to recoil spring assembly (1). 2 Sliding portion of piston: Grease (G2-LI) 2 Wear ring: Grease (G2-LI)

a install the piston assembly so the valve installing position is on the outside. a Fill the inside of the cylinder with 300cc of grease (G2-LI), then bleed the air and check that the grease comes out of the grease hole.

PC160LC-7

30-49 (2)

TRACK ROLLER

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY

790-101-5201

Push tool KIT

• 790-101-5221 • 01010-51225 • 790-101-5261

• Grip • Bolt • Plate

790-434-1640

Installer

791-601-1000

Oil pump

1 L

t q

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

a When installing floating seals (5) and (6), thoroughly clean, degrease, and dry the contact surfaces of the O-rings and floating seals (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. a After installing the floating seals, check that their slant is less than 1 mm and their projection a is 7 – 11 mm.

1 1

DISASSEMBLY a Disassemble according to the following figure.

ASSEMBLY a Assemble according to the following figure. a Only precautions for assembly are explained below. Assemble the track roller assembly similarly to the idler assembly, unless otherwise specified.

a Using tool L3, fill the track roller assembly with oil and tighten plug (8). 5 Track roller: Applox. 190 – 200 cc (EO30-CD)

3 Plug (8): 10 – 20 Nm {1 – 2 kgm}

a Tighten mounting bolts (11) of the track roller assembly to the following torque. 3 1st time : 196 ± 20 Nm {20 ± 2 kgm} 2nd time : 90° ± 5° (Angle tightening)

30-50 (2)

PC160LC-7

CARRIER ROLLER

DISASSEMBLY AND ASSEMBLY

a When installing floating seals (7) and (8), thoroughly clean, degrease, and dry the contact surfaces of the O-rings and floating seals (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. a After installing the floating seals, check that their slant is less than 1 mm and their projection a is 5 – 7 mm.

DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY

790-101-5001

Push tool KIT

• 790-101-5081 • 790-101-5021 • 01010-50816

• Plate • Grip • Bolt

790-434-1660

Installer

791-601-1000

Oil pump

1 K

t q

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

1 1

DISASSEMBLY a Assemble according to the following figure.

ASSEMBLY

a Using tool K3, fill the carrier roller assembly with oil and tighten plug (10). 5 Carrier roller: 75 – 85 cc (EO30-CD)

a Only precautions for assembly are explained below. a Assemble the carrier roller assembly similarly to the idler assembly, unless otherwise specified.

PC160LC-7

30-51 (2)

SWING MOTOR AND SWING MACHINERY

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY

3. Remove 13 mounting bolts. Using forcing screw [1], lift off swing motor and swing machinery assembly (8). a Take care that the assembly will not interfere with the hoses around it. 4 Swing motor and swing machinery assembly: 180 kg

REMOVAL

k Release the residual pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Release of residual pressure from hydraulic circuitt. k Lower the work equipment to the ground in a stable position and set the safety lock lever to the LOCK position. 1. Remove cover (1).

INSTALLATION •

2. Disconnect 6 hoses (2) – (7). • (2) : Between swing motor and control valve (Port MA) • (3) : Between swing motor and control valve (Port MB) • (4) : Suction hose (Port S) • (5) : Pilot hose for releasing swing brake (Port PB) • (6) : Drain hose between swing motor and swivel joint (Port DB) • (7) : Drain hose between swing motor and hydraulic tank (Port DB)

30-52 (2)

Carry out installation in the reverse order to removal.

• Refilling with water a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. • Bleeding air a For details, see TESTING AND ADJUSTING, Bleeding air from each part.

PC160LC-7

SWING MOTOR AND SWING MACHINERY

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY

KBATZ080080

Wrench

G 2

KBATZ030190

Adapter

KBATZ060400

Stopper

t t t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

DISASSEMBLY

2) Remove No. 1 carrier assembly (6). a Insert a flat-head screwdriver, etc. under planetary gear (7) to float and remove the planetary gear.

1. Draining oil Loosen the drain plug and drain the oil from the swing machinery case. 6 Swing machinery case: 4.5 l

2. Swing motor assembly 1) Set the swing motor and swing machinery assembly on blocks. 2) Pull out level gauge (1) and remove pipe (2) and bracket. a Turn and remove pipe (2). 3) Loosen the mounting nut of pipe (3) and remove the pipe and bracket together. 4) Lift off swing motor assembly (4). a Make match marks on the swing motor case and cover (16) for reassembly.

4. Cover Remove cover (16). a Make match marks on cover (16) and ring gear (26) for reassembly.

3. No. 1 carrier assembly 1) Remove No. 1 sun gear (5).

PC160LC-7

30-53 (2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

5. No. 2 carrier assembly 1) Remove No. 2 sun gear (17).

2) Using a bar, etc., float and remove No. 2 carrier assembly (18).

6. Ring gear Remove ring gear (26). a Make match marks on ring gear (26) and housing (28) for reassembly.

30-54 (2)

7. Ring nut 1) Using punch [1], etc., straighten the bent parts (3 places) of ring nut (27) around the pinion shaft spline.

2) Place the flange of housing (28) on a block and float the pinion shaft at the center. 3) Install tool G1 to the pinion shaft and install tool G2 to the ring nut.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

8. Housing and pinion shaft 1) Remove 6 mounting screws (32) of front cover (31).

4) Fix tool G2. Using power wrench (25-time power) [2], turn tool G1 to loosen the ring nut. • Tightening torque of ring nut (Reference): 1100 – 1200 Nm {112.2 – 122.3 kgm}

5) Remove ring nut (27).

PC160LC-7

2) Using puller [3], separate housing (28) and pinion shaft assembly (29).

3) Using a press, separate pinion shaft assembly (29) and bearing (30).

30-55 (2)

DISASSEMBLY AND ASSEMBLY

4) Remove front cover (31) and spacer (36).

SWING MOTOR AND SWING MACHINERY

ASSEMBLY 1. Housing and pinion shaft 1) Using tool G3, install oil seal (35) to housing (28) as shown in the following figure. a Press fit the oil seal until its end reaches the housing end.

5) Remove seal ring (33) from front cover (31).

2) Using push tool [4], press fit spacer (36) to pinion shaft (29).

6) Remove bearing (34) and oil seal (35) from housing (28).

3) Install seal ring (33) to front cover (31).

30-56 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

4) Set front cover (31) to pinion shaft (29).

5) Using push tool [5], press fit bearing (30) to pinion shaft (29). a Press fit the bearing until the inner race end reaches the spacer. 2 Bearing:Grease (SHELL RETINAX HD-2 or equivalent)

7) Using push tool [6], press fit pinion shaft assembly (29) to housing (28). a Press fit the bearing until the end of bearing (30) reaches the end of housing (28).

2 Mounting screw: LOCTITE 243 or equivalent

8) Tighten 6 front cover mounting screws (32). 6) Set pinion shaft assembly (29) to housing (28).

2 Housing:Grease (SHELL RETINAX HD-2 or equivalent)

PC160LC-7

3 Mounting screw: 25 Nm {2.5 kgm}

30-57 (2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

9) Using push tool [7], press fit bearing (34). a Press fit bearing (34) until its end reaches the shoulder of pinion shaft (29).

2. Ring nut 1) Install ring nut (27) to the pinion shaft.

2) Place the flange of housing (28) on blocks and float the pinion shaft at the center. 3) Install tool G1 to the pinion shaft and install tool G2 to the ring nut.

30-58 (2)

4) Fix tool G2. Using power wrench (25-time power) [2], turn tool G1 to tighten the ring nut. 3 Ring nut: 1100 – 1200 Nm {112.2 – 122.3 kgm}

5) Using a punch, etc., bend the inside parts of ring nut (27) toward the spline of pinion shaft (29). a Bend 3 parts at intervals of 120°.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

3. No. 2 carrier assembly 1) Install No. 2 carrier assembly (18).

SWING MOTOR AND SWING MACHINERY

5. Cover 1) Fit the O-ring to the ring gear mounting face of cover (16). 2) Install cover (16). a Match the match marks made when the cover was removed.

2) Install No. 2 sun gear (17).

6. No. 1 carrier assembly 1) Install No. 1 carrier assembly (6).

4. Ring gear 1) Fit the O-ring to the housing. 2) Install ring gear (26). a Match the match marks made when the ring gear was removed.

PC160LC-7

30-59 (2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

2) Install No. 1 sun gear (5).

3) Check that dimension a from the end of cover (16) to the end of No. 1 sun gear (5) is as follows. 0 • Dimension a = 1.5 – 0.5 mm

8. Refilling with oil

5 Swing machinery case: 4.5 l (EO30-CD)

7. Swing motor assembly 1) Install swing motor assembly (4). a Match the match marks made when the swing motor assembly was removed.

3 Mounting bolt: 85 ± 4.3 Nm {8.7 ± 0.44 kgm} 2) Install pipe (3) and bracket.

3 Pipe mounting nut (2 places): 56.4 ± 7.3 Nm {5.8 ± 0.74 kgm} 3) Install pipe (2) and bracket and insert level gauge (1). 3 Pipe: 12.3 ± 2.5 Nm {1.25 ± 0.25 kgm}

30-60 (2)

PC160LC-7

SWING MOTOR

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR ASSEMBLY

2) Remove valve plate (3) from the cover assembly.

799-301-1600

Oil leak tester kit

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

DISASSEMBLY 1. Set the swing motor and swing machinery assembly on blocks.

3) Remove 2 plugs (4), 2 springs (5), and 2 poppets (6).

2. Reverse prevention valve assembly Remove reverse prevention valve assembly (1).

4) Remove relief valve assembly (7). a Do not disassemble the relief valve assembly. a Note that the poppet seat at the relief valve end may be left in the cover. 5) Remove 2 plugs (40).

3. Cover assembly 1) Remove cover assembly (2). a Note that the valve plate may fall from the cover assembly. 6) Remove bearing outer race (8).

PC160LC-7

30-61 (2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

4. Springs Remove 16 springs (9). a There are outer springs (large) and inner springs (small). Only the outer springs (large) are installed to 4 places a.

7. Discs and plates Remove 3 discs (14) and 2 plates (15). a The number of the discs includes the one removed in step 6. 5. Brake piston Using tool D1, supply compressed air to port PB of the case to float and remove brake piston (10). a When installing the cover, make match marks on the brake piston and case so that the dowel pin of the cover will not shift from the dowel pin hole of the brake piston.

k If high-pressure air is supplied, the brake piston jumps out. Accordingly, supply very low-pressure air at first and check the movement of the brake piston, and then adjust the air pressure. 8. Cylinder block assembly 1) Place case (21) on its side. 2) Pull out cylinder block assembly (11). a When removing the cylinder block assembly, slant the case down a little so that the internal parts (piston, retainer holder, and pin) will not be left in the case.

6. Collar Using a puller, etc., remove collar (13). a Remove 1 disc (14) so that you can remove the collar easily.

30-62 (2)

PC160LC-7

SWING MOTOR

DISASSEMBLY AND ASSEMBLY

3) Lift up retainer plate (17) and remove it and piston (18) together from cylinder block (11). 4) Separate retainer plate (17) and piston (18).

9. Thrust plate Remove thrust plate (19). 5) Remove retainer holder (16).

6) Remove 3 pins (12).

10. Shaft and case 1) Remove bearing inner race (20).

7) Press down collar (30) with a press, etc. and remove snap ring (31). 8) Remove collar (30), spring (32), and collar (33).

PC160LC-7

30-63 (2)

SWING MOTOR

DISASSEMBLY AND ASSEMBLY

2) Turn over case (21) and set it on blocks. 3) Remove snap ring (22). 4) Press the end of shaft (23) with a press, etc. to remove the shaft.

ASSEMBLY a Clean the all parts and check them for dirt or damage. a Coat the sliding surfaces of each part with engine oil (EO10-CD). 1. Shaft and case 1) Using push tool [1], press fit bearing (25) to shaft (23). a Press fit the bearing until the end of its inner race reaches the shoulder of the shaft.

5) Remove bearing (25) from shaft (23).

2) Using push tool [2], press fit oil seal (24) to case (21) as shown in the following figure. a Press fit the oil seal until its end reaches the case end.

2 Lip surface of oil seal: Grease (G2-LI)

6) Remove oil seal (24) from case (21).

30-64 (2)

PC160LC-7

SWING MOTOR

DISASSEMBLY AND ASSEMBLY

3) Press the end of shaft (23) with a press, etc. to press fit it to case (21). a Press fit the shaft until the end of the bearing outer race reaches the case end. 4) Install snap ring (22).

5) Install inner race (20).

2. Thrust plate Install thrust plate (19). a Install the thrust plate with small hole side b up.

PC160LC-7

3. Cylinder block assembly 1) Install collar (33), spring (32), and collar (30). 2) Press down collar (30) with a press, etc., and install snap ring (31).

3) Install 3 pins (12). a Apply grease (G2-LI) to the pins so that they will not fall when the cylinder block assembly is installed.

4) Install retainer holder (16).

30-65 (2)

SWING MOTOR

DISASSEMBLY AND ASSEMBLY

5) Install piston (18) to retainer plate (17). a Set chamfered periphery c of retainer plate (17) toward the cylinder block side. 6) Install the retainer plate and piston assembly to the cylinder block assembly (11). a Apply engine oil (EO10-CD) fully to the sliding surfaces of the piston and cylinder block.

4. Discs and plates Install 3 discs (14) and 2 plates (15) alternately. a When installing discs, set their wider nospline teeth sides d and narrower no-spline teeth sides e to each other respectively. a The wider and narrower no-spline teeth sides may be installed in any direction of the cylinder block.

7) Place case (21) on its side. 8) Install cylinder block assembly (11) to the case. a Take care that the piston will not come out of the cylinder block.

5. Collar 1) Fit the O-ring to collar (13).

30-66 (2)

2 Periphery of O-ring: Grease (G2-LI) 2) Using push tool [3], press fit collar (13) evenly.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

6. Brake piston 1) Fit the O-ring to brake piston (10).

2 Periphery of O-ring: Grease (G2-LI) 2) Using push tool [4], press fit brake piston (10) evenly. a When press fitting the brake piston, align the intermediate point between tap hole (f) of the brake piston and dowel pin hole (g) with the center of port (h) of the case so that the dowel pin of the cover will be aligned with the dowel pin hole of the brake piston when the cover is installed (in step 8). (Match the match marks made when the brake piston was removed.) 3) Fit the O-ring to the case. 2 Periphery of O-ring: Grease (G2-LI)

8. Cover assembly 1) Using push tool [5], press fit bearing outer race (8) to cover (2). a Press fit the bearing outer race until its end reaches the cover end.

7. Springs Install 16 springs (9). a There are outer springs (large) and inner springs (small). Install only the outer springs (large) to 4 places a.

PC160LC-7

30-67 (2)

SWING MOTOR

DISASSEMBLY AND ASSEMBLY

2 Periphery of O-ring: Grease (G2-LI)

2) Install 2 plugs (40).

3 Plug: 46 ± 0.98 Nm {4.7 ± 0.1 kgm}

3) Fit the backup ring and O-ring and install 2 relief valve assemblys (7).

2 Periphery of backup ring and O-ring: Grease (G2-LI)

3 Relief valve assembly: 373 ± 20 Nm {38.0 ± 2.0 kgm} 4) Install 2 poppets (6), 2 springs (5), and plugs (4).

6) Install cover assembly (2). a When installing the cover assembly, match the dowel pin on the cover side to the dowel pin hole on the brake piston side. a Do not apply an impact to the cover assembly. If it is applied, the valve plate may fall.

2 Periphery of O-ring: Grease (G2-LI)

3 Plug: 157 ± 10 Nm {16.0 ± 1.0 kgm}

3 Mounting bolt: 294 ± 20 Nm {29.9 ± 2.0 kgm}

7) Tighten the mounting bolts.

9. Reverse prevention valve assembly Install reverse prevention valve assembly (1). 5) Install valve plate (3). a When installing the valve plate, set its circularly grooved side toward the cover and match the cut on its periphery to the dowel pin. a Apply grease (G2-LI) to the cover mounting face so that the valve plate will not fall when the cover assembly is installed.

30-68 (2)

3 Mounting bolt: 32.4 ± 2.0 Nm {3.3 ± 0.2 kgm}

PC160LC-7

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY REMOVAL

k Release the residual pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Release of residual pressure from hydraulic circuit. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1. Disconnect 14 hoses (1) – (14). a Hose (9) may be disconnected from the swing motor. • (1) : Between center swivel joint (Port DR) and left travel motor (Port T) • (2) : Between center swivel joint (Port DR) and right travel motor (Port T) • (3) : Between center swivel joint (Port B) and right travel motor (Port PB) • (4) : Between center swivel joint (Port D) and left travel motor (Port PA) • (5) : Between center swivel joint (Port A) and right travel motor (Port PA) • (6) : Between center swivel joint (Port C) and left travel motor (Port PB) • (7) : Between center swivel joint (Port E) and left travel motor (Port P) • (8) : Between center swivel joint (Port E) and right travel motor (Port P) • (9) : Between center swivel joint (Port DR) and swing motor (Port DB) • (10) : Between center swivel joint (Port E) and solenoid valve • (11) : Between center swivel joint (Port B) and control valve right travel (Port B2) • (12) : Between center swivel joint (Port D) and control valve left travel (Port B3) • (13) : Between center swivel joint (Port A) and control valve right travel (Port A2) • (14) : Between center swivel joint (Port C) and control valve left travel (Port A3) 2. Remove pin (15).

PC160LC-7

30-69 (2)

CENTER SWIVEL JOINT

DISASSEMBLY AND ASSEMBLY

3. Remove the 4 mounting bolts and lift off center swivel joint assembly (16). [*1] 4 Center swivel joint assembly: 40 kg

INSTALLATION • [*1]

Carry out installation in the reverse order to removal. a When installing center swivel joint assembly (16), set ports B and D toward the front of the machine (in the direction of the arrow). [(17) in the following figure indicates the sprocket.]

30-70 (2)

PC160LC-7

CENTER SWIVEL JOINT

DISASSEMBLY AND ASSEMBLY

Part name

790-101-2501

Push puller

• 790-101-2510 • 790-101-2520 • 791-112-1180 • 790-101-2540 • 790-101-2630 • 790-101-2570 • 790-101-2560 • 790-101-2650

• Block • Screw • Nut • Washer • Leg • Plate • Nut • Adapter

4. Remove seal (6) from swivel shaft (5).

Sketch

Part No.

New/Remodel

5. Remove O-ring (7) and slipper seal (8) from swivel rotor (4).

Q'ty

SPECIAL TOOLS Necessity

3. Using tool E, pull out swivel rotor (4) and ring (3) from swivel shaft (5).

Symbol

DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY

1 1 1 1 1 2 4 2 2

ASSEMBLY DISASSEMBLY

1. Assemble slipper seal (8) and O-ring (7) to swivel rotor (4). 2. Assemble seal (6) in swivel shaft (5). 3. Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install. 2 Contact surface of rotor, shaft: Grease (G2-LI) a When installing the rotor, be extremely careful not to damage the slipper seal and the Oring.

4. Install ring (3) and secure with snap ring (2). 3 Mounting bolt: 31.4 ± 2.9Nm {3.2 ± 0.3 kgm}

5. Fit O-ring and install cover (1).

1. Remove cover (1). 2. Remove snap ring (2).

PC160LC-7

30-71 (2)

WORK EQUIPMENT

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY

Remover

790-101-4000

Puller (490 kN {50t} long)

790-101-1102

Pump (294 kN {30t})

Part name

Sketch

796-900-1200

Part No.

New/Remodel

Q'ty

Necessity

Symbol

SPECIAL TOOLS

REMOVAL

k Except the arm and bucket fully. Lower the work equipment to the ground and set the safety lock lever to the lock position. k Release the residual pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Release of residual pressure from hydraulic circuit. 1. Disconnect grease hose (1).

4. Start the engine and retract the piston rod. a Fasten the piston rod with wire so that it will not slip out and lower the cylinder onto a stand, or place a support under the bottom of the cylinder to support it. In the latter case, remove the grease fitting on the bottom side first. a Remove the bottom cylinder on the other side in the same manner. 5. Disconnect 2 bucket cylinder hoses (6) and 2 arm cylinder hoses (7), two for each. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. a Put an oil stopper plug to each hose connecting part and bind the hose with ropes, etc. so that it will not be an obstacle to the work.

2. Sling boom cylinder assembly (2), and remove lock bolt (3). 3. Remove plate (4), then remove head pin (5). [*1] a There are shims installed, so check the number and thickness, and keep them in a safe plate.

30-72 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

6. Disconnect connector A42 (8).

8. Lift work equipment assembly (11) and disassemble it. 4 Work equipment assembly: 2,700 kg

7. Lift off work equipment and remove plate (9) and then pin (10) at the foot. [*2]

•

When removing them, first remove plate (9) and then remove pin (10) at the foot, using tool R. a Shims are installed, so do not forget to check their number and each location of installation.

PC160LC-7

30-73 (2)

DISASSEMBLY AND ASSEMBLY

IINSTALLATION •

Install in reverse order of removal.

[*1]

a When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 – 1.5 mm.

2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G)

k When aligning the position of the pin hole, never insert your fingers into the pin hole.

SWING MOTOR k When aligning the position of the pin hole, never insert your fingers into the pin hole. a Adjust clearance a between boom (14) and frame (15) with shim (13) (Thickness: 2.0 mm) so that it will be less than 1 mm. • Thickness of standard shims: 2.0, 2.5, 3.0 and 3.5 mm.

• Refilling with oil (hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • Bleeding air a Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

a Adjust the shim thickness so that clearance a between cylinder rod (12) and plate (4) is below 1.5 mm. a Standard shim thickness: 1.0 mm and 2.0 mm.

[*2]

2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) 2 Grease after assembling pin: Grease (LM-G)

30-74 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY REMOVAL

REVOLVING FRAME

7. Remove plate (3) and pin (4) and lift off boom cylinder assembly (2). a Remove the boom cylinder on the opposite side simultaneously. 4 Boom cylinder assembly: 130 kg

1. Remove the work equipment assembly. For details, see REMOVAL AND INSTALLATION OF WORK EQUIPMENT. 2. Remove the counterweight assembly. For details, see REMOVAL AND INSTALLATION OF COUNTERWEIGHT. 3. Remove the engine hood. 4. Remove the plate from the rear of the engine compartment (between the engine compartment and counterweight). a Move or remove other parts which may interfere with the sling of the revolving frame assembly. 5. Disconnect 4 hoses (1).

8. Disconnect 6 hoses (5) – (10) above the swivel joint assembly. a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. a For detail of the routes of the hoses, see REMOVAL AND INSTALLATION OF SWIVEL JOINT ASSEMBLY. 9. Pull out the pin on the center swivel joint side and disconnect plate (11) from the swivel joint.

6. Sling boom cylinder assembly (2) temporarily.

PC160LC-7

30-75 (2)

REVOLVING FRAME

DISASSEMBLY AND ASSEMBLY

10. Remove the 32 mounting bolts and lift off revolving frame assembly (12). [*1] a Using a lever block, etc., balance the revolving frame assembly in longitudinal and lateral directions, and then remove the all mounting bolts, except the 2 each on the front and rear sides. k When removing the revolving frame assembly, take care that it will not interfere with the center swivel joint assembly. 4 Revolving frame assembly: 3,050 kg

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

2 Mating face of swing circle: Gasket sealant (LG-1)

2 Threads of revolving frame mounting bolt: Adhesive (LT-2) 3 Revolving frame mounting bolt: 1st time : 294.2 ± 29.4 Nm {30 ± 3kgm} 2nd time: Retighten by 60° or to 588 – 677 Nm {60 – 69 kgm} • Refilling with oil (Hydraulic tank) a Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. • Bleeding air a Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-76 (2)

PC160LC-7

SWING CIRCLE

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

2 Threads of swing circle mounting bolt: Adhesive (LT-2) 3 Swing circle mounting bolt: 1st time : 191.2 ± 19.6 Nm {19.5 ± 2 kgm} 2nd time: Retighten by 48° ± 5° (Angle tightening)

REMOVAL 1. Remove the revolving frame assembly. For details, see REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY. 2. Remove 36 mounting bolts (1).

[*1] [*2]

a Set the soft zone (marked with S) of the inner race on the right side of the machine. (The arrow indicates the front of the machine.) 2 Quantity of grease for circle: Grease (G2-LI), 14.6 l

3. Lift off swing circle assembly (2).

4 Swing circle assembly: 270 kg

PC160LC-7

[*2]

30-77 (2)

HYDRAULIC TANK

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY

5. Remove cover (4).

REMOVAL 1. Drain oil from the hydraulic tank. 6 Hydraulic tank: 121 l

[*1]

2. Remove cover (1).

6. Disconnect connector A60 (5). 7. Remove handrail (6). 8. Move tool case assembly (7) forward.

3. Disconnect hose (2). 4. Remove clamp mounting bolt (3).

9. Remove cover (8).

30-78 (2)

PC160LC-7

HYDRAULIC TANK

DISASSEMBLY AND ASSEMBLY

14. Disconnect 7 hoses (16) – (22).

10. Remove cover (9) and plates (10) and (11).

11. Remove the mounting bolts of oil filter bracket (12) and frame (13). 12. Disconnect connector A61 (14). 13. Remove pipe and hose assembly (15). a Prepare a container to receive oil.

[*2]

15. Remove the undercover and 6 lower mounting bolts and lift off hydraulic tank assembly (23).[*3] 4 Hydraulic tank assembly: 120 kg

PC160LC-7

30-79 (2)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

INSTALLATION • Carry out installation in the reverse order to removal. [*1]

[*2]

3 Hydraulic tank drain plug: 58.5 – 78.5 {5.97 – 8.0 kgm} a Tighten hose clamp screws (24) at 180° to each other as shown below.

3 Hose clamp:90 ± 5 Nm {8.8 ± 0.5 kgm}

[*3]

3 Mounting bolt: 245.2 – 308.9 Nm {25 – 31.5 kgm}

Bleeding air • Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-80 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY REMOVAL

k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank. k Set the safety lock lever in the LOCK position.

a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. • The 7-spool valve specification (6-spool valve + service valve) without an attachment is explained below.

CONTROL VALVE

3. Disconnect the following hoses from the front of the control valve. • (1) : Bucket cylinder (Head side) • (2) : Bucket cylinder (Bottom side) • (3) : Arm cylinder (Head side) • (4): Arm cylinder (Bottom side) • (5): Travel PPC valve • (6): Travel PPC valve • (7): Hydraulic tank • (8): Pump LS valve • (9): Right travel motor • (10) : Right travel motor • (11) : Left travel motor • (12): Left travel motor • (13): Swing motor • (14): Swing motor

1. Open the engine hood and remove cover (1).

2. Remove covers (2) and (3).

PC160LC-7

30-81 (4)

DISASSEMBLY AND ASSEMBLY

4. Disconnect the following hoses and wiring connector from the left of the control valve. • (15) : Bucket CURL PPC valve (Hose band: White) • (16) : Arm IN PPC valve (Hose band: Blue) • (17) : Boom LOWER PPC valve (Hose band: Blown) • (18) : Boom cylinder (Head side) • (19) : Oil cooler • (20) : Pump merge-divider valve solenoid valve • (21) : Travel junction valve solenoid valve • (22) : Left travel REVERSE PPC valve • (23) : Right travel REVERSE PPC valve (Hose band: Blue) • (24) : Swing RIGHT PPC valve • (25) : R pump pressure sensor connector A52

30-82 (2)

CONTROL VALVE

5. Disconnect the following hoses and wiring connector from the right of the control valve. • (26) : Main pump • (27) : Bucket DUMP PPC valve (Hose band: Black) • (28) : Arm OUT PPC valve (Hose band: Yellow) • (29) : Boom RAISE PPC valve (Hose band: Green) • (30) : Boom cylinder (Bottom side) • (31) : Hydraulic tank • (32) : 2-stage relief solenoid valve • (33) : Left travel FORWARD PPC valve (Hose band: Red) • (34) : Right travel FORWARD PPC valve (Hose band: Green) • (35) : Swing LEFT PPC valve (Hose band: Red) • (36) : Swing motor • (37) : F pump pressure sensor connector A51 • (38) : Oil pressure pickup hose (under pump merge-divider block)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

7. Remove the 4 mounting bolts and lift off control valve assembly (46). 4 Control valve assembly: 140 kg

6. Disconnect the following hoses from the rear of the control valve. • (39): Hydraulic tank • (40): Travel PPC valve • (41): Travel PPC valve • (42): Main pump • (43): Main pump • (44): Oil pressure pickup hose • (45): Boom RAISE PPC valve

PC160LC-7

30-83 (2)

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

INSTALLATION •

Carry out installation in the reverse order to removal.

30-84 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY a Only precautions for assembling the control valve assembly are described below. a For the tightening torque of the control valve parts which are not shown in the following sectional view and explanation, see STRUCTURE AND OPERATION, Maintenance standard, CONTROL VALVE.

ASSEMBLY

a When tightening plugs (1) and (2) shown in the above figure, apply a drop (approx. 0.02 g) of LOCTITE (No. 638) to each of their parts "a" shown in the figure at right. • Dimension a = 2 – 3 mm 3 Plugs (1) and (2): 14.7 – 19.6 Nm {1.5 – 2 kgm}

PC160LC-7

30-85 (2)

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

a Tighten the 4 combination nuts on the top of the control valve in the following numerical order in 3 times. a The arrow in the figure indicates the front of the machine. 3 Combination nut: 1st time : 58.8 – 68.8 Nm {6 – 7 kgm} 2nd time : 78.5 – 88.3 Nm {8 – 9 kgm} 3rd time : 98.1 – 113 Nm {10 – 11.5 kgm}

a Tighten the 4 combination nuts on the underside of the control valve in the following numerical order in 3 times. a The arrow in the figure indicates the front of the machine. 3 Combination bolt: 1st time : 19.6 – 29.4 Nm {2 – 3 kgm} 2nd time : 39.2 – 49.0 Nm {4 – 5 kgm} 3rd time : 58.8 – 73.5 Nm {6 – 7.5 kgm}

30-86 (2)

PC160LC-7

HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY

796-460-1210

Oil stopper

796-770-1320

Adapter

q q

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

1 1

REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery.

4. Remove plates (2) and (3) and covers (4) and (5).

k Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic oil filler cap slowly to release the internal pressure of the hydraulic tank.

a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them. 1. Remove the hydraulic tank strainer. Using tool D, stop oil from flowing out. a When not using tool D, remove the drain plug and drain oil from the hydraulic tank. [*1] 6 Hydraulic tank: 121 l

5. Disconnect connectors V21 (6) and A61 (7) and remove the wiring harness clamp. 6. Disconnect hoses (8) and (9) and tube (10). a Prepare a container to receive oil flowing out of tube (10).

2. Drain oil from the damper case. 6 Damper case: 0.75 l

3. Lift off engine hood (1).

4 Engine hood: 40 kg

PC160LC-7

30-87 (2)

HYDRAULIC PUMP

DISASSEMBLY AND ASSEMBLY

7. Disconnect hoses (11), (12), (13), and (14).

INSTALLATION

8. Disconnect ground wire (15).

•

Carry out installation in the reverse order to removal.

[*1]

3 Hydraulic tank drain plug: 58.5 – 78.5 Nm {5.9 - 8.0 kgm}

[*2]

2 Hydraulic pump shaft spline: Lubricant containing molybdenum disulfide (LM-G) 2 Mating face of hydraulic pump case: Gasket sealant (LG-6)

9. Lift off hydraulic pump assembly (16).

4 Hydraulic pump assembly: 140 kg

[*2]

• Refilling with oil (Damper case) a Add oil through the oil filler to the specified level. 5 Damper case: 0.75 l (EO30-CD)

• Bleeding air a Bleed air. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-88 (2)

PC160LC-7

HYDRAULIC PUMP INPUT SHAFT OIL SEAL

DISASSEMBLY AND ASSEMBLY

Part name

791-463-1350

Push tool

790-201-2740

Spacer

t t

•

Sketch

Part No.

New/Remodel

[*1]

Q'ty

SPECIAL TOOLS Necessity

INSTALLATION

Symbol

REMOVAL AND INSTALLATION OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL

Carry out installation in the reverse order to removal. a Using tool N, press fit oil seal (3).

2 Lip and periphery of oil seal: Grease (G2-LI) a Apply grease thinly to the periphery of the oil seal.

1 1

REMOVAL 1. Remove the hydraulic pump assembly. For details, see REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY. 2. Remove snap ring (1) and spacer (2). 3. Pry off oil seal (3) with a screwdriver, etc. [*1] a Take extreme care not to damage the shaft.

PC160LC-7

30-89 (2)

WORK EQUIPMENT PPC VALVE

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY DISASSEMBLY a Disassemble according to the following figure.

ASSEMBLY a Assemble according to the following figure. a Only precautions for assembly are explained below.

a When installing pistons (10), apply grease (G2LI) to their outside and the inside of the valve body holes. a Tighten mounting bolts (16) of plates (14) and (15) (to be tightened together) to the following torque.

3 Mounting bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

a Apply grease (G2 -LI) to the rocking parts of joint (17) and contact surfaces of disc (18) and pistons (10) by the following quantity. • Rocking part of joint: 2 – 4 ml/all round • Contact parts of disc and pistons: 0.3 – 0.8 ml/1 part a Install joint (17) to valve body (1) according to the following procedure. 1) Degrease and dry the threads of the joint and body thoroughly. 2) Apply 1 drop (approx. 0.02 g) of LOCTITE (No. 262) each to the 2 parts of dimension a from the end of the body screw hole. • Dimension a : 5 – 7 mm

3) Tighten joint (17) to the following torque. a Install springs (6) with the small-diameter (inside diameter) end turns on the shims (5) side. • Diameters of spring end turn (Inside diameter) Small diameter end turn : 4.9 mm Large diameter end turn : 5.55 mm a Springs (8) and (9) are used for different hydraulic ports. When installing them, see the following table. a The position of each port is stamped on the underside of valve body (1). Position of port

Spring

Part No.

Free length

P1, P2

(9)

702-16-53590

44.45 mm

P3, P4

(8)

702-16-53470

42.48 mm

30-90 (2)

3 Joint: 39 – 49 Nm {4 – 5 kgm}

a Tighten nut (19) to the following torque. 3 Nut: 69 – 88 Nm {7 – 9 kgm}

a Adjust the play of the lever. For details, see TESTING AND ADJUSTING, Adjustment of work equipment and swing PPC valve.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

TRAVEL PPC VALVE

DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY DISASSEMBLY a Disassemble according to the figure at right.

ASSEMBLY a Assemble according to the figure at right. a Only precautions for assembly are explained below. a Install spring (11) with the small-diameter (inside diameter) end turn on the shim (12) side. • Diameters of spring end turn (Inside diameter) Small diameter end turn : 4.9 mm Large diameter end turn: 5.55 mm a When installing piston (8), apply grease (G2-LI) to its outside and the inside of the valve body hole. a Apply 0.3 – 0.8 ml of grease (G2-LI) to the contact surfaces of lever and piston (8). a Install washers (4) by the thickness and quantity checked when disassembled to the original position. a Tighten mounting bolts (3) to the following torque.

3 Mounting bolt: 27 – 34 Nm {2.8 – 3.5 kgm}

a Tighten mounting bolts (1) to the following torque.

3 Mounting bolt: 25 – 31 Nm {2.5 – 3.2 kgm}

PC160LC-7

30-91 (2)

HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY

790-502-1003

Cylinder repair stand

790-102-4300

Wrench assembly

2 3

t t t q

1 1 2

790-102-4310

790-720-1000

Expander

796-720-1660

Ring (for boom and bucket) q

07281-01159

Clamp (for boom and bucket) q

796-720-1670

Ring (for arm)

07281-01279

Clamp (for arm)

q q t

1 1

790-201-1702

Push tool kit • Push tool (for boom)

• 790-201-1940

• Push tool (for arm)

• 790-201-1811

• Push tool (for bucket)

• 790-101-5021

• Grip

• 01010-50816

• Bolt

790-201-1500

Push tool kit

• 790-201-5021

• Grip

1 1

• 01010-50816

• Bolt

• 790-201-1630

• Plate (for boom)

• Plate (for bucket)

790-201-1980

Plate (for arm)

790-201-5021

Grip

01010-50816

Bolt

4) Set piston rod assembly (2) to tool Q1.

• 790-201-1821

• 790-201-1620

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

q q q

5) Remove piston assembly lock screw (3). a If the screw is so caulked that you cannot remove it, tighten it temporarily and cut the threads on it, and then remove it.

1 1 1

DISASSEMBLY a The following explanation is common to the boom, arm, and bucket cylinders, unless otherwise specified. 1. Piston rod assembly 1) Remove the piping from the cylinder assembly. 2) Remove the mounting bolts and cylinder head assembly (1). 3) Pull out piston rod assembly (2). a Put a container under the cylinder to receive oil.

30-92 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

6) Using tool Q2, remove piston assembly (4).

7) Remove plunger (5) and collar (6). a Perform this work for only the boom and arm cylinders. 8) Remove cylinder head assembly (7).

HYDRAULIC CYLINDER

2. Disassembly of piston assembly 1) Remove rings (11), wear rings (12), and piston ring (13). 2) Remove the O-ring and backup rings (14).

3. Disassembly of cylinder head assembly 1) Remove the O-ring and backup ring (15). 2) Remove snap ring (16) and dust seal (17). 3) Remove rod packing (18), buffer ring (19), and bushing (20).

9) Remove cap (8), 11 balls (9), and plunger (10). a Take care not to lose the balls. a Perform this work for only the arm cylinder.

PC160LC-7

30-93 (2)

DISASSEMBLY AND ASSEMBLY

ASSEMBLY

HYDRAULIC CYLINDER

2) Using tool Q4, install piston ring (13).

a The following explanation is common to the boom, arm, and bucket cylinders, unless otherwise specified. a Take care not to damage the packings, dust seals, O-rings, etc. a Clean the all parts. After installing them, cover the piping ports and pin holes to prevent dirt from entering. a Do not insert each backup ring forcibly, but warm it in water at 50 – 60 °C and then insert it. 1. Assembly of cylinder head assembly 1) Using tool Q5, press fit bushing (20). 2) Install buffer ring (19) and rod packing (18). 3) Using tool Q6, install dust seal (17) and secure it with snap ring (16). 4) Install backup ring (15) and O-ring.

3) Install backup rings (14) and O-ring. 4) Install wear rings (12). 5) Install rings (11). a Do not increase the closed gap of the ring too much. 2 Ring groove: Grease (G2-LI)

3. Piston rod assembly 1) Set piston rod assembly (2) to tool Q1.

2. Assembly of piston assembly 1) Set piston ring (13) to tool Q3 and turn the handle 8 – 10 times to expand the piston ring.

30-94 (2)

PC160LC-7

HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY

2) Install cylinder head assembly (7). 3) Fit the O-ring and backup ring to collar (6), and then install them. a Perform this work for only the boom and arm cylinders. 4) Install plunger (5). a Perform this work for only the boom and arm cylinders.

7) Tighten screw (3).

2 Threads of screw: Adhesive (LOCTITE No. 262) 3 Screw:

5) Set plunger (10) to the piston rod. Install 11 balls (9) and secure them with cap (8). a After installing the plunger, check that it has a little play at its end. a Perform this work for only the arm cylinder.

58.9 – 73.6 Nm {6 – 7.5 kgm} 8) Caulk threaded part a by 4 places with a punch.

•

When reusing the rod and piston assembly, assemble them according to the following procedure. a Clean the parts thoroughly and remove metal chips, dirt, etc. 6) Tighten piston assembly (4). Then, using tool Q2, tighten piston assembly (4) until the screw holes are aligned. a Remove the burrs from the threads with a file.

PC160LC-7

30-95 (2)

HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY

•

When replacing either or both of the rod and piston assembly (2), assemble the new parts according to the following procedure. a Make a mark of the cushion plug position on the end of the rod having the bottom cushion. (Perform this work for only the arm cylinder.) 9) Using tool Q2, tighten piston assembly (4) until it reaches end b of the rod.

3 Piston assembly: 294 ± 29.4 Nm {30 ± 3.0 kgm} a After tightening the piston, check that plunger (5) has some play. a Perform this work for only the boom and arm cylinders.

10) Make a screw hole to install screw (3). a Apply a drill to the V-groove of the threaded parts of piston (4) and rod (2) and make a hole. a When making a hole on the cylinder having the bottom cushion, make it around the cushion plug. (Perform this work for only the arm cylinder.) • Dimensions of screw hole (mm) Tap drill diameter

Tap drill hole depth

Tap to be used

Tapping depth

10.3

12 x 1.75

12) Tighten screw (3).

2 Threads of screw: Adhesive (LOCTITE No. 262) 3 Screw:

58.9 – 73.6 Nm {6 – 7.5 kgm} 13) Caulk the threaded part by 4 places with a punch.

14) Install piston rod assembly (2). a Set the abutment joint of the ring at a side and insert the piston rod, aligning it with the cylinder tube. a After inserting the piston rod, check that the ring is not broken or removed, and then insert to the end.

11) After making the hole, remove all metal chips and dirt.

30-96 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

15) Tighten the mounting bolts of cylinder head assembly (1).

3 Mounting bolt: Boom/Bucket cylinder: 270 ± 39.0 Nm {27.5 ± 4.0 kgm} Bucket cylinder: 172 ± 24.5 Nm {17.5 ± 2.5 kgm}

16) Install the piping. a Tighten the bolts to install the piping band to the cylinder to the following torque. 3 27.4 ± 6.9 Nm {2.8 ± 0.7 kgm}

PC160LC-7

30-97 (2)

COUNTERWEIGHT

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF COUNTERWEIGHT REMOVAL 1. Set eyebolts [1] to counterweight assembly (1) and sling the counterweight assembly temporarily. 2. Remove 4 mounting bolts (2).

[*1]

3. Lift off counterweight assembly (1). a Take care not hit the counterweight against the engine. [*2] 3 Counterweight: 2,900 kg

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1]

2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 2,160 – 2,450 Nm {220 – 250 kgm}

[*2]

a Install the counterweight so that the clearance between it and the revolving frame and the clearance between it and exterior door will be 10 ± 5 mm on each side.

30-98 (2)

PC160LC-7

AIR CONDITIONER UNIT

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY

3. Pull dowm outside air filler cover operating closing lever (2).

Serial No.: 10001 – 11000

799-703-1200 799-703-1100 S

799-703-1111 799-703-1121 799-703-1401

t Vacuum pump (100V) t Vacuum pump (220V) t Vacuum pump (240V) t Gas leak detector t

Service tool KIT

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

1 1 1 1

4. Remove outside air filter (3).

REMOVAL

k First, disconnect the cable from the negative terminal (–) of the battery. k Collect the air conditioner gas (R134a). 1. Drain coolant.

6 Coolant: Approx. 18.6 l

2. Remove floor mat (1). 5. Remove monitor panel lower covers (4) and (5). a When removing cover (4), first remove the M19 wiring for cigarette lighter.

PC160LC-7

30-99 (4)

AIR CONDITIONER UNIT

DISASSEMBLY AND ASSEMBLY

6. Remove dust (6).

11. Remove cover (15).

7. Remove covers (7), (8) and (9).

12. Disconnect cab intermediate connectors (18) at the following two points. • H09: Upper side • H08: Lower sid 13. Disconnect radio antenne (19). 14. Remove plate (20) and then remove cover (21).

8. Remove duct (10). 9. Remove plate (11) and then remove duct (12). 10. Remove plate (13) and duct (14). 15. Remove duct (22). 16. Disconnect connectors at the following seven points. • (23): D01 • (24): D02 • (25): C09 • (26): From top to bottom, M26, M27, M28 and M33. 17. Remove the mounting clamp and disconnect air conditioner wiring connector (27).

30-100 (4)

PC160LC-7

AIR CONDITIONER UNIT

DISASSEMBLY AND ASSEMBLY

18. Remove the four mounting bolts and remove governor pump control assembly (28). a Put the governor pump control assenbly aside. 19. Remove cover (29).

INSTALLATION • Install in reverse order of removal. a Install hoses in the air conditioner circuit with care so that dirt, dust, water, etc. may not enter them. a Install air conditioner hoses only after checking that an O-ring is in place at the connecting part. a Check that there is no damage on O-rings, or that they have not deteriorated. [*1]

a Coat the threads of the refrigerant piping at the connecting part with compressor oil (NDOIL8), and then tighten the piping with a double-ended spanner.

3 Hoses clamp screw: 8.83 – 14.7 Nm {0.9 – 1.5 kgm}

3 Hoses screw M16 x 1.5: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 3 Hoses screw M24 x 1.5: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

20. Disconnect air conditioner hoses (30) and (31) as well as air conditioner tubes (32) and (33). [*1] 21. Remove the eight mounting bolts and remove air conditioner unit assembly (34). a When removing the air conditioner unit assembly, do not forget to disconnect the two air conditioner hoses connected to the bottom.

PC160LC-7

•

Filling air conditioner gas. Fill the air conditioner circuit with air conditioner gas (R134a), using tool S.

30-101 (4)

AIR CONDITIONER UNIT

DISASSEMBLY AND ASSEMBLY

799-703-1200 799-703-1100 S

799-703-1111 799-703-1121 799-703-1401

Part name

t Vacuum pump (100V) t Vacuum pump (220V) t Vacuum pump (240V) t Gas leak detector t Service tool KIT

6. Remove ducts (10) and (11). Sketch

Part No.

New/Remodel

5. Remove plate (8) and duct (9). a Remove the duct lock clip.

Q'ty

SPECIAL TOOLS Necessity

4. Remove duct (5), cover (6), and plate (7).

Symbol

Serial No.: 11001 and up

1 1 1 1 1

REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery. k Collect the air conditioner gas (R134a). 1. Swing the upper structure by 90°. 2. Open the engine hood. 3. Remove rear covers (1), (2), (3), and (4).

30-101-1 (4)

7. Disconnect connectors D01 (12), D02 (13), C09 (14), R22 (15), R20 (16), and K19 (17). 8. Remove and sling controller (18). 9. Remove plate (19). 10. Disconnect air conditioner unit connectors M27 (20) and M33 (21).

PC160LC-7

AIR CONDITIONER UNIT

DISASSEMBLY AND ASSEMBLY

11. Remove the air conditioner unit undercover. a Part A

INSTALLATION •

Carry out installation in the reverse order to removal. a When installing the air conditioner circuit hoses, take care that dirt, water, etc. will not enter them. a When connecting each air conditioner hose, check that the O-ring is fitted to the joint. a Check that each O-ring is free from flaw and deterioration. [*1]

a Apply compressor oil (ND-OIL8) to the threads of the refrigerant pipe joints and tighten each nut with double spanner.

3 Hose clamp (M6 bolt): 8 – 12 Nm {0.8 – 1.2 kgm}

12. Remove mounting bolt (24) and connector (25). [*1]

3 Hose screw of M16 x 1.5: 12 – 15 Nm {1.2 – 1.5 kgm} 3 Hose screw of M22 x 1.5: 20 – 25 Nm {2.0 – 2.5 kgm}

13. Disconnect heater hoses (22) and (23) and air conditioner tube (26). [*1] a Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.

3 Hose screw of M24 x 1.5: 30 – 35 Nm {3.0 – 3.5 kgm} •

Charging air conditioner with refrigerant gas Using tool S, charge the air conditioner circuit with refrigerant (R134a).

14. Remove the 7 mounting bolts and air conditioner unit assembly (27).

PC160LC-7

30-101-2 (4)

DISASSEMBLY AND ASSEMBLY

OPERATOR'S CAB

REMOVAL AND INSTALLATION OF OPERATOR'S CAB Serial No.: 10001 – 11000 REMOVAL

k Disconnect the cable from the negative (-) terminal of the battery. 1. Remove floor mat (1).

4. Disconnect cab wiring intermediate connectors H10 (7), H11 (8), and H12 (9). 5. Remove ducts (10) and (11). 6. Remove plates (12) and (13).

2. Remove covers (2) and (3) under the monitor panel. a Before removing cover (2), disconnect cigarette lighter connector M19.

7. Pull fresh air filter cover lever (14).

3. Remove rear covers (4), (5), and (6).

30-102 (4)

PC160LC-7

OPERATOR'S CAB

DISASSEMBLY AND ASSEMBLY

8. Remove fresh air filter (15).

13. Remove duct (22). 9. Remove duct (16). (See the previous page.) 14. Disconnect windshield washer hose (23). 10. Remove cover (17).

15. Remove step plate (24). 11. Disconnect 2 cab wiring intermediate connectors (20). • H09: Upper side • H08: Lower side

16. Remove 5 mounting bolts (25) and 4 mounting nuts (26). a Check the length of the bolts.

12. Disconnect radio antenna (21).

PC160LC-7

30-103 (2)

DISASSEMBLY AND ASSEMBLY

OPERATOR'S CAB

17. Lift off operator's cab assembly (27).

4 Operator's cab assembly: 280 kg

INSTALLATION •

Carry out installation in the reverse order to removal.

30-104 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

Serial No.: 11001 and up

OPERATOR'S CAB

5. Remove air conditioner connector plate (14).

REMOVAL

k Disconnect the cable from the negative (–) terminal of the battery. 1. Remove rear covers (1), (2), (3), and (4).

6. Disconnect connectors M71 (15), H10 (16), H11 (17), and H12 (18). 7. Disconnect upper and lower duct joints (19) and (20).

2. Remove duct (5), cover (6), and plate (7).

8. Remove controller sub-plate (21) and incline it against the air conditioner.

3. Remove plate (8), duct (9) and the element. a Remove the duct lock clip.

9. Remove cover (22) and floor mat (23).

4. Remove clip (10) and disconnect cab wiring connectors M45 (11), H08 (12), and H09 (13).

PC160LC-7

30-104-1 (4)

DISASSEMBLY AND ASSEMBLY

10. Move right console (24) into the cab.

OPERATOR'S CAB

17. Take grommet (35) out of the right front of the cab.

11. Remove monitor panel undercover (25). 18. Disconnect the windshield washer hose from (36). 19. Remove 4 mounting bolts (37) and 5 mounting bolts (38). a Check the types of the bolts. a In the initial period, 7 mounting bolts (38) are used.

12. Disconnect cab wiring connector W04 (26) (Wiper motor). 13. Remove ducts (27) and (28). a Both (27) and (28) are 2 in number. a Cut the tie-wrap on the monitor wiring harness. 14. Remove cover (29) and monitor assembly (30).

20. Using lever block [1], lift off operator's cab assembly (39). 4 Operator's cab assembly: 300 kg

15. Disconnect radio antenna (31). 16. Remove clip (32) and take wiring harness (33) out of grommet (34).

30-104-2 (4)

PC160LC-7

OPERATOR'S CAB

DISASSEMBLY AND ASSEMBLY

21. When starting the engine while the operator's cab is removed (for transportation, etc.), use the following brackets. 1) Bracket (41) for controller (40) Part No.: 208-53-13920

INSTALLATION •

Carry out installation in the reverse order to removal.

2) Bracket (42) for monitor panel assembly (30) Part No.: 208-53-13910

PC160LC-7

30-104-3 (4)

DISASSEMBLY AND ASSEMBLY

OPERATOR'S CAB GLASS

REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)

Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) – (4) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator's cab.) For the procedure for replacing the front window assembly, see REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.

PC160LC-7

(1) : Right side window glass (2) : Left side rear window glass (3) : Door lower window glass (4) : Front window glass (5) : Front window assembly (Front window glass + Front frame) (6) : Both-sided adhesive tape (16): Center trim seal

30-105 (2)

OPERATOR'S CAB GLASS

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOLS

793-498-1210

Lifter (Suction cup)

20Y-54-13180

Adapter

t t

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol X

(The figure shows the operator's cab of a wheel loader.)

2 2

REMOVAL *

Remove the window glass to be replaced according to the following procedure.

1. Using seal cutter [1], cut the adhesive between broken window glass (7) and operator's cab (metal sheet) (8).

a If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. a Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4]. (The figure shows the operator's cab of a wheel loader.)

a If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it.

30-106 (2)

2. Remove the window glass.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

INSTALLATION

OPERATOR'S CAB GLASS

(The figure shows the operator's cab of a wheel loader.)

1. Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator's cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfaces. (If the painted surfaces are scratched, adhesion will be lowered.) (The figure shows the operator's cab of a wheel loader.)

2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry.

PC160LC-7

3. Apply primer (10). a The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. a Use the primer within 2 hours after unpacking it. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is packed.) 1) Stir the primers for paint and glass sufficiently before using them. a If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. a After washing the brush, check it again for dirt and foreign matter. a Prepare respective brushes for the paint primer glass primer.

30-107 (2)

DISASSEMBLY AND ASSEMBLY

3) Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operator's cab (8) which will be coated with the adhesive.

2 Paint primer: SUNSTAR PAINT PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)

OPERATOR'S CAB GLASS

a In addition to the above parts, apply the primer to right side window glass (1) and door lower window glass (3). • Range to apply primer additionally for right side window glass (1): (b) • Range to apply primer additionally for door lower window glass (3): (c) a After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry.

a Parts to be coated with primer: Apply the primer all over dimension (a). • Dimension to apply primer (a): 25 mm

a Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.

30-108 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

4) Evenly apply glass primer to the sticking surfaces of window glass (9). 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER or equivalent a Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)

a Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension (d) which will be on both-sided adhesive tape (6) and operator's cab (8). a Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. a After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. a Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.

PC160LC-7

OPERATOR'S CAB GLASS

4. Stick both-sided adhesive tape (6) along the inside edge of the glass sticking section. a Do not remove the release tape of the bothsided adhesive tape on the glass sticking side before sticking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take that the both-sided adhesive tape will not float at each corner of the window frame.

a When sticking both-sided adhesive tape (6) around a frame, do not lap its finishing end over the starting end but make clearance e of about 5 mm between them. 1) Stick both-sided adhesive tape (6) for right side window glass (1) as shown in the figure.

30-109 (2)

DISASSEMBLY AND ASSEMBLY

a Stick both-sided adhesive tape (6a) additionally for right side window glass (1). • Positions to stick additional both-sided adhesive tape for right side window glass: (f) : 50 mm (g) : 90 mm (h) : 250 mm

2) Stick both-sided adhesive tape (6) for left side rear window glass (2) as shown in the figure.

30-110 (2)

OPERATOR'S CAB GLASS

3) Stick both-sided adhesive tape (6) for door lower window glass (3) as shown in the figure.

a Stick both-sided adhesive tape (6b) additionally for door lower window glass (3). a Positions to stick additional both-sided adhesive tape for door lower window glass: (j) : 110 mm (k) : 90 mm (m) : 200 mm

PC160LC-7

DISASSEMBLY AND ASSEMBLY

4) Stick both-sided adhesive tape (6) for front window glass (4) as shown in the figure.

a Stick both-sided adhesive tape (6c) of the lower side of the front window glass along the outside edge of the lower line, differently from other both-sided adhesive tapes (6). (If it is stuck along the inside, it will be seen through the transparent part of the glass.)

PC160LC-7

OPERATOR'S CAB GLASS

5. Position the new window glass. 1) Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then adjust it evenly. 2) Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line n. a Stick tapes [6] to the right, left, and lower parts of the right side window glass, left side rear window glass, and door lower window glass for accurate positioning. 3) Cut the tape between window glass (9) and operator's cab (8) with a knife, and then remove the window glass. a Do not remove the tapes left on the window glass and operator's cab before installing the window glass.

30-111 (2)

DISASSEMBLY AND ASSEMBLY

a When positioning front window glass (4), set its horizontal position to the frame width and set its vertical position so that height difference (p) between it and the frame top will be 3 mm.

6. Apply adhesive. a Use either of the 2 types of the adhesive.

2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER "S" 2 Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER "W" a The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 25°C. a Never heat the adhesive higher than 30°C. a When reusing the adhesive, remove the all hardened part from the nozzle tip. 1) Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.

30-112 (2)

OPERATOR'S CAB GLASS

2) Cut the tip of the adhesive nozzle (14) so that dimensions (q) and (r) will be as follows. • Dimension (q) : 10 mm • Dimension (r) : 15 mm

3) Set adhesive cartridge (12) to caulking gun [7]. a An electric caulking gun is more efficient.

4) Remove the release tape of the both-sided adhesive tape on the glass side.

PC160LC-7

DISASSEMBLY AND ASSEMBLY

5) Apply adhesive (15) to the outside of bothsided adhesive tape (6) of the operator's cab.

OPERATOR'S CAB GLASS

a Apply adhesive (15) additionally for additional both-sided adhesive tape (6a) of the right side window glass and additional both-sided adhesive tape (6b) of door lower window glass.

a Apply adhesive (15) to dimensions (s) and (t) of both-sided adhesive tape (6) of operator's cab (8). • Dimension (s) : 10 mm • Dimension (t) : 15 mm a Apply adhesive (15) higher than bothsided adhesive tape (6). a Apply the adhesive evenly.

PC160LC-7

30-113 (2)

DISASSEMBLY AND ASSEMBLY

7. Install the window glass. 1) Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly.

OPERATOR'S CAB GLASS

a After installing front window glass (4), fill the clearances between it and center trim seal (16) with caulking material in range (s) to dimensions (t) and (u). After applying the primer to glass (4) of section A – A, apply adhesive as caulking material. • Caulking dimension (t) : 2 mm • Caulking dimension (u): 5 mm a When caulking, mask the glass side and form the adhesive with a rubber spatula as shown in the figure. a Wipe off projected adhesive. 2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER 2 Adhesive: SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"

a You can perform this work efficiently by pulling window glass (9) from inside of the operator's cab with suction cup X1.

30-114 (2)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

8. Fix the window glass. 1) After installing right window glass (1) to the operator's cab, insert stopper rubbers X2 to 2 places (v) at the bottom of the glass to fix the glass.

OPERATOR'S CAB GLASS

9. After installing the window glass, remove the primer and adhesive from the operator's cab and window glass. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glass, do not give an impact to it. 10. Protect the stuck window glass. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20°C and humidity of 60%). 2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually.

2) Using styrene foam blocks [9] and rubber bands [10], fix the window glass and bothsided adhesive tape to fit them completely.

PC160LC-7

30-115 (2)

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY

FRONT WINDOW

7. Remove rollers (8) and (9) under the both sides of the front window.

k Lower the work equipment to the ground and stop the engine. a To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure for removing and installing the front window assembly (front frame and front window glass) is explained below.

REMOVAL 1. Raise the front window assembly to the ceiling and fix it with the rear locks (on both sides). 2. Remove left corner blocks (1) and (2) and right corner block (3). [*1] 3. Remove left striker bolt (4), right striker bolt (5), left corner block bracket, and right corner block bracket (7). [*2] 4. Install left striker bolt (4) to the operator's cab again and tighten it lightly. a This bolt will be used to hang the pull-up assist cable in step 8. 8. Remove left lower pin (10). [*3] a If left lower pin (10) is removed, plate (12) at the end of pull-up assist cable (11) comes off. a Hang plate (12) on the left striker bolt. k The return load of 58.8 N {6 kg} is applied to the rear of the operator's cab. Accordingly, take care when removing left lower pin (10) to disconnect pull-up assist cable (11).

5. Release the rear locks. 6. Lower the front window assembly carefully a little. Put out rollers (8) and (9) under the both sides of the front window through the portion from which the corner blocks were removed in step 3 (the portion where the rail is open) and hold them.

30-116 (4)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

FRONT WINDOW

11. Twist front window assembly (13) to the right and left to remove both upper rollers (14) and (15) from the rails, and then remove front window assembly (13).

9. Put out the bottom of front window assembly (13) through the rail opening portion and lower it gradually.

10. Lower front window assembly (13) completely. a Do not let the front window assembly touch the monitor.

PC160LC-7

30-117 (4)

DISASSEMBLY AND ASSEMBLY

INSTALLATION •

Carry out installation in the reverse order to removal.

[*1] [*2] • Adjust opening and closing of the front window assembly according to the following procedure. 1. Open and close the front window to check that it does not interfere with the rails and the rollers are not hitch. 2. If there is any problem in opening or closing of the front window, loosen the mounting bolts of roller adjustment brackets (16) and (17) and adjust the condition of the front window, and then tighten the mounting bolts again.

FRONT WINDOW

4. Install right corner block (3) and fix right corner block bracket (7) with right striker bolt (5). a Tighten the striker bolt securely after adjusting it in step 6. a Install the right corner block so that there will be no level difference at part a. a Install the right corner block so that level difference b between the rail and right corner block (3) at part PF will be 0 – 1.0 mm. Check that the right corner block is not projected from the rail at the rolling surface of the roller. a Secure roller clearance c at part PJ.

3 Mounting bolt: 98 Nm {1.0 kgm}

3. Raise the front window assembly and fix it with the rear locks (on both sides). a Check that the locks in the rear of the operator's cab are applied securely.

30-118 (4)

PC160LC-7

DISASSEMBLY AND ASSEMBLY

5. Install left corner blocks (1) and (2) and secure left corner bracket (6) with left striker bolt (4). a Tighten the striker bolt securely after adjusting it in step 6. a Install the left corner blocks so that there will be no level difference at 2 part d. a Secure roller clearance e.

PC160LC-7

FRONT WINDOW

6. Adjust the striker bolts according to the following procedure (Adjust the "CLOSE" positions of the front window assembly locks). 1) Tighten left striker bolt (4) and right striker bolt (5) at roughly right positions so that front window glass (18) will be fitted to cab-side trim seal (19).

30-119 (4)

DISASSEMBLY AND ASSEMBLY

FRONT WINDOW

2) Open and close the front window assembly and check the working condition of both locks (20) and (21). i) If both locks do not work normally, move the striker bolts toward the rear of the cab and tighten them again. ii) After moving the striker bolts, check the fitness of the front window glass and cabside trim seal which was checked in step 1). iii) Repeat the work in i) and ii) until the fitness of the front window and the working condition of both locks (20) and (21) are acceptable, and then tighten the striker bolts.

7. After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak into the cab. 8. Adjust the "opening" lock of the front window assembly. 1) After adjusting the "closing" lock of the front window in steps 6 and 7, raise the front window assembly to the ceiling. 2) Set the right and left front window assembly locks at the rear of the operator's cab to the "OPEN" positions, and then check the following items. • Check that right and left locks (20) and (21) are closed normally. • Check that right and left locks (20) and (21) are inserted in parallel in right and left striker plates (22). • Check that right and left rubber stoppers (24) are in contact with the front window assembly and their deflection allowance is 1.5 – 3.0 mm. 3) After checking the above items, if necessary, adjust them by moving right and left striker plates (22) at the rear of the operator's cab.

30-120 (4)

9. Adjust the front window stoppers. 1) After adjusting "closing" lock of the front window assembly in step 8, check the contact of both front window stoppers (23). 2) If both stoppers (23) do not contact normally, adjust and fix them at places where they contact normally.

PC160LC-7

FRONT WINDOW, MONITOR

DISASSEMBLY AND ASSEMBLY

10. Check the latching effort of the front window assembly. 1) After finishing steps 6 – 9, check that latching efforts of both locks (20) and (21) are even. a Check the latching efforts on both "closing" side (in the front of the operator's cab) and "opening" side (in the rear of the operator's cab).

REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY REMOVAL

k First, disconnect the cable from the negative terminal (–) of the battery. 1. Remove cover (1) and then disconnect the wiring connector P15 for air conditioner sunlight sensor (2). a Lift the cover up to remove it. 2. Remove the three mounting screws and remove monitor assembly (3). a Disconnect monitor panel wiring connectors P01, P02 and P03 at the three points, and then remove the monitor assembly.

[*3]

3 Left lower pin: 27 – 34 Nm {2.75 – 3.47 kgm} 2 Mounting bolt: Adhesive (LT-2)

INSTALLATION •

PC160LC-7

Install in reverse order of removal.

30-121 (4)

GOVERNOR, PUMP CONTROLLER

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY Serial No.: 10001 – 11000

Serial No.: 11001 and up

REMOVAL

1. Remove cover (1).

1. Remove covers (1), (2) and (3).

2. Disconnect governor, pump controller wiring connectors C01 (2), C02 (3) and C03 (4).

2. Disconnect governor, pump controller wiring connectors C01 (4), C02 (5) and C03 (6).

3. Remove the four mounting bolts and remove governor, pump controller assembly (5).

3. Remove the four mounting bolts and remove governor, pump controller assembly (7).

INSTALLATION

•

k First, disconnect the cable from the negative terminal (–) of the battery.

Install in reverse order of removal.

30-122 (4)

k First, disconnect the cable from the negative terminal (–) of the battery.

Install in reverse order of removal.

PC160LC-7

90 OTHERS Hydraulic circuit diagram............................................... 90- 3 Serial No.: 10001 – 11000 Electrical circuit diagram (1/4)..................................... 90- 5 Electrical circuit diagram (2/4)..................................... 90- 7 Electrical circuit diagram (3/4)..................................... 90- 9 Electrical circuit diagram (4/4)......................................90-11 Serial No.: 11001 and up Electrical circuit diagram (1/4)..................................... 90-13 Electrical circuit diagram (2/4)..................................... 90-15 Electrical circuit diagram (3/4)..................................... 90-17 Electrical circuit diagram (4/4)..................................... 90-19

PC160LC-7

90-1 (4)

HYDRAULIC CIRCUIT DIAGRAM

PC160LC-7

90-3

ELECTRICAL CIRCUIT DIAGRAM (1/4) Serial No.: 10001 – 11000

PC160LC-7

90-5 (4)

ELECTRICAL CIRCUIT DIAGRAM (2/4) Serial No.: 10001 – 11000

PC160LC-7

90-7 (4)

ELECTRICAL CIRCUIT DIAGRAM (3/4) Serial No.: 10001 – 11000

PC160LC-7

90-9 (4)

ELECTRICAL CIRCUIT DIAGRAM (4/4) Serial No.: 10001 – 11000

PC160LC-7

90-11 (4)

ELECTRICAL CIRCUIT DIAGRAM (1/4) Serial No.: 11001 and up

PC160LC-7

90-13 (4)

ELECTRICAL CIRCUIT DIAGRAM (2/4) Serial No.: 11001 and up

PC160LC-7

90-15 (4)

ELECTRICAL CIRCUIT DIAGRAM (3/4) Serial No.: 11001 and up

PC160LC-7

90-17 (4)

ELECTRICAL CIRCUIT DIAGRAM (4/4) Serial No.: 11001 and up

PC160LC-7

90-19 (4)