Professional Documents
Culture Documents
160LC 7
160LC 7
• 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.
© 2007
All Rights Reserved 00-1
Printed in Japan 09-07 (02) (6)
CONTENTS
No. of page
01 GENERAL .................................................................................................................01-1
90 OTHERS ....................................................................................................................90-1
00-2 PC160LC-7
(2)
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
PC160LC-7 00-2-1
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Revision Revision Revision Revision Revision
Mark Page number Mark Page number Mark Page number Mark Page number Mark Page number
10-176 (5) 20-116 (1) 20-167 (1) 20-224 (4) 20-305 (4)
10-177 (5) 20-117 (1) 20-169 (3) 20-225 (1) 20-306 (4)
10-178 20-118 (4) 20-170 (3) 20-226 (1) 20-307 (1)
10-179 20-119 (1) 20-171 (3) 20-227 (4) 20-308 (1)
10-180 20-120 (1) 20-172 (3) 20-228 (1) 20-310 (1)
10-181 20-121 (4) 20-173 (3) 20-229-1 (4) 20-311 (1)
10-182 20-122 (4) 20-174 (3) 20-229-2 (4) 20-312 (1)
10-183 20-123 (1) 20-175 (3) 20-229-3 (4) 20-313 (4)
10-184 20-124 (1) 20-176 (3) 20-229-4 (4) 20-314 (1)
10-185 20-125 (4) 20-177 (3) 20-229-5 (4) 20-315 (1)
10-186 20-126 (1) 20-178 (3) 20-230 (4) 20-316 (1)
10-187 20-127 (1) 20-179 (3) 20-231 (1) 20-317 (1)
10-188 20-128 (4) 20-180 (3) 20-231-1 (4) 20-318 (4)
10-189 20-129 (1) 20-181 (3) 20-231-2 (4) 20-319 (1)
10-191 (3) 20-130 (1) 20-182 (3) 20-232 (4) 20-319-1 (4)
10-192 (3) 20-131 (4) 20-183 (3) 20-233 (1) 20-319-2 (4)
10-193 (3) 20-132 (4) 20-184 (3) 20-233-1 (4) 20-320 (1)
10-194 (3) 20-133 (1) 20-186 (4) 20-233-2 (4) 20-321 (1)
10-195 (3) 20-134 (1) 20-186-1 (4) 20-234 (4) 20-322 (1)
10-196 (3) 20-135 (1) 20-187 (3) 20-235 (1) 20-323 (1)
10-197 (3) 20-136 (1) 20-188 (3) 20-235-1 (4) 20-324 (4)
10-198 (5) 20-137 (1) 20-189 (3) 20-235-2 (4) 20-325 (1)
10-199 (3) 20-138 (1) 20-190 (3) 20-236 (1) 20-325-1 (4)
10-200 (3) 20-139 (1) 20-191 (3) 20-237 (1) 20-325-2 (4)
20-140 (1) 20-201 (1) 20-238 (1) 20-326 (4)
20-1 (1) 20-141 (1) 20-202 (1) 20-239 (1) 20-327 (1)
20-2 (1) 20-142 (1) 20-203 (1) 20-240 (1) 20-327-1 (4)
20-3 (1) 20-143 (1) 20-204 (1) 20-241 (1) 20-327-2 (4)
20-4 (1) 20-144 (1) 20-205 (1) 20-242 (1) 20-328 (4)
20-5 (1) 20-145 (1) 20-206 (1) 20-243 (1) 20-329 (1)
20-6 (1) 20-146 (1) 20-207 (1) 20-244 (1) 20-329-1 (4)
20-7 (1) 20-147 (1) 20-208 (1) 20-245 (1) 20-329-2 (4)
20-8 (1) 20-148 (1) 20-209 (1) 20-246 (1) 20-330 (4)
20-9 (1) 20-149 (1) 20-210 (1) 20-247 (1) 20-331 (1)
20-10 (1) 20-150 (1) 20-211 (1) 20-248 (1) 20-331-1 (4)
20-11 (1) 20-151 (1) 20-212 (1) 20-249 (1) 20-331-2 (4)
20-101 (3) 20-152 (1) 20-213 (4) 20-250 (1) 20-332 (4)
20-102 (4) 20-153 (1) 20-214 (4) 20-251 (1) 20-333 (1)
20-103 (4) 20-154 (1) 20-215 (4) 20-252 (1) 20-333-1 (4)
20-104 (4) 20-155 (1) 20-216 (4) 20-253 (1) 20-333-2 (4)
20-105 (1) 20-156 (1) 20-218 (4) 20-254 (1) 20-334 (4)
20-106 (4) 20-157 (1) 20-219 (4) 20-255 (1) 20-335 (1)
20-107 (1) 20-158 (1) 20-220 (4) 20-256 (1) 20-335-1 (4)
20-108 (1) 20-159 (1) 20-221 (4) 20-257 (1) 20-335-2 (4)
20-109 (1) 20-160 (1) 20-222 (4) 20-257-1 (4) 20-336 (4)
20-110 (1) 20-161 (1) 20-223 (1) 20-258 (1) 20-337 (1)
20-111 (1) 20-162 (1) 20-223-1 (4) 20-259 (1) 20-337-1 (4)
20-112 (1) 20-163 (1) 20-223-2 (4) 20-260 (4) 20-337-2 (4)
20-113 (4) 20-164 (1) 20-223-3 (4) 20-301 (1) 20-338 (4)
20-114 (1) 20-165 (1) 20-223-4 (4) 20-302 (1) 20-339 (1)
20-115 (1) 20-166 (1) 20-223-5 (4) 20-304 (4) 20-339-1 (4)
00-2-2 PC160LC-7
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Revision Revision Revision Revision Revision
Mark Page number Mark Page number Mark Page number Mark Page number Mark Page number
20-339-2 (4) 20-387 (1) 20-446 (1) 20-604 (4) 30-27 (2)
20-340 (4) 20-388 (1) 20-447 (1) 20-605 (4) 30-28 (2)
20-341 (1) 20-389 (1) 20-448 (1) 20-606 (4) 30-29 (2)
20-341-1 (4) 20-390 (1) 20-449 (1) 20-607 (4) 30-30 (2)
20-341-2 (4) 20-401 (4) 20-450 (1) 20-608 (4) 30-31 (2)
20-342 (4) 20-402 (4) 20-451 (1) 20-609 (4) 30-32 (2)
20-343 (1) 20-403 (1) 20-452 (4) 20-610 (4) 30-33 (2)
20-343-1 (4) 20-404 (4) 20-453 (1) 20-611 (4) 30-34 (4)
20-343-2 (4) 20-405 (1) 20-453-1 (4) 20-612 (4) 30-35 (2)
20-344 (1) 20-406 (1) 20-453-2 (4) 20-613 (4) 30-36 (2)
20-345 (1) 20-407 (1) 20-453-3 (4) 20-614 (4) 30-37 (2)
20-346 (1) 20-408 (4) 20-453-4 (4) 20-615 (4) 30-38 (2)
20-347 (1) 20-409 (1) 20-453-5 (4) 20-616 (4) 30-39 (2)
20-348 (1) 20-410 (1) 20-453-6 (4) 20-617 (4) 30-40 (2)
20-349 (1) 20-411 (1) 20-453-7 (4) 20-618 (4) 30-41 (2)
20-350 (1) 20-412 (1) 20-453-8 (4) 20-619 (4) 30-42 (2)
20-351 (1) 20-413 (1) 20-453-9 (4) 20-620 (4) 30-43 (2)
20-352 (1) 20-414 (1) 20-453-10 (4) 20-621 (4) 30-44 (2)
20-353 (1) 20-415 (1) 20-453-11 (4) 20-622 (4) 30-45 (2)
20-354 (1) 20-416 (1) 20-454 (1) 20-623 (4) 30-46 (2)
20-355 (1) 20-417 (1) 20-455 (1) 20-624 (4) 30-47 (2)
20-356 (1) 20-418 (4) 20-501 (1) q 30-48 (6)
20-357 (1) 20-419 (4) 20-502 (1) 30-1 (4) 30-49 (2)
20-358 (1) 20-420 (1) 20-503 (1) 30-2 (4) 30-50 (2)
20-359 (1) 20-421 (1) 20-504 (1) 30-3 (2) 30-51 (2)
20-360 (1) 20-422 (4) 20-505 (1) 30-4 (2) 30-52 (2)
20-361 (1) 20-422-1 (4) 20-506 (1) 30-5 (2) 30-53 (2)
20-362 (1) 20-423 (1) 20-507 (1) 30-6 (2) 30-54 (2)
20-363 (1) 20-424 (1) 20-508 (1) 30-7 (4) 30-55 (2)
20-364 (1) 20-425 (1) 20-509 (1) 30-8 (4) 30-56 (2)
20-365 (1) 20-426 (1) 20-510 (1) 30-9 (4) 30-57 (2)
20-366 (1) 20-427 (1) 20-511 (1) 30-9-1 (4) 30-58 (2)
20-367 (1) 20-428 (1) 20-512 (1) 30-10 (2) 30-59 (2)
20-368 (1) 20-429 (1) 20-513 (1) 30-11 (2) 30-60 (2)
20-369 (1) 20-430 (1) 20-514 (1) 30-12 (2) 30-61 (2)
20-370 (1) 20-431 (1) 20-515 (1) 30-13 (2) 30-62 (2)
20-371 (4) 20-432 (1) 20-516 (1) 30-14 (2) 30-63 (2)
20-372 (1) 20-433 (1) 20-517 (1) 30-15 (2) 30-64 (2)
20-373 (4) 20-434 (4) 20-518 (1) 30-16 (4) 30-65 (2)
20-374 (1) 20-435 (1) 20-519 (1) 30-17 (4) 30-66 (2)
20-375 (1) 20-435-1 (4) 20-520 (1) 30-17-1 (4) 30-67 (2)
20-376 (1) 20-435-2 (4) 20-521 (1) 30-17-2 (4) 30-68 (2)
20-377 (1) 20-436 (1) 20-522 (1) 30-18 (4) 30-69 (2)
20-378 (1) 20-437 (1) 20-523 (1) 30-19 (4) 30-70 (2)
20-380 (1) 20-438 (1) 20-524 (1) 30-20 (2) 30-71 (2)
20-381 (1) 20-439 (1) 20-525 (1) 30-21 (2) 30-72 (2)
20-382 (1) 20-440 (1) 20-526 (1) 30-22 (2) 30-73 (2)
20-383 (1) 20-441 (1) 20-527 (1) 30-23 (2) 30-74 (2)
20-384 (1) 20-442 (1) 20-601 (4) 30-24 (2) 30-75 (2)
20-385 (1) 20-443 (4) 20-602 (4) 30-25 (2) 30-76 (2)
20-386 (1) 20-444 (1) 20-603 (4) 30-26 (2) 30-77 (2)
PC160LC-7 00-2-3
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Revision Revision Revision Revision Revision
Mark Page number Mark Page number Mark Page number Mark Page number Mark Page number
30-78 (2) 90-1 (4)
30-79 (2) 90-3
30-80 (2) 90-5 (4)
30-81 (4) 90-7 (4)
30-82 (2) 90-9 (4)
30-83 (2) 90-11 (4)
30-84 (2) 90-13 (4)
30-85 (2) 90-15 (4)
30-86 (2) 90-17 (4)
30-87 (2) 90-19 (4)
30-88 (2)
30-89 (2)
30-90 (2)
30-91 (2)
30-92 (2)
30-93 (2)
30-94 (2)
30-95 (2)
30-96 (2)
30-97 (2)
30-98 (2)
30-99 (4)
30-100 (4)
30-101 (4)
30-101-1 (4)
30-101-2 (4)
30-102 (4)
30-103 (2)
30-104 (2)
30-104-1 (4)
30-104-2 (4)
30-104-3 (4)
30-105 (2)
30-106 (2)
30-107 (2)
30-108 (2)
30-109 (2)
30-110 (2)
30-111 (2)
30-112 (2)
30-113 (2)
30-114 (2)
30-115 (2)
30-116 (4)
30-117 (4)
30-118 (4)
30-119 (4)
30-120 (4)
30-121 (4)
30-122 (4)
00-2-4 PC160LC-7
(5)
SAFETY SAFETY NOTICE
SAFETY
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 danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
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
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 judge-
ments. 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 fur-
ther divided into the each main group of components.
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
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
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).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
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. Q’ty Container Main applications, features
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 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.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
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
0 1 2 3 4 5 6 7 8 9
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 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
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 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 Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn 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
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
PC160LC-7 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
WORKING RANGES
01-2 PC160LC-7
GENERAL SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
WORKING RANGES
PC160LC-7 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model PC160LC-7
Gradeability deg. 35
Model SAA4D102E-2
Type
injection, with turbocharger and aftercooler
01-4 PC160LC-7
GENERAL SPECIFICATIONS
Max. torque
{kgm/rpm} {46/1,500}
Max. speed at no load rpm 2,450
Alternator 24V, 35 A
Battery 12V, 80 Ah x 2
PC160LC-7 01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is for use when handling components or when transporting the machine.
Unit: kg
Machine model PC160LC-7
• Engine 445
• Damper 6
Operator's seat 35
Counterweight 2,850
Travel motor 98 x 2
• Idler 99 x 2
• Carrier roller 16 x 4
• Track roller 36 x 14
01-6 PC160LC-7
GENERAL WEIGHT TABLE
Unit: kg
Machine model PC160LC-7
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
GENERAL FUEL, COOLANT, AND LUBRICANTS
SAE 30
SAE 10W
Engine oil pan 14.3 14.0
SAE 10W-30
SAE 15W-40
SAE 10W
SAE 10W-30
Hydraulic system 190 121
SAE 15W-40
Hydrau-
lic oil HO46-HM (★)
01-8 PC160LC-7
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PC160LC-7 10-1
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE RELATED PARTS
10-2 PC160LC-7
RADIATOR • OIL COOLER •
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AFTERCOOLER
PC160LC-7 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Idler 7. Engine
2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing motor (MSG-85P-17TR)
5. Travel motor (HMV 110ADT-2) 11. Swing machinery
6. Hydraulic pump (HPD71) 12. Swing circle
10-4 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
SWING MACHINERY
PC160LC-7 10-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
10-6 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
10-8 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
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:
Unit: mm
PC160LC-7 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
10-10 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
Standard shoe
Model PC160LC-7
Item
Shoe width 600 mm
Unit: mm
109.0 kN
558.5 X 237 437 — —
{11,110 kg}
PC160LC-7 10-11
(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
10-12 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
Unit: mm
PC160LC-7 10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm
3 Width of tread 43 —
5 Width of flange 14 —
Tolerance Replace
Standard Clearance
Standard size
Clearance between shaft and Shaft Hole clearance limit
6
bushing
– 0.179 + 0.284
40 0.339 – 0.474 —
– 0.190 + 0.169
10-14 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
5 Inside width 85 —
PC160LC-7 10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
10-16 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
Unit: mm
59.3 — 54.3
5 160.4
7 18
Regular 2.5
Adjust or
11 Protrusion of pin
replace
Master 2.5
Regular 4.85
12 Protrusion of bushing
Master 0.0
Regular 212
13 Overall length of pin
Master 212
Regular 138.5
Overall length of
14
bushing
Master 128.7
Standard 10.4
Thickness of bushing Reverse or
15
metal When turned / Impact replace
5.4
Load
16 Thickness of spacer —
PC160LC-7 10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
Unit: mm
Tolerance Standard
Standard size
Shaft Hole interference
21 Interference between bushing and link
+ 0.434 + 0.074
59 0.320 – 0.434
+ 0.394 0
+ 0.222 + 0.138
22 Interference between regular pin and link 38 0.300 – 0.422
+ 0.162 – 0.200
Tolerance Standard
Standard size
Shaft Hole clearance
23 Clearance between regular pin and bushing
+ 0.222 + 0.902 Adjust or
38 0.180 – 0.740
+ 0.162 + 0.402 replace
Tolerance Standard
Standard size
Shaft Hole interference
Interference between master pin and link
24 + 0.062
+ 0.280
37.8 0.188 – 0.280
+ 0.250 0
Tolerance Standard
Standard size
Shaft Hole clearance
Clearance between master pin and bushing
25
– 0.150 + 0.902
38 0.552 – 1.252
– 0.350 + 0.402
Standard size Repair limit Lug weld-
— Height of grouser ing, rebuild
26 16 or replace
10-18 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
Unit: mm
2 Thickness 8.5
3 26
Length of base
4 19
Rebuild or
replace
5 20
6 Length at tip 14
7 19
PC160LC-7 10-19
HYDRAULIC EQUIPMENT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LAYOUT DRAWING
10-20 PC160LC-7
HYDRAULIC EQUIPMENT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LAYOUT DRAWING
PC160LC-7 10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
Lever positions
1. Travel PPC valve 8. Accumulator (1) Hold (9) Swing "RIGHT"
2. Service PPC valve 9. Hydraulic pump (2) Boom "RAISE" (10) Swing "LEFT"
3. Service pedal 10. Control valve (3) Boom "LOWER" (11) Neutral
4. L.H. travel lever 11. Solenoid block (4) Bucket "DUMP" (12) Travel "REVERSE"
5. R.H. travel lever 12. Junction box (5) Bucket "CURL" (13) Travel "FORWARD"
6. R.H. PPC valve 13. L.H. work equipment (6) Hold
7. R.H. work equipment control lever (7) Arm "IN"
control lever 14. L.H. PPC valve (8) Arm "OUT"
10-22 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
PC160LC-7 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 PD1: Case drain port 1. Main pump
PB: Pump pressure input PEN: Pump control pressure pickup 2. LS valve
PM: PC mode selector pressure pickup port 3. PC valve
port PLS: Load pressure input 4. PC-EPC valve
PS: Suction port of pump PA1C: P1 pump discharge pressure 5. No. 1 check valve
PA1: Discharge port of pump pickup port 6. No. 2 check valve
PA2: Discharge port of pump PA2C: P2 pump discharge pressure 7. Shuttle valve
pickup port
PEPC: EPC base pressure input
PLSC: Load pressure pickup port
10-24 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
1. Shaft 6. Piston
2. Cradle 7. Cylinder block
3. Case 8. Valve plate
4. Rocker cam 9. End cap
5. Shoe 10. Servo piston
PC160LC-7 10-25
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
FUNCTION
• The rotation and torque transmitted to the pump • Rocker cam (4) has flat surface A, and shoe (5)
shaft are converted into hydraulic energy, and is always pressed against this surface while slid-
pressurized oil is discharged according to the ing in a circular movement.
load. • Rocker cam (4) brings high pressure oil at cylin-
• It is possible to change the discharge amount by der surface B with cradle (2), which is secured to
changing the swash plate angle. the case, and forms a static pressure bearing
when it slides.
STRUCTURE • Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
• Cylinder block (7) is supported to shaft (1) by a
cylinder block (7).
spline a, and shaft (1) is supported by the front
• The cylinder block seals the pressure oil to valve
and rear bearings.
plate (8) and carries out relative rotation. This
• The tip of piston (6) is a concave ball, and shoe
surface is designed so that the oil pressure bal-
(5) is caulked to it to form one unit. Piston (6) and
ance is maintained at a suitable level. The oil
shoe (5) form a spherical bearing.
inside each cylinder chamber of cylinder block
(7) is sucked in and discharged through valve
plate (8).
10-26 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 cyl-
inder block (7), so a difference between vol-
umes 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 vol-
u 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 dis-
charged to each of discharge ports PA1 and
PA2.
PC160LC-7 10-27
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
10-28 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
LS VALVE
PC VALVE
PC160LC-7 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 pres-
sure 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 horse-
power 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 pres-
sure rises, it reduces the discharge amount
from the pump; and if the pump discharge pres-
sure 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 PC-
E 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 pres-
sure) 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.)
PC160LC-7 10-31
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
2) Operation in increase direction for pump • For this reason, the pressure at the large diam-
discharge amount eter end of servo piston (12) becomes drain
• When the difference between the main pump pressure PT, and pump pressure PP enters port
pressure PP and LS pressure PLS, in other J at the small diameter end, so servo piston
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 , (12) is pushed to the right. Therefore, the
becomes smaller (for example, when the area swash plate moves in the direction to make the
of opening of the control valve becomes larger discharge amount 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 pres-
sure PT. (The operation of the PC valve is
explained later).
10-32 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
PC160LC-7 10-33
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
10-34 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
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 • The size of command current X is determined
flows to PC-EPC solenoid (1). This command by the nature of the operation (lever operation),
current acts on the PC-EPC valve and outputs the selection of the working mode, and the set
the signal pressure. When this signal pressure value and actual value for the engine speed.
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 10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
10-36 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
PC160LC-7 10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
10-38 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
PC160LC-7 10-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
10-40 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
PC160LC-7 10-41
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PC-EPC VALVE
PC-EPC VALVE
1. Body PM : To PC valve
2. Spool PT : To tank
3. Spring PEPC : From self-reducing pressure valve
4. Rod
5. Coil
6. Plunger
7. Connector
10-42 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PC-EPC VALVE
FUNCTION
• The EPC valve consists of the proportional sole-
noid 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 out-
puts 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 pressur-
ized 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
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.
OPERATION
1. When PA1 > PA2 2. When PA1 < PA2
• Discharge pressures PA1 and PA2 of the main • Reversely to 1., poppet valve (1) is kept closed
pumps are applied to poppet valves (1) and (2). and PA2 is output to PP1.
Since PA1 > PA2, however, poppet valve (2) is
kept closed and PA1 is output to PP1.
PC160LC-7 10-45
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PC-EPC VALVE
SHUTTLE VALVE
FUNCTION
The shuttle valve selects and outputs the lower dis-
charge pressure of the 2 main pumps.
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) • 7-spool valve (6-spool valve + Service valve)
• 6-spool valve (Without service valve, with alarm • 7-spool valve (6-spool valve + Service valve,
lock 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 PB2: From left travel reverse PPC valve
A2: To left travel motor PB3: From right travel forward PPC valve
A3: To right travel motor PB4: From boom lower PPC valve
A4: To boom cylinder bottom PB5: From arm IN PPC valve
A5: To arm cylinder head PB6: From bucket CURL PPC valve
A6: To bucket cylinder head PB7: From service 1 PPC valve
A7: To attachment PP1: Pressure sensor port
B1: To swing motor (If equipped with pressure sensor)
B2: To left travel motor PP2: Pressure sensor port
B3: To right travel motor (If equipped with pressure sensor)
B4: To boom cylinder head PST: From travel junction solenoid valve
B5: To arm cylinder bottom SA5: From travel PPC valve
B6: To bucket cylinder bottom SA6: From travel PPC valve
B7: To attachment SB4: From travel PPC valve
LS: To pump LS valve SB5: From travel PPC valve
P1: From main pump TS1: To tank
P2: From main pump TS2: To tank
PP: To main pump
PR: To solenoid valve, PPC valve, and EPC valve 1. Swing bleed valve
PS: From merge-divider solenoid valve 2. LS check valve
PX: From 2-stage relief solenoid valve 3. Travel junction valve + LS check valve
TB: To tank 4. Arm regeneration valve
TC: To oil cooler 5. Boom hydraulic drift prevention valve
BP1: From boom raise PPC valve 6. Cover
BP2: From attachment circuit selector solenoid valve 7. Service valve
PA1: From swing left PPC valve 8. Butterfly valve
PA2: From left travel PPC valve 9. Arm valve
PA3: From right travel reverse PPC valve 10. Boom valve
PA4: From boom raise PPC valve 11. Right travel valve
PA5: From arm OUT PPC valve 12. Left travel valve
PA6: From bucket dump PPC valve 13. Swing valve
PA7: From service 1 PPC valve 14. Block
PB1: From swing right PPC valve 15. Pump merge-divider valve block
10-48 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
PC160LC-7 10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
10-50 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
10-52 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed length Installed load Free length Installed load
25 Piston spring Outside diameter
4.9 N 3.9 N
16 × 16 12.6
{0.5 kg} {0.4 kg}
2.0 N 1.6 N
26 Suction spring 10.5 × 7 6.8
{0.21 kg} {0.17 kg}
5.5 N 4.4 N
27 Suction spring 46.8 × 7.5 40.6
{0.56 kg} {0.45 kg}
5.1 N 4.1 N
28 Suction spring 39.2 × 4.5 33.5
{0.52 kg} {0.42 kg}
221 N 177 N
31 Spool return spring 42.4 × 28 39
{22.6 kg} {18.1 kg}
56 N 45 N
33 Spool return spring 27.1 × 25.8 25.5
{5.7 kg} {4.6 kg}
141 N 113 N
35 Spool return spring 41.8 × 19 38.5
{14.4 kg} {11.5 kg}
PC160LC-7 10-53
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
10-54 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed length Installed load Free length Installed load
18 Check valve spring Outside diameter
5.9 N 4.7 N
41.5 × 8.5 31.5
{0.6 kg} {0.5 kg}
2.9 N 2.3 N
19 Check valve spring 20.3 × 13.7 16
{0.3 kg} {0.24 kg} If damaged or
deformed,
9.8 N 7.8 N
20 Flow control valve spring 36.2 × 5.3 32 replace spring
{1 kg} {0.8 kg}
PC160LC-7 10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
10-56 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed length Installed load Free length Installed load
19 Check valve spring Outside diameter
3.9 N 3.1 N
21 Bleed spool return spring 23.3 × 12.5 23
{0.4 kg} {0.3 kg}
PC160LC-7 10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
10-58 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed length Installed load Free length Installed load
15 Unload valve spring Outside diameter
180 N 144 N
47.2 × 17.3 32.5
{18.9 kg} {14.7 kg}
83.4 N 66.7 N
16 Sequence valve spring 58.9 × 13 53
{8.5 kg} {6.8 kg}
135 N 108 N
19 Lift check valve spring 77.3 × 20.7 40
{13.8 kg} {11 kg}
5.9 N 4.7 N
21 Check valve spring 41.5 × 8.5 31.5
{0.6 kg} {0.48 kg}
PC160LC-7 10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
1. Hydraulic drift prevention valve (Boom) 12. Pressure compensation valve F (Service)
2. Pressure compensation valve F (Boom) 13. Variable pressure compensation valve (Service)
3. Pressure compensation valve R (Boom) 14. Spool (Service)
4. Spool (Boom) 15. Safety-suction valve
5. Suction valve 16. Safety-suction valve
6. Safety-suction valve 17. Safety-suction valve
7. Pressure compensation valve F (Bucket) 18. Air bleed plug
8. Pressure compensation valve R (Bucket)
F: Flow control valve
9. Spool (Bucket)
R: Pressure reducing valve
10. Suction valve
11. Suction valve
10-60 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
PC160LC-7 10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- • The CLSS consists of a variable capacity single
tem, and has the following featues. piston pump, control valve, and actuators.
• Fine control not influenced by load • The pump body consists of the main pump, PC
• Control enabling digging even with fine control valve and LS valve.
• 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 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 pres-
sure ∆PLS (the difference between pump (dis-
charge) 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)
PC160LC-7 10-63
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
2. Pressure compensation control between the upstream (inlet port) and down-
• A pressure compensation valve is installed to the stream (outlet port) the same, regardless of the
inlet port side of the control valve spool to bal- size of the load (pressure). In this way, the flow
ance the load. of oil from the pump is divided (compensated) in
When to actuators are operated together, this proportion to the area of openings S1 and S2 of
valve acts to make pressure difference ∆P each valve when it is operated.
10-64 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
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
10-68 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
13. Arm hydraulic drift prevention valve
PC160LC-7 10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Unload valve
1. When control valve is at HOLD
Function Operation
• When the control valve is at HOLD, pump dis- • Pump discharge pressures P1 and P2 are acting
charge amount Q discharged by the minimum on the left end of unload spool (1) and LS pres-
swash plate angle is released to the tank circuit. sures LS1 and LS2 are acting on the right end.
At this time, pump discharge pressure P1/P2 is (P1 = P2, LS1 = LS2)
set by spring (2) in the valve. (LS pressure LS1/ • When the control valve is at HOLD, LS pres-
LS2 = 0 MPa {0 kg/cm2}) sures LS1 and LS2 are not generated, so only
• Since the pump merge-divider valve is at the pump discharge pressures P1 and P2 act, and
merge position, pump discharge pressures P1 P1 and P2 are set by only the load of spring (2).
and P2 are merged. LS pressures LS1, LS2, • As pump discharge pressure P1/P2 rises and
and LS3 are also merged. 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)
10-70 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Function Operation
• When any work equipment valve is operated if • When any work equipment valve is operated for
the demand flow for the actuator becomes a long stroke, LS pressures LS1 and LS2 are
greater than the pump discharge from the mini- generated and act on the right end of unload
mum swash plate angle, the oil flow to tank cir- spool (1) (P1 = P2, LS1 = LS2).
cuit T is cut off, and all pump discharge amount • For this reason, the difference between pump
Q flows to the actuator circuit. discharge pressure P1/P2 and LS pressure LS1/
• Since the pump merge-divider valve is at the LS2 does not reach the load of spring (2), so
merge position, pump discharge pressures P1 spool (1) is pushed to the left by spring (2).
and P2 are merged. LS pressures LS1, LS2, • As a result, pump discharge pressures P1 and
and PLS3 are also merged. P2 and tank circuit T are shut off, and all pump
discharge amount Q flows to the actuator circuit.
PC160LC-7 10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Function Operation
• When the difference between pump discharge • When fine control is carried out on both travel
pressure P1/P2 and LS pressure LS1/LS2 valves, LS pressures LS1 and LS2 are gener-
reaches the load of spring (2), unload spool (1) ated and act on the right end of spool (1) (P1,
opens, so excessive oil (maximum pump dis- P2, LS1, and LS2 are separated).
charge mount - demand flow) flows into the tank • When this happens, the area of the opening of
circuit. both travel valve spools is small, so LS pres-
• Since the pump merge-divider valve is at the sures LS1 and LS2 are very different from pump
separate position, pump discharge pressures P1 discharge pressures P1 and P2.
and P2 are separated. LS pressures LS1 and • When the difference between pump discharge
LS2 are also separated. pressure P1/P2 and LS pressure LS1/LS2
• The swash plate angle of the pump becomes reaches the load of spring (2), spool (1) moves to
maximum, so the pump discharge amount the right, and pump discharge pressures P1 and
becomes maximum. (For details, see the sec- P2 are connected to tank circuit T and the exces-
tions on the pump merge-divider valve.) sive 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 cir-
cuit T.
10-72 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Function Operation
• During operation of both travel valves, when the • When both travel valves are operated to the
demand flow becomes maximum, the oil flow to stroke ends, LS pressures LS1 and LS2 are
tank circuit T is cut off, and all pump discharge generated and act on the right end of unload
amount Q flows to both travel circuits. spool (1) (P1, P2, LS1, and LS2 are separated).
• Since the pump merge-divider valve is at the • When this happens, the area of the openings of
separate position, pump discharge pressures P1 both travel valve spools is large, so LS pressures
and P2 are separated. LS pressures LS1 and LS1 and LS2 are not so different from pump dis-
LS2 are also separated. charge pressures P1 and P2.
• The swash plate angle of the pump becomes • For this reason, the difference between pump
maximum, so the pump discharge amount discharge pressure P1/P2 and LS pressure LS1/
becomes maximum. (For details, see the sec- LS2 does not reach the load of spring (2), so
tions on the pump merge-divider valve .) 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.
PC160LC-7 10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
10-74 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Merge-divider valve
Function
• Pump discharge pressures P1 and P2 are • At this time, P1 = P2 and LS1 = LS2 = LS3 and
merged in pump merge-divider spool (3). LS1, the pump swash plate is controlled by the differ-
LS2, and LS3 are also merged. ence between P and LS.
• Pump discharge pressures P1 and P2 are • As a result, there is not difference between P
divided in pump merge-divider spool (3). LS1, and LS and the pump swash plate is set to the
LS2, and LS3 are also divided. maximum position.
• At this time, higher one of P1 and P2 is applied
through pump merge-divider spool (3) to the out-
put port of the LS pressure.
PC160LC-7 10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Introduction of LS pressure
1. Work equipment valve
Function Operation
• The LS pressure is the actuator load pressure at • When spool (1) is operated, pump discharge
the outlet port end of the control valve. pressure PP flows from flow control valve (2)
• Actually, pump discharge pressure PP is through notch (a) in the spool and bridge pas-
reduced by reducing valve (3) of the pressure sage (b) to actuator circuit A.
compensation valve to the same pressure as • At the same time, reducing valve (3) also moves
actuator circuit pressure A and sent to LS circuit to the right, so pump discharge pressure PP is
PLS. reduced by the pressure loss at notch (c). It goes
• In the travel valve, actuator circuit pressure A is to LS circuit PLS, and then goes to spring cham-
directly introduced to LS circuit PLS. ber 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 pres-
sure 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.
10-76 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 pas-
sage (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 equip-
ment 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
10-78 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
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 opera-
tion, 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 com-
pound 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
PC160LC-7 10-81
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
1. In case of compound operation with high load work equipment (like boom RAISE)
10-82 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Operation
• When the boom is lowered and falls due to its • At the time, part of the return flow on the bottom
own weight, the bottom side pressure A in the side passes through the regeneration passage a
boom cylinder (1) will rise above the head side of the boom spool (2), pushes the check valve
pressure B. (3) to open it and flows to the head side.
• This increases the boom lower speed.
PC160LC-7 10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Operation
• When the boom is lowered and is in the load pro- • At the time, the head side pressure B and the
cess, the head side pressure B of the boom cyl- spring (4) close the check valve (3), and the cir-
inder (1) rises above the bottom side pressure A. cuits on the head side and the bottom side are
interrupted.
10-84 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Operation
• When the arm falls for digging due to its own 1. Arm cylinder
weight, the head side pressure A in the arm cyl- 2. Arm spool
inder (1) will rise above the bottom side pressure 3. Check valve
B.
• At the time, part of the return flow on the head A : Head circuit (pressure)
side passes through the regeneration passage a B : Bottom circuit (pressure)
of the arm spool (2), pushes the check valve (3) PP : Pump circuit (pressure)
to open it and flows to the bottom side.
• This increases the arm digging speed.
PC160LC-7 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 bot- 1. Arm cylinder
tom side pressure B of the arm cylinder (1) will 2. Arm spool
rise, close the check valve (3) and interrupt the 3. Check valve
circuits on the head side and the bottom side.
A : Head circuit (pressure)
B : Bottom circuit (pressure)
PP : Pump circuit (pressure)
10-86 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Function Operation
• While the boom and arm levers are not operated, • If the boom is raised and the arm is moved out,
the hydraulic drift prevention valve prevents oil the main pressure from the control valve pushes
from leaking from the boom bottom and arm up poppet (5). As a result, the main pressure
head through spool (1) to prevent the boom and from the control valve flows through the valve
arm from drifting hydraulically. into the boom cylinder bottom.
PC160LC-7 10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Operation
• If the control lever is returned to the neutral posi-
tion while the boom is raised and the arm is
moved out, the holding pressure in the boom cyl-
inder 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
Operation
• If the boom is lowered and the arm is moved in • If the pressure in chamber b is lowered below
pilot pressure P1 from the PPC valve pushes the pressure in port Aa, poppet (5) opens and
pilot spool (3) and the pressurized oil in chamber the pressurized oil from port Ab flows through
b in the poppet is drained. port Aa into the control valve.
• The oil pressure in port Ab is raised by the pres-
surized oil from the boom cylinder bottom and
arm cylinder head, but the oil pressure in cham-
ber b is lowered by orifice a.
PC160LC-7 10-89
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
10-90 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.
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
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 pis-
ton (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
PC160LC-7 10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE
10-94 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT
1. Cover A1. To L.H. travel motor port PB D1. To R.H. travel motor port PB
2. Body A2. From control valve port A5 D2. From control valve port B2
3. Slipper seal B1. To L.H. travel motor port PA E. To L.H. and R.H. travel motors port P
4. O-ring B2. From control valve port B5 T1. From L.H. and R.H. travel motors port T
5. Shaft C1. To R.H. travel motor port PA T2. To tank
C2. From control valve port A2
Unit: mm
No. Check item Criteria Remedy
Standard size Standard clearance Repair limit
6 Clearance between rotor and
Replace
shaft
80 – –
PC160LC-7 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
10-96 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMV110ADT-2
Min.
2,851 rpm
Capacity
Rated speed
Max.
1,644 rpm
Capacity
PC160LC-7 10-97
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
10-98 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
7.16 N 5.69 N
32.5 × 6.5 24.2
{0.73 kg} {0.58 kg} If damaged or
1.96 N 1.57 N deformed,
2 Check valve spring 13.0 × 6.5 9.5 {0.2 kg} {0.16 kg} replace spring
427 N 341 N
3 Return spring 58.43 × 30 42.0
{43.5 kg} {34.8 kg}
55 N 44 N
4 Regulator valve spring 21.5 × 11.1 17.1
{5.6 kg} {4.5 kg}
PC160LC-7 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 • At the same time, the pressurized oil at regulator
pressure oil from the main pump does not flow to piston (15) passes through orifice c in regulator
port P. valve (9) and is drained to the motor case.
• For this reason, regulator valve (9) is pushed to • As a result, rocker cam (4) moves in the maxi-
the right in the direction of the arrow by spring mum swash plate angle direction, the motor
(10). capacity becomes maximum.
• 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 maxi-
mum swash plate angle.
10-100 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
PC160LC-7 10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
10-102 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
PC160LC-7 10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
10-104 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
PC160LC-7 10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
P: From main pump P1: Left: Arm OUT / Right: Boom LOWER
T: To tank P2: Left: Arm IN / Right: Boom RAISE
P3: Left: Swing RIGHT / Right: Bucket CURL
P4: Left: SwingLEFT / Right: Bucket DUMP
10-106 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
16.7 N 13.7 N
14 Metering spring 26.5 × 8.2 24.9 {1.7 kg} {1.4 kg}
PC160LC-7 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).
10-108 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
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
10-110 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
PC160LC-7 10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
8.8 N 7.1 N
3 Steering signal spring 12.8 × 7.3 8.5
{0.9 kg} {0.72 kg}
10-112 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).
PC160LC-7 10-113
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
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 con-
nected to pump pressure chamber PP. There-
fore, 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
OPERATION
1) While in NEUTRAL
The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not out-
put.
PC160LC-7 10-115
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
10-116 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
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
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 Repair limit
16.7 N 13.7 N
10 Metering spring 22.7 × 8.1 22
{1.7 kg} {1.4 kg}
PC160LC-7 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
PC160LC-7 10-121
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing holding brake, merge-divider, travel junction solenoid valves
10-122 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
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.
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
PC160LC-7 10-125
ATTACHMENT CIRCUIT SELECTOR
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Replace spring if
Free length x Out- Installed
3 Spool return spring Installed load Free length Installed load any damages or
side diameter length deformations are
833 N 666 N found
132.0 × 29 114.5 {85.0 kg}
{68.0 kg}
10-126 PC160LC-7
ATTACHMENT CIRCUIT SELECTOR
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 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 attach-
ment 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 intercon-
nected, and ATT port and port T are shut off, so
the attachment and main valve are intercon-
nected.
PC160LC-7 10-127
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-128 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
Unit: mm
– 0.030 + 0.279
Clearance Boom 75 0.096 – 0.355 0.445
1 between piston rod – 0.076 + 0.065 Replace
bushing
and bushing – 0.030 + 0.222
Arm 85 0.083 – 0.312 0.445
– 0.090 + 0.047
– 0.030 + 0.259
Bucket 70 – 0.076 + 0.063 0.093 – 0.335 0.445
– 0.030 + 0.190
Boom 70 – 0.060 + 0.070 0.100 – 0.250 1.0
Clearance
between piston rod – 0.030 + 0.175
2 Arm 80 0.105 – 0.251 1.0
support pin and – 0.076 + 0.075
bushing
– 0.030 + 0.170
Bucket 70 0.100 – 0.246 1.0
– 0.076 + 0.070 Replace pin
– 0.030 + 0.190 or bushing
Boom 70 – 0.060 + 0.070 0.100 – 0.250 1.0
Clearance
between cylinder – 0.030 + 0.175
3 bottom support pin Arm 80 – 0.076 + 0.075 0.105 – 0.251 1.0
and bushing
– 0.030 + 0.170
Bucket 70 0.100 – 0.230 1.0
– 0.060 + 0.070
PC160LC-7 10-129
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
10-130 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
PC160LC-7 10-131
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
1. DIMENSION OF ARM
10-132 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
Model
No. PC160LC-7
+ 0.1
1 80 0
2 99.3 + 01.5
0
3 286– 0.5
– 0.036
4 90 – 0.071
5 414.7 ± 1.0
6 196.3 ± 0.5
7 747.4 ± 1.0
8 2,603
9 2,001.7 ± 1.0
10 330 ± 1.0
11 583 ± 0.5
12 524 ± 0.5
13 400.8
14 1,347
15 70
16 311.5 ± 1.0
17 70
0
Arm as individual part 276 – 0.5
18
When pressfitting bushing 310
Min. 1,501
19
Max. 2,528
PC160LC-7 10-133
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
2. DIMENSION OF BUCKET
10-134 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
Model
No. PC160LC-7
1 400.5 ± 0.5
2 14.8 ± 0.5
3 97° 7’
4 400.8
5 1,334.7
6 180.7
7 –
8 0
+ 0.2
9 70 0
10 311.5 ± 1
11 50
12 96
13 440.5
14 18
15 130
16 160
17 135
18 112
19 80
20 80
21 339.5 ± 1
22 44
PC160LC-7 10-135
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
10-136 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
PC160LC-7 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.
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 com-
pletely, 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 turn-
ing the knob.
• As the potentiometer shaft is turned, the resis-
tance 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 OPERATION
2. Cover
While motor is stopped
3. Shaft
• Electric power is applied to both phases A and B
4. Dust seal
of the motor.
5. Bearing
6. Motor
While motor is running
7. Gear
• The engine throttle and pump controller supplies
8. Connector
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 moni-
tor 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
10-142 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
PC160LC-7 10-143
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
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
7
Swing control function
8
Travel control function
9
ATT flow control, circuit selector function (if equipped)
Self-diagnosis function
PC160LC-7 10-145
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
10-146 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
PC160LC-7 10-147
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
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 absorp-
tion 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
Mode A
• Matching point in mode A: Rated speed
Model
Mode PC160LC-7
10-150 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Model 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}
PC160LC-7 10-151
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
10-152 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
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 pres-
sure 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.
10-154 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
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
⇓
Software cut-off function
Working Engine/Pump
2-stage relief function Operation time
mode control
34.8 MPa {355 kg/cm2}
Matching at rated Automatically
A, E ⇓ Cancel
output point reset at 8.5 sec
37.2 MPa {380 kg/cm2}
10-156 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 automati-
cally 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 oper-
ation 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.
10-158 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
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
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1) Auto-warm-up function
• After the engine is started, if the engine cool-
ing water temperature is low, the engine
speed is raised automatically to warm up the
engine.
Operating condition (All) Operated
⇓
Resetting condition (Any one) Reset
⇒
Water temperature: Above 30°C
Auto
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
Manual
longer
⇒ ⇒
Work mode: Any mode Fuel control dial: Return to low
Water and oil temper- Engine speed: Low idle idle position once.
ature: Above 105°C Monitor alarm lamp: Lights up • Under above condition, control-
Alarm buzzer: Sounds ler is set to condition before
operation of function. (Manual
reset)
⇒ ⇒
102°C
OR B
Water and oil temper- • Under above condition, control-
Engine speed: Keep as is.
ature: Above 102°C ler is set to condition before
Monitor alarm lamp: Lights up.
operation of function. (Auto-
Lower pump discharge.
matic reset)
⇒ ⇒
Work mode: Mode A Below 100°C
Water and oil temper- • Under above condition, control-
Engine speed: Keep as is.
ature: Above 100°C ler is set to condition before
Lower pump discharge.
operation of function. (Auto-
matic reset)
⇒ ⇒
Work mode: Travel Below 97°C
Water and oil temper- • Under above condition, control-
Engine speed: Keep as is.
ature: Above 97°C ler is set to condition before
Lower travel speed.
operation of function. (Auto-
matic reset)
10-160 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
FUNCTION
• When the engine is started, if the engine cooling
water temperature is low (below 0°C), the low-
temperature 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 spe-
cial water temperature sensor is used for this
function.)
PC160LC-7 10-161
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
FUNCTION
The swing lock and swing holding brake functions
are installed.
10-162 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1) Swing lock and swing holding brake func- 2) Quick hydraulic oil warm-up function
tions when swing lock switch is turned on
• The swing lock function (manual) is used to • If swing lock switch (4) is turned on, the
lock the machine from swinging at any posi- pump-cut function is cancelled and the relief
tion. pressure rises from 34.8 MPa {355 kg/cmð}
The swing holding brake function (automatic) to 37.2 MPa {380 kg/cmð}. If the work equip-
is interlocked with the swing operation and ment is relieved under this condition, the
used to prevent hydraulic drift while the hydraulic oil temperature rises quickly and
machine is not swinging. the warm-up time can be shortened.
• Swing lock switch and swing lock/holding
brake
Lock Lock
Function Operation
switch lamp
If swing lever is set in neu-
tral, swing brake operates in
Swing
about 5 sec. If swing lever
OFF OFF holding
is operated, brake is
brake
released and machine can
swing freely.
Swing lock operates and
machine is locked from
Swing swinging. Even if swing
ON ON
lock lever is operated, swing lock
is not reset and machine
does not swing.
PC160LC-7 10-163
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
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
PC160LC-7 10-165
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
FUNCTION
This function is available only with the ATT specifica-
tion. 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
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
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
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 con-
troller.
• 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 • The monitor panel also has various mode selec-
machine with sensors installed on various parts tor switches and functions to operate the
of the machine. It processes and immediately machine control system.
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 con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
10-170 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 Process-
ing 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
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
10-172 PC160LC-7
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PC160LC-7 10-173
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
OFF ON Flashes
ON ON ON
Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
10-174 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
A1 105 Red
A2 102 Red
A3 100 Green
Engine coolant tem-
perature (°C)
A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
B3 100 Green
Hydraulic oil tempera-
ture (°C)
B4 80 Green
B5 40 Green
B6 20 White
C1 289 Green
C2 244.5 Green
C3 200 Green
Fuel level ( )
C4 100 Green
C5 60 Green
C6 41 Red
PC160LC-7 10-175
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
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 dis-
played.
Check before
Symbol Display item starting item When engine is stopped When engine is running
Battery charge q —
Lights up when
abnormal
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 dis-
played.
10-176 PC160LC-7
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
Monitor
Displays
Auto- actuation
deceleration ON OFF
status
Lights up when
Service meter Service meter When service meter is working service meter
indicator is working
PC160LC-7 10-177
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
SWITCHES
10-178 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
• 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.
PC160LC-7 10-179
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
• Control switch
This is used for control when using the mainte-
nance function or select function.
(For details, see each function.)
10-180 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
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.
1 30
PC160LC-7 10-181
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
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.
01 →
02 →
03 →
10-182 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
6 120 or 130
5 100 or 110
4 80 or 90
3 60 or 70
2 40 or 50
1 70
PC160LC-7 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 main-
tenance items, press maintenance switch (1) and the
caution display (yellow or red) appears on the moni-
tor display for 30 seconds after the key is turned ON
to remind the operator to carry out lubrication main-
tenance.
★ Maintenance items
Display Condition
Remaining time for main-
None tenance for all items is
more than 30 hours
There is one or more
Notice display (black sym-
items with less than 30
bol displayed on yellow
hours remaining time for
background)
maintenance
There is one or more
Warning display (wiper
items with less than 0
symbol displayed on red
hours remaining time for
background)
maintenance
10-184 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MAINTENANCE OPERATION
1. After completing the selection, press input confir-
mation 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
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.
02 Contrast
03 Brightness
10-186 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PC160LC-7 10-187
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
10-188 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PC160LC-7 10-189
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
• The monitor system monitors the condition of the • The monitor panel also has various mode selec-
machine with sensors installed on various parts tor switches and functions to operate the
of the machine. It processes and immediately machine control system.
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 con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
PC160LC-7 10-191
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
1. Monitor panel
The monitor panel has a CPU (Central Process- 1 Key switch (Battery) 1 Engine water temperature
ing Unit) in it to process, display, and output the 2 Key switch (Battery) 2 Fuel
information. 3 Washer motor output 3 Radiator water level
The monitor display unit consists of LCD (Liquid 4 Key switch (Terminal C) 4 NC
Crystal Display) and LED (Light Emitting Diode). 5 Wiper contact W 5 Air cleaner clogging sensor
The switches are flat sheet switches. 6 GND 6 NC
7 GND 7 Engine oil pressure sensor
8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (–) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
13 GND (For analog signal)
14 NC
15 Wind limit switch
16 Buzzer cancel
17 Swing lock
18 Preheating
19 Limit switch
20 Network (GND)
10-192 PC160LC-7
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
PC160LC-7 10-193
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
Symbol Displayed item Display range When engine is stopped While engine is running
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
10-194 PC160LC-7
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
PC160LC-7 10-195
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and replace-
ment 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 PC160LC-7
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
• There are 4 sets of the mode selector switches Operations table of switch section
on the switch section. Each time one switch is
pressed, the machine condition changes. The a The bold letters are the positions of the switches
current condition is indicated by the lighting of reset when the starting switch is turned on.
the LED above the switch.
Item Operation
• The initial setting of only the work mode after the
starting switch is turned on can be changed. Work mode Ai
oEi
oB
a For how to change the setting, see "Work mode
Auto-deceleration ON i
o OFF
default setting mode" in TROUBLESHOOTING-
Display and special functions of monitor panel. Wiper OFF i
o Intermittent i
o ON
Travel speed Hi i
o Lo
PC160LC-7 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.
1. Connector
2. Bracket
3. Float
4. Switch
10-198 PC160LC-7
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
PC160LC-7 10-199
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
1. Float
2. Connector
3. Cover
4. Variable resistor
10-200 PC160LC-7
(3)
20 TESTING AND ADJUSTING
Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
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)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Engine SAA4D102E-2
Difference
Oil temperature: 40 – 60ºC MPa Min. 2.4 between cyinders
Compression pressure
Engine speed: 250rpm {kg/cm2} {Min. 24.6} Min. 1.0
{Min. 10.3}
Oil temperature Whole speed range (inside oil pan) ºC 80 – 110 120
20-2 PC160LC-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
• Engine stopped
Spool stroke
PC160LC-7 20-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
20-4 PC160LC-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
• Working mode: A
• Travel speed: Lo
Travel deviation Max. 150 Max. 250
• 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. mm
PC160LC-7 20-5
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
operating range
• Engine: High idling 3.5 ± 0.4 Max. 4.9
• Working mode: A
Work equipment
20-6 PC160LC-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
• Working mode: A
Arm time lag • Move in arm from OUT stroke end and sec Max. 3.0 Max. 4.2
Work equipment
range
performance
PC160LC-7 20-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
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 spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of mea-
surement, and use them as a base for calculating the pump discharge amount at the specified speed.
20-8 PC160LC-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Posture of machine for measuring performance Travel 2: Travel speed (Actual travel), travel devia-
and measuring method tion
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
20-10 PC160LC-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC160LC-7 20-11
(1)
TESTING AND ADJUSTING
PC160LC-7 20-101
(3)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q’ty
Test, measurement item Part No. Part Name Remarks
Handy smoke
1 799-201-9001 checker 1
Exhaust gas color B Bosch index = 0 – 9
Commercially
2 available Smoke meter 1
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 KIT (analog type) 1 {25, 60, 400, 600 kg/cm2}
1
Engine oil pressure G Oil pressure gauge
790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 KIT (analog type) 1 {25, 60, 400, 600 kg/cm2}
1
Hydraulic oil pressure of Oil pressure gauge
work equipment, swing and J 790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
travel circuit
799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 KIT (analog type) 1 {25, 60, 400, 600 kg/cm2}
1
Oil pressure gauge
Control circuit basic pres- K 790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
sure
799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1
799-101-5002 Oil pressure gauge 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
(analog type) {25, 60, 400, 600 kg/cm2}
1
Pump PC control circuit oil 790-261-1204 Oil pressure gauge 1 Pressure gauge: 58.8 MPa {600kg/cm2}
L (digital type)
pressure
799-101-5220 Nipple 3 10 x 1.25 mm
2
07002-11023 O-ring 3
20-102 PC160LC-7
(4)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q’ty
Test, measurement item Part No. Part Name Remarks
799-101-5002 Oil pressure gauge 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
KIT (analog type) {25, 60, 400, 600 kg/cm2}
1
Oil pressure gauge
790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
Pump LS control circuit oil M
pressure 799-101-5220 Nipple 3 10 x 1.25 mm
2
07002-11023 O-ring 3
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 KIT (analog type) 1 {25, 60, 400, 600 kg/cm2}
1
Oil pressure gauge
Solenoid vallve output N 790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
pressure
799-401-3100 Adapter 1 02 size
2
799-401-3200 Adapter 1 03 size
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 KIT (analog type) 1 {25, 60, 400, 600 kg/cm2}
PPC vallve output pressure P 1
Oil pressure gauge
790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
Q Commercially
Oil leakage available Measuring cylinder 1
– Commercially
Stroke, hydraulic drift available Scale 1
– Commercially
Work equipment Speed available Stopwatch 1
– Commercially
Voltage, resistance available Tester 1
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)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM
20-104 PC160LC-7
(4)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM
Adjustment
1. Adjustment of RPM at low idling
If the rpm at low idling deviates from the stan-
dard value, make adjustment using the ad-
justment function provided in the monitor
panel.
For the adjustment procedures, refer to the
section, "Special Function of Monitor Panel"
PC160LC-7 20-105
(1)
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR
20-106 PC160LC-7
(4)
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
PC160LC-7 20-107
(1)
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
20-108 PC160LC-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF COMPRESSION PRESSURE
4. Open the engine hood and remove nozzle 7. Crank up the engine with the engine starting
holder (1) of the cylinder to be measured. motor, and measure the compression pressure.
Read off the value, when the needle of the
compression gauge steadies itself.
When taking measurement of the compres-
sion pressure, be sure to measure the engine
rpm, too, so that it stays within the range of
designated measurement conditions.
PC160LC-7 20-109
(1)
TESTING AND ADJUSTING MEASUREMENT OF BLOW-BY PRESSURE
20-110 PC160LC-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
3. Rotate the crankshaft forward with gear F1 and 5. Disconnect plug (4) of the fuel injection pump.
match yellow paint (a) of the crank pulley to the
tip of pointer (2) to set No. 1 cylinder to the com- 6. Reverse and push in timing pin (5) of the fuel
pression top dead center. injection pump, and confirm its cut-out portion
Take off the cylinder head cover for No.1 cyl- matches with protruding portion b inside the
inder, and confirm that its rocker arm can be pump.
manually moved as much as the valve clear- If timing pin (5) can be pushed in smoothly,
ance. If it cannot be moved, that means that then injection timing is correct.
No.1 cylinder is not yet at the top dead cen- If timing pin (5) cannot be pushed in smooth-
ter. In that case, rotate it by one more turn. ly, 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.
PC160LC-7 20-111
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
20-112 PC160LC-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE
PC160LC-7 20-113
(4)
TESTING AND ADJUSTING ADJUSTMENT OF ENGINE SPEED SENSOR
20-114 PC160LC-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
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) ten-
sion by shifting the position of compressor
bracket (1).
PC160LC-7 20-115
(1)
TESTING AND ADJUSTING MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
Follow the steps explained below, when measur- 5. Read off the value in dial gauge H in this condi-
ing clearance in the swing circle bearing in the tion.
actual machine. The value indicated in dial gauge H express-
Be careful not to put a hand or foot under the un- es clearance in the bearings.
dercarriage, while taking measurement.
20-116 PC160LC-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
Adjustment
If the track shoe tension is not proper, adjust it in
the following manner.
PC160LC-7 20-117
(1)
INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT,
TESTING AND ADJUSTING SWING, AND TRAVEL CIRCUITS
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 pres-
sure from the piping, and then loosen the oil
filler cap of the hydraulic tank slowly to re- 3) Run the engine and heighten the hydraulic
lease the residual pressure from the tank. oil temperature to the operating range.
1) Remove oil pressure pickup plugs (1) and
(2).
• (1): Front pump discharge pressure pick-
up plug
20-118 PC160LC-7
(4)
INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT,
TESTING AND ADJUSTING SWING, AND TRAVEL CIRCUITS
2. Combination of pump, actuator, and valve 5. Measurement of swing circuit relief pressure
When the pump is separated, the front pump 1) Start the engine and turn the swing lock
and rear pump act independently on each ac- switch ON.
tuator as shown in the table. Note that differ- 2) Run the engine at high idling and swing to
ent actuators relieve different valves. the right and left to relieve the swing circuit
When the work equipment circuit or swing and measure the oil pressure at this time.
circuit are relieved singly, the oils of the The pressure measured when the swing
pumps are merged. When the travel circuit is motor safety valve is relieved is indicat-
relieved singly, the oils of the pump are divid- ed.
ed. The swing motor relief pressure is lower
The actuators in the table are arranged in the than the main relief valve.
order when the control valve is seen from the
front of the machine (and 1 attachment is in- 6. Measurement of travel circuit relief pressure
stalled to the service valve). 1) Start the engine and lock the travel mecha-
nism.
Pump Actuator Valve relieved
(Centralized safety valve) Set pin [2] between the sprocket and
Service Safety-suction valve track frame to lock the travel mechanism
securely.
Bucket Main relief valve
Rear Arm Main relief valve
RAISE: Main relief valve
Boom
LOWER: Safety-suction valve
(Front unload valve) (Rear unload valve) (Main relief valve)
(Pump merge-divider valve) (Self-pressure reducing valve)
Front Left travel Main relief valve
Right travel Main relief valve
Rear
Swing Swing motor safety valve
(LS separate valve)
PC160LC-7 20-119
(1)
INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT,
TESTING AND ADJUSTING SWING, AND TRAVEL CIRCUITS
1) Disconnect pilot hose (4). 1) Fixing screw (9), loosen locknut (10).
2) Fixing holder (5), loosen locknut (6). Fix the screw with a hexagonal wrench.
3) Turn holder (5) to adjust the pressure. 2) Turn screw (9) to adjust the pressure.
If the holder is If the screw is
• Turned to the right, the pressure • Turned to the right, the pressure
rises. rises.
• Turned to the left, the pressure • Turned to the left, the pressure
lowers. lowers.
Quantity of adjustment per turn of holder: Quantity of adjustment per turn of screw:
Approx. 20.5 MPa {Approx. 209 kg/cm2} Approx. 9.8 MPa {Approx. 100 kg/cm2}
4) Fixing holder (5), tighten locknut (6). 3) Fixing screw (9), tighten locknut (10).
Lock nut: Lock nut:
49.0 – 58.8 Nm {5 – 6 kgm} 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
5) Connect pilot hose (4). 4) After finishing adjustment, check again that
6) After finishing adjustment, check again that the pressure is normal according to the pro-
the pressure is normal according to the pro- cedure for measurement described above.
cedure for measurement described above.
20-120 PC160LC-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
PC160LC-7 20-121
(4)
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE
20-122 PC160LC-7
(4)
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE
Pressure to be
Pressure ratio
measured
Pump delivery 3) Start the engine and keep it running until the
1
pressure hydraulic oil pressure rises to the operating
PC valve outlet Approx: 0.6 range.
pressure (Approx. 3/5)
PC160LC-7 20-123
(1)
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE
Adjusting
If the following phenomena occur and PC valve
(5) seems to be defective, adjust PC valve (5)
according to the procedure shown below. 4. After finishing adjustment, check that the PC
• When the working load is increased, the en- valve output pressure (servo piston inlet pres-
gine speed lowers largely. sure) is normal according to the procedure for
• The engine speed is normal but the working measurement described above.
speed is low.
20-124 PC160LC-7
(1)
INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE
PC160LC-7 20-125
(4)
INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE
4) Run the engine at high idling under the fol- • (2): Rear pump discharge pressure pick-
lowing condition and measure the pump dis- up plug
charge 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 pres-
sure (higher one of F and R) to the LS
valve output pressure (servo piston inlet
pressure) is as follows, those pressures
are normal.
20-126 PC160LC-7
(1)
INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE
Adjustment
If the LS differential pressure is abnormal, adjust
LS valve (5) according to the following proce-
dure.
PC160LC-7 20-127
(1)
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
20-128 PC160LC-7
(4)
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
PC160LC-7 20-129
(1)
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
20-130 PC160LC-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
Since (9) and (10) are installed under the 4. Measure the pressure when the engine is run-
cab, remove cab undercover (front one). ning at high idling and the control lever of the cir-
cuit 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 Hydraulic Pressure
In NEUTRAL 0 MPa {0 kg/cm2}
Nearly equal to control
At full stroke original pressure
(see standard value table)
PC160LC-7 20-131
(4)
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
20-132 PC160LC-7
(4)
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF
TESTING AND ADJUSTING WORK EQUIPMENT
PC160LC-7 20-133
(1)
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF
TESTING AND ADJUSTING WORK EQUIPMENT
20-134 PC160LC-7
(1)
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, ex-
tract the bucket cylinder and arm cylinder ful-
ly and set the boom angle to 45 degrees.
PC160LC-7 20-135
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION
20-136 PC160LC-7
(1)
TESTING AND ADJUSTING RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
PC160LC-7 20-137
(1)
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE
20-138 PC160LC-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE
PC160LC-7 20-139
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
1 2 3 4 5 6
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 If the engine water temperature is low and
Keep the oil filler cap of the hydraulic tank the automatic warm-up operation is started,
loosened while the air is bled from the hy- stop the engine temporarily and reset the au-
draulic pump. tomatic warm-up operation with the fuel con-
1) Loosen air bleeder (1) and check that oil ooz- trol dial (Set the starting switch in the ON
es out from it. position and hold the fuel control dial in the
2) After oil containing no bubbles flows out, MAX position for 3 seconds, and the auto-
tighten air bleeder (1). matic warm-up operation is reset).
Air bleeder:
27.5 – 35.3 Nm {2.8 – 3.6 kgm} 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 min-
utes.
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
2. Starting engine piston rod to the stroke end and relieve the
When running the engine after performing step oil.
1, keep its speed at low idling. 5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
20-140 PC160LC-7
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
4. Bleeding air from swing motor If the oil level is below line L, add new oil.
1) Run the engine at low idling.
2) Swing to the right and left slowly to bleed air.
PC160LC-7 20-141
(1)
TESTING AND ADJUSTING INSPECTION PROCEDURES FOR DIODE
20-142 PC160LC-7
(1)
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)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-144 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PC160LC-7 20-145
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-146 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PC160LC-7 20-147
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
User
Failed System Action Directed to Operator
Code
Error in pump Turn the emergency pump driving switch ON (Set it in the emergency position), and you can
E02
control system operate the machine normally. Have the machine inspected immediately, however.
Turn the swing holding brake release switch (ON) (Set it in the release position) to release
Error in swing the brake. To apply the swing brake, operate the swing lock switch manually. The brake
E03
brake system may not be released, depending on the cause of the fault. Have the machine inspected
immediately in any case.
Error in governor
E05 The governor cannot be controlled. Have the machine inspected immediately in this case.
system
20-148 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PC160LC-7 20-149
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
Classification
Error Code Failure Code
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
Abnormality in
– E101 Abnormal data in error history DAF0KT Monitor controller
controller
Short circuit in wiper motor drive, normal rota-
Windshield wiper motor (nor-
– E112 DY2DKB Short circuit
tion system mal rotation)
Short circuit in wiper motor drive, reverse rota-
Windshield 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 sole-
E03 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 sole-
E03 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
Electrical system
Travel Hi-Lo shifting solenoid
– E216 Disconnection in travel speed shifting solenoid DW43KA Disconnection
valve
Nonconfor-
S-NET communication of
– E217 Abnormality in model code input DA2SKQ mance in model
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
– E245 DXE4KB Short circuit
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
– E311 D199KB Short circuit
solenoid relay solenoid relay
Short-circuiting in low-temperature starting Low-temperature starting
– E312 D199KA Disconnection
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
20-150 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
system Classification
Error Code Failure Code
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
Electrical
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 Overrunning
Low-idling speed
– None Engine low idling out of rate A000N2 Engine
heightened
– None Air cleaner clogged AA10NX Air cleaner element Clogging
Insufficient
Mechanical system
– None Charging voltage abnormally low AB00KE Alternator
charging
Oil pressure low-
– None Engine oil pressure abnormally low B@BAZG Engine oil
ered
– None Engine oil level abnormally low B@BAZK Engine oil Oil level lowered
– None Engine cooling water overheated B@BCNS Engine cooling water Overheating
Cooling water
– None Radiator water level abnormally low B@BCZK Engine cooling water
level lowered
– None Hydraulic oil overheated B@HANS Hydraulic oil Overheating
Auto-lubrication system con-
– None Auto-lubrication system abnormal DA80MA Malfunction
troller Ass‘y
PC160LC-7 20-151
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] [2] [3]
(Enter a figure, depressing [ ])
20-152 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
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 op-
erating the machine.
20-154 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PC160LC-7 20-155
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
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 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
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. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical System
02 Mechanical Systems
PC160LC-7 20-157
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-158 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
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 re-
placement
PC160LC-7 20-159
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
1) Selection of menu
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
20-160 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PC160LC-7 20-161
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
1) Selection of menu
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
20-162 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
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. AAAAA/Default submenu
00 Return (termination of AAAAA/Default)
01 Key-on Mode
02 AA/Language
03 Unit
04 With/Without Service Cir.
PC160LC-7 20-163
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-164 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
2) Selection of submenu
Select an item to change from the submenu
and depress [ ] switch.
No. Adjustment submenu
00 Return (termination of adjustment)
01 Governor lever stroke adjustment
02 Pump Absorption Torque
03 Low Idle Speed
04 Service Current Adjustment
PC160LC-7 20-165
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-166 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PC160LC-7 20-167
(1)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
PC160LC-7 20-169
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
1 Function of displaying service meter <Operation of switch> O 3 Function of displaying service code [01]
O <Automatic> 4 Monitoring function [02]
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
20-170 PC160LC-7
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
<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.
User Caution
Error mode Remedy (shown to operator)
code buzzer
If the emergency pump drive switch is set in the upper position, the
Error in pump
E02 machine can operate normally. Have the machine inspected immediately, q
control system
however.
Set the swing holding brake release switch in the upper position to release
Error in swing the brake. When applying the swing brake, operate the swing lock switch
E03 q
brake system manually. The brake may not be released, depending on the cause of the
failure. In this case, have the machine inspected immediately.
Error in governor
E05 Have the machine inspected immediately. q
system
PC160LC-7 20-171
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
1) Operating switches
While holding caution buzzer stop switch (3),
hold auto decelerator switch (4) for 2.5 seconds.
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.
4) Executing menu
Select a menu you will use and press set switch
(5), and the menu is executed.
20-172 PC160LC-7
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
PC160LC-7 20-173
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
20-174 PC160LC-7
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
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
20-176 PC160LC-7
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
PC160LC-7 20-177
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
20-178 PC160LC-7
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
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.
PC160LC-7 20-179
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
3 Nut:
v) Tighten nuts (2) and (3).
20-180 PC160LC-7
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
PC160LC-7 20-181
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
20-182 PC160LC-7
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
PC160LC-7 20-183
(3)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
20-184 PC160LC-7
(3)
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
20-186 PC160LC-7
(4)
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
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.
PC160LC-7 20-186-1
(4)
PC160LC-7 20-187
(3)
20-188 PC160LC-7
(3)
PC160LC-7 20-189
(3)
20-190 PC160LC-7
(3)
PC160LC-7 20-191
(3)
TROUBLESHOOTING
PC160LC-7 20-201
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
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 func-
tion.
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 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
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 PC160LC-7
(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC160LC-7 20-203
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-204 PC160LC-7
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
PC160LC-7 20-205
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-206 PC160LC-7
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
PC160LC-7 20-207
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-208 PC160LC-7
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
PC160LC-7 20-209
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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 enter-
ing. 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, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
20-210 PC160LC-7
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equip-
ment, 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 sec-
ondary 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)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
20-212 PC160LC-7
(1)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Mode Content
Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
Code display
displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine assembly
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 mechan-
ical 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)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting
No. Failure-looking phenomenon
Code
E mode H mode S mode
display
Action to be taken concerning Error Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
ing to dis-
2 Display Error Code in electrical system after checking failure history
played
3 Display Failure Code in mechanical system after checking failure history code
Engine-related failure
4 Starting performance is poor (Starting always takes time) S-1
5 Engine does not turn E-1 (1) S-2 (1)
Engine turns but no exhaust smoke comes out
6 S-2 (2)
(Fuel is not being injected)
Engine does not start Exhaust smoke comes out but engine does not
7 S-2 (3)
start (Fuel is being injected)
Engine does not start easily or at all low temper-
8 E-1 (2)
ature
9 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 H-5
23 Auto engine warm-up device does not work E-6
24 Preheater does not operate E-7
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 S-4
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 PC160LC-7
(4)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting
No. Failure-looking phenomenon
Code
E mode H mode S mode
display
PC160LC-7 20-215
(4)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting
No. Failure-looking phenomenon
Code
E mode H mode S mode
display
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 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
20-218 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
A51 D 3 F pump hydraulic oil pressure sensor I-9 K-5
A52 D 3 R pump hydraulic oil pressure sensor L-5 K-5 K-5
A60 X 1 Fuel level sensor F-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
C01 DRC 24 Governor pump controller V-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller W-9 A-3 A-7 A-7
C03 DRC 40 Governor pump controller W-9 A-2 A-4 A-4
C09 S 8 Model selection connector W-6 C-9
D01 SWP 8 Assembled type diode W-7 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
D03 SWP 8 Assembled type diode P-1 H-1
D04 SWP 8 Assembled type diode Q-1 A-8 I-1
Suction type air heater
E01 Terminal 1 K-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine oil pressure switch L-8 K-6
E03 D 2 Engine oil level switch L-7 K-5
E04 D 2 Engine rotation sensor L-8 K-8 K-8
Engine cooling water temperature sensor
E05 D 2 J-9 K-4
(for high temperature)
E06 M 3 Fuel dial O-8 F-1
E06 X 1 Air conditioner compressor electromagnetic switch K-9
E08 X 1 Intermediate connector L-6 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-2
E11 D 4 Governor motor L-9 K-2
E12 – 3 Alternator L-7 K-3 K-5
Engine cooling water temperature sensor
E12 D 3 L-7 K-3
(for low temperature)
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box W-5 I-9 B-2 F-9
H08 M 8 Intermediate connector W-4 K-8
H09 S 8 Intermediate connector W-5 J-8
H10 S 16 Intermediate connector T-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
J01 J 20 Junction connector (black) W-8 C-9 D-9 C-9
J02 J 20 Junction connector (black) W-8 D-9 D-9 D-9
J03 J 20 Junction connector (green) W-8 D-9 E-9 D-9
J04 J 20 Junction connector (green) W-7 E-9 E-9 E-9
J05 J 20 Junction connector (pink) W-6 E-9 E-9 E-9
J06 J 20 Junction connector (orange) W-6 F-9 H-9
J07 J 20 Junction connector (orange) U-9 F-9 F-9 H-9
J08 J 20 Junction connector (pink) U-9 I-9
PC160LC-7 20-219
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
20-220 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
PC160LC-7 20-221
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
20-222 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC160LC-7 20-223
(1)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Connector table
Serial No.: 11001 and up
Address
Connector No. of
Type Name of device
No. pin Stereo- M G P
gram circuit circuit circuit
20-223-1 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
A60 X 1 Fuel level sensor F-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
C01 DRC 24 Governor pump controller U-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller V-9 A-3 A-7 A-7
C03 DRC 40 Governor pump controller W-9 A-2 A-4 A-4
C09 S 8 Model selection connector U-9 C-9
D01 SWP 8 Assembled type diode W-9 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
Suction type air heater
E01 Terminal 1 K-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine oil pressure switch L-8 K-6
E03 D 2 Engine oil level switch L-7 K-6
E04 D 2 Engine rotation sensor L-8 K-8 K-8
Engine cooling water temperature sensor
E05 D 2 J-9 K-4
(for high temperature)
E06 M 3 Fuel dial O-8 F-1
E06 X 1 Air conditioner compressor electromagnetic switch K-9
E08 X 1 Intermediate connector L-6 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-2
E11 D 4 Governor motor L-9 K-2
E12 – 3 Alternator L-7 K-5
Engine cooling water temperature sensor
E12 D 3 L-7 K-3
(for low temperature)
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box U-2 H-9 B-2 F-9
H08 M 8 Intermediate connector W-6 K-8
H09 S 8 Intermediate connector W-6 J-8
H10 S 16 Intermediate connector S-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-6 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
J01 J 20 Junction connector (black) T-1 C-9 D-9 C-9
J02 J 20 Junction connector (black) V-2 D-9 D-9 D-9
J03 J 20 Junction connector (green) V-2 D-9 E-9 D-9
J04 J 20 Junction connector (green) V-3 E-9 E-9 E-9
J05 J 20 Junction connector (pink) V-3 E-9 E-9 E-9
J06 J 20 Junction connector (orange) V-3 F-9
J07 J 20 Junction connector (orange) W-3 F-9 F-9 H-9
K19 M 2 Pump resistor (for driving emergency pump) W-3
K30 DT 3 CAN terminating resistor S-9 A-2 C-1
K31 DT 3 CAN terminating resistor N-4 A-4 K-7
PC160LC-7 20-223-2
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
20-223-3 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
PC160LC-7 20-223-4
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-223-5 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-224 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC160LC-7 20-225
(1)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-226 PC160LC-7
(1)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC160LC-7 20-227
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-228 PC160LC-7
(1)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-229-1 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC160LC-7 20-229-2
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-229-3 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC160LC-7 20-229-4
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-229-5 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-230 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING 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)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-231-1 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING 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)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-232 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING 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)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-233-1 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING 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 20-233-2
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-234 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING 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)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-235-1 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING 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
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
20-236 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
PC160LC-7 20-237
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
16 799-601-7320
20-238 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7390
PC160LC-7 20-239
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
20-240 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
PC160LC-7 20-241
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)
13 799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)
20-242 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
17 799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)
21 799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)
PC160LC-7 20-243
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
20-244 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
PC160LC-7 20-245
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-3460
— —
20-246 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
PC160LC-7 20-247
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
20-248 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
4 —
— —
PC160LC-7 20-249
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
20-250 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
PC160LC-7 20-251
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
20-252 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
PC160LC-7 20-253
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
20-254 PC160LC-7
(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 T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
PC160LC-7 20-255
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
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
12
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 PC160LC-7
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
1 —
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)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
20-257-1 PC160LC-7
(4)
TROUBLESHOOTING T-ADAPTER - BOXES AND T-ADAPTER TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Part No. Type of connector No. of pins
20-258 PC160LC-7
(1)
TROUBLESHOOTING T-ADAPTER - BOXES AND T-ADAPTER TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Part No. Type of connector No. of pins
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
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)
TROUBLESHOOTING T-ADAPTER - BOXES AND T-ADAPTER TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Part No. Type of connector No. of pins
—
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 Q
799-601-9320 Box for measurement For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
For fuel, boost
799-601-9420 3P Q
pressure
799-601-9430 PVC socket 2P Q
20-260 PC160LC-7
(4)
TROUBLESHOOTING ERROR CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED
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 PC160LC-7
(1)
–
–
–
–
–
–
–
–
–
code
Error
E113
E211
E116
E115
E114
E112
E311
E246
E245
E233
E232
E227
E225
E224
E218
E217
E318
E317
E316
E315
E312
E308
E306
E238
E228
E226
E216
E215
E214
E213
E206
E205
E204
E203
E201
E101
(4)
20-304
code
A000N2
A000N1
Failure
D110KB
DY10K4
D199KA
D199KB
D196KA
D196KB
AB00KE
DK10KZ
DK54KZ
AA10NX
DY20KA
DY10KB
DY10KA
DA25KP
DAF0KT
DXE4KA
DXE4KB
DXA0KA
DXA0KB
DA2SKA
DY2EKB
DLE2MA
DY2CKB
DY2DKB
DY20MA
DA2SKQ
DWJ0KA
DWJ0KB
DW91KA
DW43KA
DW45KA
DW43KB
DW45KB
DW91KB
DHPAMA
DWK0KA
DWK0KB
DHPBMA
B@BAZK
B@BCZK
B@BAZG
B@HANS
B@BCNS
q
Defective battery relay
q
q
q
Defective fuse or fusible link
TROUBLESHOOTING
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Defective monitor panel
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
Governor pump controller
q
q
q
q
Defective sensor power supply (5 V)
q
q
q
q
Defective wiper motor
q
Defective windshield washer motor
q
Defective swing lock switch
q
q
Defective emergency pump driving switch
q
Model selector connector
q
q
q
Defective fuel control dial
q
q
q
Defective governor motor
q
q
q
Defective governor potentiometer
Possible causes
q
(including adjustment)
Error codes and failure codes and possible causes of them
q
q
Defective cold starting solenoid relay
q
Defective engine oil pressure switch
q
Defective engine oil level switch
Defective engine water temperature sensor
q
(for monitor)
q
Defective radiator water level switch
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
q
Defective air cleaner clogging switch
q
Defective alternator
q
q
Defective mechanical system of engine
q
Defective adjustment of governor lever
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
PC160LC-7
q
Defective fuel control of engine
q
Low engine oil pressure
q
Low engine oil level
PC160LC-7
q
Overheating of engine
q
Low water level in radiator sub tank
TROUBLESHOOTING
q
Clogged air cleaner
q
q
Defective PC-EPC solenoid
q
q
Defective travel junction solenoid
q
q
Defective swing holding brake solenoid
q
q
Defective pump merge-divider solenoid
q
q
Defective 2-stage relief solenoid
q
q
Defective travel speed shifting solenoid
Possible causes
q
q
Defective attachment return switching relay
Defective attachment flow rate adjustment
q
q
EPC solenoid
q
q
Defective F pump pressure sensor
q
q
Defective R pump pressure sensor
q
Defective hydraulic oil temperature sensor
q
Overheating of hydraulic oil
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
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
harness
(4)
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
20-305
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Type of power
Fuse No. Fuse capacity Destination of power
supply
Switch power supply 2 20A Cold starting solenoid relay (Coil side and contact side)
(Fusible link: A34) Attachment return switching relay (Coil side and contact side)
Cigarette lighter
4 10A
Windshield washer motor
6 10A (Spare)
10 10A (Spare)
Travel alarm
15 10A
DC/DC converter
16 10A Radio
17 20A (Spare)
Constant power Starting switch / Monitor panel
supply 18 10A
(Fusible link: A35) —
20 10A (Spare)
20-306 PC160LC-7
(4)
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 control-
ler 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 sole-
noids 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 control-
ler.
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 PC160LC-7
(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness occurred.
• Defective grounding
2 A wiring harness that is not connected with a grounding circuit has a contact with the
grounding circuit.
• Short-circuiting
Cause that presumably A wiring harness that is not connected with a 24 V electric circuit has a contact with the
triggered failure in ques- electric circuit.
tion
3 (The assigned No. is for <Precaution for Troubleshooting>
filing purpose only. It 1) Connector No. display method and handling of T-adapter
does not stand for any Insert or connect T-adapters in the following manner before starting troubleshooting
priority) 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.
4 • 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 "fe-
male".
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 fol-
lowing manner unless otherwise instructed.
• Connect the positive (+) lead with the pin No. indicated at the front or the wiring har-
5
ness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring har-
ness.
20-310 PC160LC-7
(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
PC160LC-7 20-311
(1)
TROUBLESHOOTING E101
User Code Error Code Failure Code Failure Abnormal data in error history
— E101 DAF0KT phenomenon (in Monitor Panel system)
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
• None in particular
Monitor Panel
Phenomenon
occurring on • A display for information on the failure history (in the electrical system) cannot be called.
machine
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Disconnection of wiring Between wiring harness from P01 (female) (8) to J07 to Resistance
Below 1 Ω
harness FB1-17 outlet value
3
(Disconnection or Resistance
connector contact fault) Wiring harness between FB1-17 inlet and A35 (male) (2) Below 1 Ω
value
Wiring harness between A35 (male) (1) and A23 (B termi- Resistance
Below 1 Ω
nal) value
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Grounding fault of wiring Between wiring harness between P01 (female) (8) to J07 Resistance Above
harness and FB1-17 outlet and grounding value 1 MΩ
4
(Contact with grounding Between wiring harness between FB1-17 inlet and A35 Resistance Above
circuit) (male) (2) and grounding value 1 MΩ
Between wiring harness between A35 (male) (1) and A23 Resistance Above
(B terminal) and grounding value 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
P01 Voltage
Between (8) and (6) (7) 20 – 30 V
20-312 PC160LC-7
(1)
TROUBLESHOOTING E101
PC160LC-7 20-313
(4)
TROUBLESHOOTING E112
User Code Error Code Failure Code Failure Short-circuiting in normal rotation system of wind-
— E112 DY2DKB phenomenon shield 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
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stops moving.
machine
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between (3) and (1) Continued
Between (3) and grounding Above 1 MΩ
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) (9) and Resistance
circuit) Above 1 MΩ
W04 (male) (3) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between (9) and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)
20-314 PC160LC-7
(1)
TROUBLESHOOTING E112
PC160LC-7 20-315
(1)
TROUBLESHOOTING E113
User Code Error Code Failure Code Failure Short-circuiting in reverse rotation system of wind-
— E113 DY2EKB phenomenon shield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
Failure content
windshield wiper was set in motion.
Response from
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stopped moving.
machine
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (3) Continued
Between (1) and grounding Above 1 MΩ
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) (10) and Resistance
circuit) Above 1 MΩ
W04 (male) (1) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between (10) and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)
20-316 PC160LC-7
(1)
TROUBLESHOOTING E113
PC160LC-7 20-317
(1)
TROUBLESHOOTING E114
User Code Error Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Window washer drive for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring har-
circuit) Voltage Below 1 V
ness between P01 (female) (3) and D04 (female) (8) and
grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
20-318 PC160LC-7
(4)
TROUBLESHOOTING E114
PC160LC-7 20-319
(1)
TROUBLESHOOTING E114
User Code Error Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Window washer drive for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring har-
circuit) Voltage Below 1 V
ness between P01 (female) (3) and D02 (female) (7) and
grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
20-319-1 PC160LC-7
(4)
TROUBLESHOOTING E114
PC160LC-7 20-319-2
(4)
TROUBLESHOOTING E115
User Code Error Code Failure Code Failure Abnormal operation of windshield wiper
— E115 DY20KA phenomenon (in Monitor Panel system)
Failure content • W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)
Windshield wiper motor W04 (female) Windshield wiper blade Resistance value
1 defective At upper end of operation
(Internal disconnection) Below 1 Ω
range
Between (6) and (5)
Outside upper end of
Above 1 MΩ
operation range
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring for the troubleshooting.
harness Wiring harness between P01 (female) (5) and W04 (male) Resistance
2 Below 1 Ω
(Disconnection or faulty (6) value
contact with connector) Resistance
Wiring harness between W04 (male) (5) and grounding Below 1 Ω
value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of operation
Below 1 V
range
Between (5) and grounding
Outside upper end of
20 – 30 V
operation range
20-320 PC160LC-7
(1)
TROUBLESHOOTING E115
PC160LC-7 20-321
(1)
TROUBLESHOOTING E116
User Code Error Code Failure Code Failure Abnormal operation of retracting windshield wiper
— E116 DY20MA phenomenon (in Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No. 049: Monitor Input 3)
20-322 PC160LC-7
(1)
TROUBLESHOOTING E116
PC160LC-7 20-323
(1)
TROUBLESHOOTING E201
User Code Error Code Failure Code Failure Short-circuiting in travel junction solenoid
— E201 DW91KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel junction circuit, when power was supplied to the circuit.
• Power supply to the travel junction circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on • It is difficult to steer the machine at turns. (Both travel circuits are not separated)
machine
Relative • Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code
information No. 023: Solenoid 1)
20-324 PC160LC-7
(4)
TROUBLESHOOTING E201
PC160LC-7 20-325
(1)
TROUBLESHOOTING E201
User Code Error Code Failure Code Failure Short-circuiting in travel junction solenoid
— E201 DW91KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel junction circuit, when power was supplied to the circuit.
• Power supply to the travel junction circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on • It is difficult to steer the machine at turns. (Both travel circuits are not separated)
machine
Relative • Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code
information No. 023: Solenoid 1)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Travel junction solenoid during the troubleshooting.
defective V02 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
Grounding fault of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) (7) to V02 Resistance
circuit) Above 1 Mz
(female) (1) and grounding value
aTurn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump Left and right travel
3 C03 Voltage
controller defective control lever
NEUTRAL Below 1 V
Between (7) and grounding
Steering 20 – 30 V
20-325-1 PC160LC-7
(4)
TROUBLESHOOTING E201
PC160LC-7 20-325-2
(4)
TROUBLESHOOTING E203
User Code Error Code Failure Code Failure Short-circuiting in swing holding brake solenoid
E03 E203 DW45KB phenomenon (in governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing and steering brake does not return to normal-
controller
cy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the swing holding brake releasing switch to the FREE position.
(In this case, however, the holding brake does not work, when stopping the machine)
20-326 PC160LC-7
(4)
TROUBLESHOOTING E203
PC160LC-7 20-327
(1)
TROUBLESHOOTING E203
User Code Error Code Failure Code Failure Short-circuiting in swing holding brake solenoid
E03 E203 DW45KB phenomenon (in governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing and steering brake does not return to normal-
controller
cy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the swing holding brake releasing switch to the FREE position.
(In this case, however, the holding brake does not work, when stopping the machine)
20-327-1 PC160LC-7
(4)
TROUBLESHOOTING E203
PC160LC-7 20-327-2
(4)
TROUBLESHOOTING E204
User Code Error Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(The F and R pumps are not separated)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
20-328 PC160LC-7
(4)
TROUBLESHOOTING E204
PC160LC-7 20-329
(1)
TROUBLESHOOTING E204
User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(Front and rear pumps are not separated)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Merge/divide solenoid during the troubleshooting.
defective V03 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
Grounding fault of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) (17) to V03 Resistance
circuit) Above 1 Mz
(female) (1) and grounding value
aTurn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel control lever Voltage
3
controller defective NEUTRAL Below 1 V
Between (17) and grounding When operating one side
20 – 30 V
only
20-329-1 PC160LC-7
(4)
TROUBLESHOOTING E204
PC160LC-7 20-329-2
(4)
TROUBLESHOOTING E205
User Code Error Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
20-330 PC160LC-7
(4)
TROUBLESHOOTING E205
PC160LC-7 20-331
(1)
TROUBLESHOOTING E205
User Code Error Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
2-stage relief solenoid during the troubleshooting.
defective V06 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
Grounding fault of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) (28) to V06 Resistance
circuit) Above 1 Mz
(female) (1) and grounding value
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C03 Working mode Voltage
3
controller defective
Other than L mode Below 1 V
Between (28) and grounding
L mode 20 – 30 V
20-331-1 PC160LC-7
(4)
TROUBLESHOOTING E205
PC160LC-7 20-331-2
(4)
TROUBLESHOOTING E206
User Code Error Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
— E206 DW43KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
(Internal short-circuiting
or grounding fault) 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
Assembled-type diode during the troubleshooting.
2 D04 defective
D04 (male) Resistance value (Continuity)
(Internal short-circuiting)
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
Grounding fault of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) (27) to J06 to V04
(Contact with grounding Resistance
circuit) (female) (1), or between wiring harness between C03 Above 1 Mz
value
(female) (27) and D04 (female) (2) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump Travel speed +
4 C03 Voltage
controller defective Travel control lever
Lo + Neutral Below 1 V
Between (27) and grounding
Hi + Travel operation 20 – 30 V
20-332 PC160LC-7
(4)
TROUBLESHOOTING E206
PC160LC-7 20-333
(1)
TROUBLESHOOTING E206
User Code Error Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
— E206 DW43KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Travel speed shifting during the troubleshooting.
solenoid defective V04 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
Grounding fault of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) (27) to V04 Resistance
circuit) Above 1 Mz
(female) (1) and grounding value
aTurn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump Travel speed +
3 C03 Voltage
controller defective Travel control lever
Lo + Neutral Below 1 V
Between (27) and grounding
Hi + Travel operation 20 – 30 V
20-333-1 PC160LC-7
(4)
TROUBLESHOOTING E206
PC160LC-7 20-333-2
(4)
TROUBLESHOOTING E211
User Code Error Code Failure Code Failure Disconnection in travel junction solenoid
— E211 DW91KA phenomenon (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 • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • It is difficult to steer the machine while traveling. (Both travel circuits are not separated)
machine
• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code
No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
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].)
1 solenoid defective
V02 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) (7) to J06 to V02 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Resistance
Wiring harness between V02 (female) (2) and grounding Below 1 z
value
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) (7) to J06 to V02
(Contact with 24 V cir-
cuit) (female) (1), or between wiring harness C03 (female) (7) Voltage Below 1 V
and D03 (female) (3) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (7) and grounding 20 – 60 z
20-334 PC160LC-7
(4)
TROUBLESHOOTING E211
PC160LC-7 20-335
(1)
TROUBLESHOOTING E211
User Code Error Code Failure Code Failure Disconnection in travel junction solenoid
— E211 DW91KA phenomenon (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 • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • It is difficult to steer the machine while traveling. (Both travel circuits are not separated)
machine
• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code
No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
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].)
1 solenoid defective
V02 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) (7) to J06 to V02 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness from C03 (female) (3), (13), (23) to V02 Resistance
Below 1 z
(female) (2) value
Short-circuiting of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Between wiring harness from C03 (female) (7) to V02
cuit) Voltage Below 1 V
(female) (1) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (7) and grounding 20 – 60 z
20-335-1 PC160LC-7
(4)
TROUBLESHOOTING E211
PC160LC-7 20-335-2
(4)
TROUBLESHOOTING E213
20-336 PC160LC-7
(4)
TROUBLESHOOTING E213
PC160LC-7 20-337
(1)
TROUBLESHOOTING E213
User Code Error Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (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 • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake is not released)
machine
• 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 ma-
Relative chine stops, however).
information • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the RE-
LEASE 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].)
Swing holding brake aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Below 1 z
Between (3) and (4)
Presumed cause and standard value in normalcy
ON Above 1 Mz
Assembled-type aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 defective during the troubleshooting.
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) 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.
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) (4) to V05 (female) (1) Below 1 z
value
Wiring harness from C03 (female) (3), (13), (23) to V05 Resistance
Below 1 z
(female) (2) value
Short-circuiting of aTurn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
circuit) Voltage Below 1 V
(female) (7) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
6 C03 (female) Disconnect D01 and con- Resistance value
controller defective
nect pins (3) and (7) of the
Between (37) and grounding male side. 20 – 60 z
20-337-1 PC160LC-7
(4)
TROUBLESHOOTING E213
PC160LC-7 20-337-2
(4)
TROUBLESHOOTING E214
User Code Error Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (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 • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
(The F and R pumps are not separated)
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
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].)
1 defective
V03 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) (17) to J06 to V03 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Resistance
Wiring harness between V03 (female) (2) and grounding Below 1 z
value
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) (17) to J06 to V03
(Contact with 24 V cir-
cuit) (female) (1), or between wiring harness between C03 Voltage Below 1 V
(female) (17) and D03 (female) (1) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (17) and grounding 20 – 60 z
20-338 PC160LC-7
(4)
TROUBLESHOOTING E214
PC160LC-7 20-339
(1)
TROUBLESHOOTING E214
User Code Error Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (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 • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
(The F and R pumps are not separated)
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
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].)
1 defective
V03 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (17) to V03 (female) (1) Below 1 z
value
tive contact with connec-
tor) Wiring harness from C03 (female) (3), (13), (23) to V03 Resistance
Below 1 z
(female) (2) value
Short-circuiting of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Between wiring harness from C03 (female) (17) to V03
cuit) Voltage Below 1 V
(female) (1) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (17) and grounding 20 – 60 z
20-339-1 PC160LC-7
(4)
TROUBLESHOOTING E214
PC160LC-7 20-339-2
(4)
TROUBLESHOOTING E215
User Code Error Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (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 • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
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].)
1 defective
V06 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) (28) to J06 to V06 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Resistance
Wiring harness between V06 (female) (2) and grounding Below 1 z
value
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) (28) to J06 to V06
(Contact with 24 V cir-
cuit) (female) (1), or between wiring harness between C03 Voltage Below 1 V
(female) (28) and D03 (female) (2) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (28) and grounding 20 – 60 z
20-340 PC160LC-7
(4)
TROUBLESHOOTING E215
PC160LC-7 20-341
(1)
TROUBLESHOOTING E215
User Code Error Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (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 • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
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].)
1 defective
V06 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (28) to V06 (female) (1) Below 1 z
value
tive contact with connec-
tor) Wiring harness from C03 (female) (3), (13), (23) to V06 Resistance
Below 1 z
(female) (2) value
Short-circuiting of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Between wiring harness from C03 (female) (28) to V06
cuit) Voltage Below 1 V
(female) (1) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (28) and grounding 20 – 60 z
20-341-1 PC160LC-7
(4)
TROUBLESHOOTING E215
PC160LC-7 20-341-2
(4)
TROUBLESHOOTING E216
User Code Error Code Failure Code Failure Disconnection in travel speed shifting solenoid
— E216 DW43KA phenomenon (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 • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The travel speed does not shift to Hi. (The swash plate angle of the travel motor is not minimized)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
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].)
1 solenoid defective
V04 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) (27) to J06 to V04 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Resistance
Wiring harness between V04 (female) (2) and grounding Below 1 z
value
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) (27) to J06 to V04
(Contact with 24 V cir-
cuit) (female) (1), or between wiring harness between C03 Voltage Below 1 V
(female) (27) and D04 (female) (2) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (27) and grounding 20 – 60 z
20-342 PC160LC-7
(4)
TROUBLESHOOTING E216
PC160LC-7 20-343
(1)
TROUBLESHOOTING E216
User Code Error Code Failure Code Failure Disconnection in travel speed shifting solenoid
— E216 DW43KA phenomenon (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 • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The travel speed does not shift to Hi. (The swash plate angle of the travel motor is not minimized)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
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].)
1 solenoid defective
V04 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (27) to V04 (female) (1) Below 1 z
value
tive contact with connec-
tor) Wiring harness from C03 (female) (3), (13), (23) to V04 Resistance
Below 1 z
(female) (2) value
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) (27) to J06 to V04
(Contact with 24 V cir-
cuit) (female) (1), or between wiring harness between C03 Voltage Below 1 V
(female) (27) and D04 (female) (2) and grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (27) and grounding 20 – 60 z
20-343-1 PC160LC-7
(4)
TROUBLESHOOTING E216
PC160LC-7 20-343-2
(4)
TROUBLESHOOTING E217
User Code Error Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in governor • pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC200-7).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • The engine does not output sufficient power or it stalls.
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002: Controller Model Code: No. 003)
information !Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring Wiring harness between C02 (female) (7) and C09 Resistance
harness Below 1 Ω
(male) (4) value
2 (Disconnection or defec-
Wiring harness between C02 (female) (27) and C09 Resistance
tive contact with connec- Below 1 Ω
tor) (male) (2) value
Between wiring harness between C09 (male) (8) and Resistance
Below 1 Ω
grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of wiring Between wiring harness between C02 (female) (13) and Resistance
Above 1 MΩ
harness C09 (male) (7) and grounding value
3
(Contact with grounding Between wiring harness between C02 (female) (17) and Resistance
circuit) Above 1 MΩ
C09 (male) (3) and grounding value
Between wiring harness between C02 (female) (37) and Resistance
Above 1 MΩ
C09 (male) (1) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C02 Voltage
4
controller defective
Between (13), (17), (37) and grounding 20 – 30 V
Between (7), (27) and grounding Below 1 V
20-344 PC160LC-7
(1)
TROUBLESHOOTING E217
PC160LC-7 20-345
(1)
TROUBLESHOOTING E218
User Code Error Code Failure Code Failure Disconnection in S-NET signal
— E218 DA2SKA phenomenon (in governor • pump controller system)
• A failure occurred in S-NET communication between the monitor panel and controller in the past.
Failure content
(The machine operation returned to normalcy, when the display was resumed)
• While the failure is still continuing, the machine operation is controlled by the following default setting.
1) Working mode: E mode
Response from 2) Travel speed: Lo
controller 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.
• The working mode cannot be changed. (The display changes normally in the monitor panel)
Phenomenon
• The travel speed cannot be shifted. (The display changes normally in the monitor panel)
occurring on
• The auto-decelerator cannot be released. (The display changes normally in the monitor panel)
machine
• The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel)
• 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.
Relative
• The communication has already returned to normalcy by the time this Error Code No. is displayed. But
information
thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a failure
in order to prevent recurrence of failures.
20-346 PC160LC-7
(1)
TROUBLESHOOTING E218
PC160LC-7 20-347
(1)
TROUBLESHOOTING E224
User Code Error Code Failure Code Failure Abnormality in F pump pressure sensor
— E224 DHPAMA phenomenon (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 • The controller controls the F pump pressure at 0 MPa{0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
!If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected reversely, the pressure
Relative sensor will be broken. Accordingly, take care extremely when checking.
information • Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function.
(Code No. 011: F pump pressure)
firm 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 Wiring harness from C01 (female) (22) to J07 to A51 Resistance
harness Below 1 Ω
(female) (B) value
3 (Disconnection or defec-
Wiring harness between C01 (female) (10) and A51 Resistance
tive contact with connec- Below 1 Ω
tor) (female) (A) value
Wiring harness between C01 (female) (8) and A51 Resistance
Below 1 Ω
(female) (C) value
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) (8) and Resistance
circuit) Above 1 MΩ
A51 (female) (C) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness Between wiring harness between C01 (female) (22) to
5 Voltage Below 1 V
(Contact with 24 V cir- J07 and A51 (female) (B) and grounding
cuit) Between wiring harness between C01 (female) (8) and
Voltage Below 1 V
A51 (female) (C) ang grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Governor • pump C01 Voltage
6
controller defective
Between (22) and (10) Power source 4.5 – 5.5 V
Between (8) and (10) Signal 0.5 – 4.5 V
20-348 PC160LC-7
(1)
TROUBLESHOOTING E224
PC160LC-7 20-349
(1)
TROUBLESHOOTING E225
User Code Error Code Failure Code Failure Abnormality in R pump pressure sensor
— E225 DHPBMA phenomenon (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 • The controller controls the R pump pressure as 0 MPa {0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
!If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected reversely, the pressure
Relative sensor will be broken. Accordingly, take care extremely when checking.
information • Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function.
(Code No. 012: R pump pressure)
firm 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 Wiring harness from C01 (female) (22) to J07 and A52 Resistance
harness Below 1 Ω
(female) (B) value
3 (Disconnection or defec-
Wiring harness between C01 (female) (10) and A52 Resistance
tive contact with connec- Below 1 Ω
tor) (female) (A) value
Wiring harness between C01 (female) (2) and A52 Resistance
Below 1 Ω
(female) (C) value
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) (2) and Resistance
circuit) Above 1 MΩ
A52 (female) (C) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness Between wiring harness between C01 (female) (22) to
5 Voltage Below 1 V
(Contact with 24 V cir- J07 and A52 (female) (B) and grounding
cuit) Between wiring harness between C01 (female) (2) and
Voltage Below 1 V
A52 (female) (C) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Governor • pump C01 Voltage
6
controller defective
Between (22) and (10) Power source 4.5 – 5.5 V
Between (2) and (10) Signal 0.5 – 4.5 V
20-350 PC160LC-7
(1)
TROUBLESHOOTING E225
PC160LC-7 20-351
(1)
TROUBLESHOOTING E226
Error Code in Electrical System E226 (Abnormality in pressure sensor power source)
User Code Error Code Failure Code Failure Abnormality in pressure sensor power source
— E226 DA25KP phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.
• The controller turns OFF power supply to the power source circuit (5 V).
Response from
• Even when the failure cause disappears of itself, the current does not return to normalcy, unless the en-
controller
gine starting switch is once turned OFF.
Phenomenon • Signals from the pressure sensors and potentiometer are not inputted correctly.
occurring on • The Error Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at
machine the same time.
20-352 PC160LC-7
(1)
TROUBLESHOOTING E226
PC160LC-7 20-353
(1)
TROUBLESHOOTING E227
User Code Error Code Failure Code Failure Abnormality in engine rotation sensor
— E227 DLE2MA phenomenon (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 • The controller exercises a control equivalent to E mode.
controller • If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on • The machine lacks power a bit. (The engine speed cannot be sensed)
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine RPM)
20-354 PC160LC-7
(1)
TROUBLESHOOTING E227
PC160LC-7 20-355
(1)
TROUBLESHOOTING E228
User Code Error Code Failure Code Failure Short-circuiting in attachment return switching relay
— E228 D196KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from • The controller turned OFF power to the attachment return switching relay circuit.
controller • Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
• The hydraulic circuit for attachments is not switched to the single operation circuit.
occurring on
(The selector valve is not switched to the tank circuit)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No. 024:Solenoid 2)
information • 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).
Attachment return !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
switching relay defective during the troubleshooting.
1
(Internal short-circuiting R20 (male) Resistance value
or grounding fault) Between (1) and (2) 100 – 500 Ω
Short-circuiting of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
2
(Contact with 24 V cir- Between wiring harness between C02 (female) (8) and
cuit) Voltage Below 1 V
R20 (female) (2) and grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C02 Working mode Voltage
3
controller defective Other than B mode 20 – 30 V
Between (8) and grounding
B mode Below 1 V
20-356 PC160LC-7
(1)
TROUBLESHOOTING E228
PC160LC-7 20-357
(1)
TROUBLESHOOTING E232
User Code Error Code Failure Code Failure Short-circuiting in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the PC-EPC solenoid circuit.
• The controller reduces the output to the PC-EPC solenoid circuit to OFF.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative • If the solenoid and wiring harness are free from abnormality, the machine can be operated with the out-
information put 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.
or grounding fault)
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.
Defective emergency
pump driving switch Emergency pump
2 S25 (male) Resistance value
(Internal short-circuiting driving switch
or grounding fault) Between (3) and (4) Above 1 MΩ
Normal
Between (3) and grounding Above 1 MΩ
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of wiring during the troubleshooting.
harness Between wiring harness from C03 (female) (16) to S25 Resistance
3 Above 1 MΩ
(Contact with grounding (female) (3) and grounding value
circuit) Between wiring harness from S25 (female) (2) to V21 Resistance
Above 1 MΩ
(female) (1) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump C03 (female) Resistance value
4
controller defective
Between (16) and (3) (13) (23) 7 – 14 Ω
Between (16) and grounding Above 1 MΩ
20-358 PC160LC-7
(1)
TROUBLESHOOTING E232
PC160LC-7 20-359
(1)
TROUBLESHOOTING E233
User Code Error Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the PC-EPC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative
• If the solenoid and wiring harness are free from abnormality, the machine can be operated with the out-
information
put 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.
Normal
(Internal disconnection) Between (2) and (3)
Emergency Above 1 MΩ
Normal Below 1 Ω
Between (5) and (6)
Emergency Above 1 MΩ
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Resistance
Disconnection of wiring Wiring harness between C03 (female) (16) and S21 (3) Below 1 Ω
value
harness
Resistance
3 (Disconnection or defec- Wiring harness between S21 (2) and V21 (female) (1) Below 1 Ω
value
tive contact with connec-
tor) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Below 1 Ω
S25 (female) (6) value
Wiring harness between S25 (female) (5) and V21 Resistance
Below 1 Ω
(female) (2) value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness Between wiring harness between C03 (female) (16) and
4 Voltage Below 1 V
(Contact with 24 V cir- S25 (female) (3) and grounding
cuit) Between wiring harness between S25 (female) (2) and
Voltage Below 1 V
V21 (female) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
5
controller defective C03 (female) Resistance value
Between (16) and (3) (13) (23) 7 – 14 Ω
20-360 PC160LC-7
(1)
TROUBLESHOOTING E233
PC160LC-7 20-361
(1)
TROUBLESHOOTING E238
User Code Error Code Failure Code Failure Disconnection in attachment return switching relay
— E238 D196KA phenomenon (in governor • pump controller system)
• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24 V
Failure content
voltage is not generated.
Response from • None in particular
controller • If the failure cause disappears, the governor returns to normalcy.
Phenomenon
• The hydraulic circuit for attachments cannot be switched to the single operation
occurring on
(The selector valve is not switched to the tank circuit)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No. 024:Solenoid 2)
information • 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).
20-362 PC160LC-7
(1)
TROUBLESHOOTING E238
PC160LC-7 20-363
(1)
TROUBLESHOOTING E245
User Code Error Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
— E245 DXE4KB phenomenon EPC solenoid (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
• The controller turns OFF power to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • The attachments do not move. (The PPC basic pressure is not supplied to the service PPC valve)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Attachment oil flow rate
during the troubleshooting.
adjusting EPC solenoid
1 defective V30 (male) Resistance value
(Internal short-circuiting Between (1) and (2) 7 – 14 Ω
or grounding fault)
Between (1) and grounding Above 1 MΩ
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness between C03 (female) (26) and Resistance
circuit) Above 1 MΩ
V30 (female) (1) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump C03 (female) Resistance value
3
controller defective
Between (26) and (3) (13) (23) 7 – 14 Ω
Between (26) and grounding Above 1 MΩ
20-364 PC160LC-7
(1)
TROUBLESHOOTING E246
User Code Error Code Failure Code Failure Disconnection in attachment oil flow rate adjusting
— E246 DXE4KA phenomenon EPC solenoid (in governor • pump controller system)
Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from • None in particular (The solenoid does not work, as there is no current flowing to it)
controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
occurring on • The attachments do not move. (The PPC basic pressure is not supplied to the service PPC valve)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
PC160LC-7 20-365
(1)
TROUBLESHOOTING E306
User Code Error Code Failure Code Failure Abnormality in governor potentiometer
— E306 DK54KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
• The controller exercises control by computing the motor position through voltage right before a failure
Response from occurred.
controller • 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.
• 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)
Phenomenon
• The auto-decelerator or automatic warming-up function does not work.
occurring on
• There is hunting while the engine is running.
machine
• The engine stalls.
• The engine does not stop.
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: Governor potentiometer voltage)
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to E10 Resistance
harness Below 1 Ω
(female) (A) value
3 (Disconnection or defec-
Wiring harness between C01 (female) (21) and E10 Resistance
tive contact with connec- Below 1 Ω
tor) (female) (C) value
Wiring harness between C01 (female) (13) and E10 Resistance
Below 1 Ω
(female) (B) value
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) (13) and Resistance
circuit) Above 1 MΩ
E10 (female) (B) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness Between wiring harness from C01 (female) (22) to J07 to
5 Voltage Below 1 V
(Contact with 24 V cir- E10 (female) (A) and grounding
cuit) Between wiring harness between C01 (female) (13) and
Voltage Below 1 V
E10 (female) (B) and grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C01 Resistance value
6
controller defective
Between (22) and (21) Power sourse 4.5 – 5.5 V
Between (13) and (21) Signal 0.5 – 4.5 V
20-366 PC160LC-7
(1)
TROUBLESHOOTING E306
PC160LC-7 20-367
(1)
TROUBLESHOOTING E308
User Code Error Code Failure Code Failure Abnormality in fuel dial
E05 E308 DK10KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
• The controller exercises control by computing the fuel dial position through voltage right before a failure
Response from
occurred.
controller
• If the failure cause disappears, the fuel dial returns to normalcy.
• If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL.
Phenomenon
• If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL.
occurring on
• There is hunting while the engine is running.
machine
• The engine cannot attain the specified rotation at high idling and lacks power.
Relative • Input from the fuel dial (voltage) can be confirmed in the monitor function.
information (Code No. 030: Fuel dial voltage)
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to E06 Resistance
harness Below 1 Ω
(female) (1) value
3 (Disconnection or defec-
Wiring harness between C01 (female) (21) and E06 Resistance
tive contact with connec- Below 1 Ω
tor) (female) (3) value
Wiring harness between C01 (female) (19) and E06 Resistance
Below 1 Ω
(female) (2) value
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) (19) and Resistance
circuit) Above 1 MΩ
E06 (female) (2) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness Between wiring harness from C01 (female) (22) to J07 to
5 Voltage Below 1 V
(Contact with 24 V cir- E06 (female) (1) and grounding
cuit) Between wiring harness between C01 (female) (19) and
Voltage Below 1 V
E06 (female) (2) and grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C01 Resistance value
6
controller defective
Between (22) and (21) Power sourse 4.5 – 5.5 V
Between (19) and (21) Signal 0.5 – 4.5 V
20-368 PC160LC-7
(1)
TROUBLESHOOTING E308
PC160LC-7 20-369
(1)
TROUBLESHOOTING E311
Error Code in Electrical System E311 (Short-circuiting in cold starting solenoid relay)
User Code Error Code Failure Code Failure Short-circuiting in cold starting solenoid relay
— E311 D199KB phenomenon (in governor•pump controller system)
Failure content • Abnormal current flowed when the cold starting solenoid relay circuit was grounded (power ON).
• The controller turns OFF power to the cold starting solenoid relay circuit.
Response from
• Even when the failure cause disappears, the current does not return to normalcy, unless the engine
controller
starting switch is once turned OFF.
Phenomenon
• The engine does not start easily or at all when temperature is low.
occurring on
(The fuel injection pump rack does not move in the increasing direction.)
machine
Relative • This error code detects abnormality on the primary side (coil side) of the cold starting solenoid relay but
information does not detect abnormality on the secondary side (contact side).
Cold starting solenoid !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
relay defective during the troubleshooting.
1
(Internal short-circuiting R22 (male) Resistance value
or grounding fault) Between (1) and (2) 100 – 500 Ω
Short-circuiting of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
2
(Contact with 24 V cir- Between wiring harness between C02 (female) (9) and
cuit) Voltage Below 1 V
R22 (female) (2) and grounding
!Turn the engine starting switch OFF for the preparations, and perform troubleshooting
when turning it ON.
C02 Engine water temperature Voltage
Governor • pump
3 20 – 30 V
controller defective Below 0°C
(for 3 sec at max)
Between (9) and grounding
0°C or higher Below 1 V
20-370 PC160LC-7
(1)
TROUBLESHOOTING E311
PC160LC-7 20-371
(4)
TROUBLESHOOTING E312
Error Code in Electrical System E312 (Disconnection in cold starting solenoid relay)
User Code Error Code Failure Code Failure Disconnection in cold starting solenoid relay
— E312 D199KA phenomenon (in governor • pump controller system)
• When the cold starting solenoid relay is disconnected from grounding (power OFF), 24 V voltage is not
Failure content
generated.
Response from • None in particular.
controller • If the failure cause disappears, the voltage returns to normalcy.
Phenomenon
• The engine does not start easily or at all when temperature is low.
occurring on
(The fuel injection pump rack does not move in the increasing direction.)
machine
Relative • This error code detects abnormality on the primary side (coil side) of the cold starting solenoid relay but
information does not detect abnormality on the secondary side (contact side).
20-372 PC160LC-7
(1)
TROUBLESHOOTING E312
PC160LC-7 20-373
(4)
TROUBLESHOOTING E315
User Code Error Code Failure Code Failure Short-circuiting in battery relay
— E315 D110KB phenomenon (in governor • pump controller)
Failure content • Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.
• The controller turns OFF power to the battery drive circuit.
Response from
• Even when the failure cause disappears, the relay does not return to normalcy, unless the engine start-
controller
ing switch is once turned OFF.
Phenomenon
occurring on • The engine does not stop. (The controller power cannot be maintained until the engine stops)
machine
Relative • It can be confirmed in the monitor function how the battery relay works (ON or OFF).
information (Code No. 037: Controller output)
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Battery relay defective Battery relay (Unit) Resistance value
1
(Internal failure) Between A21 (BR terminal) and A20 (E
Approx. 100 Ω
terminal)
Between A21 (BR terminal) and grounding Above 1 MΩ
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) (4) to D01 to Resistance
circuit) Above 1 MΩ
J01 to A21 (BR terminal) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump
3 C03 (female) Engine starting switch Voltage
controller defective
20 – 30 V
Between (4) and grounding ON → OFF
(for 4 to 7 seconds)
20-374 PC160LC-7
(1)
TROUBLESHOOTING E315
PC160LC-7 20-375
(1)
TROUBLESHOOTING E316
User Code Error Code Failure Code Failure Step-out in governor motor
— E316 DY10K4 phenomenon (in governor • pump controller)
Failure content • There is a big difference between signals from the potentiometer and the set values in the controller.
• The controller repeats the same controlling motions (step-out).
Response from
• Even when the failure cause disappears, the governor motor does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon • The engine rotation cannot be controlled.
occurring on • There is hunting in the rotation.
machine • The engine does not stop.
2 Governor potentiometer system defective If Service Code [E306] is displayed, troubleshoot that failure first.
Governor motor system defective
value in normalcy
20-376 PC160LC-7
(1)
TROUBLESHOOTING E317
Error Code in Electrical System E317 (Disconnection in governor motor Phase A and B)
User Code Error Code Failure Code Failure Disconnection in governor motor Phase A and B
E05 E317 DY10KA phenomenon (in governor • pump controller)
Failure content • No current flew to the governor motor, when power was supplied to the motor.
Response from • None in particular.
controller • If the failure cause disappears, the governor returns to normalcy.
• The engine rotation drops to low idling.
Phenomenon
• There is hunting in the rotation
occurring on
• The engine does not stop.
machine
• The governor motor steps out.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
1 tive
(Internal disconnection) Between (1) and (2) 2.5 – 7.5 Ω
Between (3) and (4) 2.5 – 7.5 Ω
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between C03 (female) (5) and E11 Resistance
Disconnection of wiring Below 1 Ω
(female) (1) value
harness
Wiring harness between C03 (female) (15) and E11 Resistance
2 (Disconnection or defec- Below 1 Ω
(female) (2) value
tive contact with connec-
tor) Wiring harness between C03 (female) (25) and E11 Resistance
Below 1 Ω
(female) (3) value
Wiring harness between C03 (female) (35) and E11 Resistance
Below 1 Ω
(female) (4) value
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump C03 (female) Resistance value
3
controller defective
Between (5) and (15) 2.5 – 7.5 Ω
Between (25) and (35) 2.5 – 7.5 Ω
PC160LC-7 20-377
(1)
TROUBLESHOOTING E317
20-378 PC160LC-7
(1)
TROUBLESHOOTING E318
User Code Error Code Failure Code Failure Short-circuiting in governor motor Phase A and
E05 E318 DY10KB phenomenon 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 • None in particular
controller • If the failure cause disappears, the governor motor returns to normalcy.
• The engine rotation cannot be controlled.
Phenomenon
• The engine rotation drops to low idling.
occurring on
• There is hunting in the rotation.
machine
• The engine does not stop.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
20-380 PC160LC-7
(1)
TROUBLESHOOTING E318
PC160LC-7 20-381
(1)
TROUBLESHOOTING A000N1 / A000N2
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling)
User Code Error Code Failure Code Failure Out-of-rate engine rotation at high idling
— — A000N1 phenomenon (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 • None in particular
controller • If the failure cause disappears of itself, the engine rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if is used continuously without adjustment.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)
User Code Error Code Failure Code Failure Out-of-rate engine rotation at low idling
— — A000N2 phenomenon (in mechanical system)
Failure content • Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
Response from • None in particular
controller • If the failure cause disappears of itself, the rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without adjustment.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)
20-382 PC160LC-7
(1)
TROUBLESHOOTING AA10NX
User Code Error Code Failure Code Failure Air cleaner clogged
— — AA10NX phenomenon (in mechanical system)
• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
• This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative panel while the engine is running.
information • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)
normal condition)
!Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Air cleaner clogging
2 switch defective A31 (male) Air cleaner Resistance value
(Internal disconnection) When in normal condition Below 1 Ω
Between (1) and (2)
When clogged Above 1 MΩ
!Turn the engine starting switch OFF for the preparations, and hold it running during the
Disconnection of wiring troubleshooting.
harness
Wiring harness between P02 (female) (5) and A31 Resistance
3 (Disconnection or defec- Below 1 Ω
(female) (1) value
tive contact with connec-
tor) Resistance
Between wiring harness A31 (female) (2) and grounding Below 1 Ω
value
!Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective P02 Air cleaner Voltage
When in normal condition Below 1 V
Between (5) and grounding
When clogged 20 – 30 V
PC160LC-7 20-383
(1)
TROUBLESHOOTING AB00KE
User Code Error Code Failure Code Failure Abnormally lowered charging voltage
— — AB00KE phenomenon (in mechanical system)
Failure content • Generation signal from the alternator is not inputted, while the engine is running.
Response from
• None in particular
controller
Phenomenon
• There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
• If the charge monitor of the monitor panel lights up in red while the engine is running, this failure code
Relative is recorded.
information • Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)
1
(short generating output) E12 (male) Engine rotation Voltage
Between (1) and grounding Above medium speed 27.5 – 29.5 V
Disconnection of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2 (Disconnection or defec-
Wiring harness from P02 (female) (11) to J02 to E12 Resistance
tive contact with connec- Below 1 Ω
tor) (female) (1) 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 Between each wiring harness between C02 (female) (11),
3 J02, and E12 (female) (1), between C02 (female) (11) and
(Contact with grounding Resistance
circuit) A27 (female) (2), between C02 (female) (11) and D01 Above 1 MΩ
value
(female) (6), and between C02 (female) (11) and other
related circuits and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective
P02 Engine rotation Voltage
Between (11) and grounding Above medium speed 27.5 – 29.5 V
20-384 PC160LC-7
(1)
TROUBLESHOOTING AB00KE
PC160LC-7 20-385
(1)
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)
User Code Error Code Failure Code Failure Abnormally lowered engine oil pressure
— — B@BAZG phenomenon (in mechanical system)
• The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
Failure content
engine was running.
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine may seize, if the engine is kept running without corrective action.
machine
• If the engine oil pressure monitor of the monitor panel lights up in red while the engine is running, this
Relative failure code is recorded.
information • Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 046: Monitor input 2)
20-386 PC160LC-7
(1)
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code Error Code Failure Code Failure Abnormally lowered engine oil level
— — B@BAZK phenomenon (in mechanical system)
• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
Failure content
engine is stopped (with the starting switch in the ON position).
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
• If the engine oil level monitor of the monitor panel lights up in red while the engine is stopped (with the
Relative starting switch in ON position), this failure code is recorded.
information • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 Engine oil level Voltage
When in normal condition Below 1 V
Between (8) and grounding
When lowered 20 – 30 V
PC160LC-7 20-387
(1)
TROUBLESHOOTING B@BCNS
User Code Error Code Failure Code Failure Engine cooling water overheated
— — B@BCNS phenomenon (in mechanical system)
Failure content • The engine cooling water sensor inputted a signal of 102°C, while the engine was running.
Response from
• Response from controller
controller
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• If the engine water temperature monitor of the monitor panel lights up in red while the engine is running,
Relative this failure code is recorded.
information • Input from the engine cooling water temperature sensor (temperature) can be confirmed in the monitor
function. (Code No. 041: Engine cooling water temperature)
20-388 PC160LC-7
(1)
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level)
User Code Error Code Failure Code Failure Abnormally lowered radiator water level
— — B@BCZK phenomenon (in mechanical system)
Failure content • The signal circuit in the radiator water level switch was opened (i.e. disconnected from grounding).
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• If the radiator water level monitor of the monitor panel lights up in red while the engine is stopped (with
Relative the starting switch in ON position), this failure code is recorded.
information • Input from the radiator water level switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 045: Monitor input 1)
normal condition)
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Radiator water level
2 switch defective A33 (male) Sub-tank water level Resistance value
(Internal disconnection) When in normal condition Below 1 Ω
Between (1) and (2)
When lowered Above 1 MΩ
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness between P02 (female) (3) and A33 (female) Resistance
3 (Disconnection or defec- Below 1 Ω
(1) value
tive contact with connec-
tor) Resistance
Wiring harness between A33 (female) (2) and grounding Below 1 Ω
value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 Sub-tank water level Resistance value
When in normal condition Below 1 V
Between (3) and grounding
When lowered 20 – 30 V
Electrical Circuit Diagram for Radiator Water Level Switch in Monitor Panel
PC160LC-7 20-389
(1)
TROUBLESHOOTING B@HANS
20-390 PC160LC-7
(1)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
PC160LC-7 20-401
(4)
TROUBLESHOOTING BEFORE CONDUCTING E-MODE TROUBLESHOOTING
Type of power
Fuse No. Fuse capacity Destination of power
supply
Switch power supply 2 20A Cold starting solenoid relay (Coil side and contact side)
(Fusible link: A34) Attachment return switching relay (Coil side and contact side)
Cigarette lighter
4 10A
Windshield washer motor
6 10A (Spare)
10 10A (Spare)
11 20A Air conditioner unit
Travel alarm
15 10A
DC/DC converter
16 10A Radio
17 20A (Spare)
Constant power Engine starting switch / Monitor panel
supply 18 10A
(Fusible link: A35) —
20 10A (Spare)
20-402 PC160LC-7
(4)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
Presumed cause and standard value in normalcy
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
PC160LC-7 20-403
(1)
TROUBLESHOOTING E-1
Failure
• Engine does not start. (1) Engine does not turn.
information
• The engine starting circuit has the following 2 starting lock mechanisms.
Relative
1) Starting lock by password of monitor panel
information
2) Starting lock by safety lock lever
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Starting motor cut-off during the troubleshooting.
relay R11 or R13 R11 (female), R13 (female) Resistance value
5 defective
Between (1) and (2) 100 – 500 z
(Internal disconnec-
tion or short-circuit) 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
Relay terminal A27 Voltage/Resistance value
starting switch
Power
Between B and grounding 20 – 30 V
source
Starting motor safety Between E and grounding GND Below 1 z
6 relay defective Between A27 (2) and ground- Generation
(Internal failure) Below 1 V
ing signal START
Between A27 (1) and ground- Starting
20 – 30 V
ing input
Starting out-
Between C and grounding 20 – 30 V
put
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 motor Voltage
starting switch
Starting motor
Power
7 defective Between B and grounding 20 – 30 V
source
(Internal failure) START
Starting
Between C and grounding 20 – 30 V
signal
If the power source and starting signal are normal but the starting motor does not rotate, the
starting motor is defective.
20-404 PC160LC-7
(4)
TROUBLESHOOTING E-1
Wiring harness between FB1-3 outlet and S14 (male) (1) Below 1 Ω
value
Resistance
Wiring harness between S14 (male) (3) and R11 (female) (1) Below 1 Ω
value
Resistance
Wiring harness between R11 (female) (2) and R13 (female) (6) Below 1 Ω
value
Wiring harness between R13 (female) (3) and J04 and Resistance
Below 1 Ω
grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between FB1-18 outlet and H15 Resistance
Above 1 MΩ
(female) (1) and grounding value
Between wiring harness from H15 (female) (4) to J01 and
R11 (female) (5), or H15 (female) (4) and P01 (female) (4), or Resistance
Above 1 MΩ
H15 (female) (4) and C01 (female) (17), or H15 (female) (4) value
to other relative circuits and grounding
Grounding fault of
wiring harness Between wiring harness between R11 (female) (3) and A27 Resistance
10 Above 1 MΩ
(Contact with (female) (1) and grounding value
grounding circuit) Between wiring harness between starting motor safety relay Resistance
Above 1 MΩ
C and starting motor C and grounding value
Between wiring harness between FB1-3 outlet and S14 (male) Resistance
Above 1 MΩ
(1) and grounding value
Between wiring harness between S14 (male) (3) and R11 Resistance
Above 1 MΩ
(female) (1) and grounding value
Between wiring harness from P02 (female) (14) to J05 and Resistance
Above 1 MΩ
R13 (female) (2) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuit of wiring ing the troubleshooting.
harness Between wiring harness from A27 (female) (2) and E12
11
(Contact with 24 V (female) (1), or A27 (female) (2) to J02 and D01 (female) (6),
circuit) Voltage Below 1 V
or A27 (female) (2) and P02 (female) (11), or A27 (female) (2)
to other relative circuits and grounding
PC160LC-7 20-405
(1)
TROUBLESHOOTING E-1
20-406 PC160LC-7
(1)
TROUBLESHOOTING E-1
Failure (2) Engine does not start easily or at all at low tem-
• Engine does not start.
information perature.
• If the engine starting switch is turned ON when temperature is low (Engine water temperature: Below
Relative 0°C), the cold start solenoid is turned ON to increase the fuel injection rate.
information • 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.
Cold start solenoid !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
defective
4
(Internal disconnec- V07 (Unit) Resistance value
tion or short-circuit) Between terminal and solenoid body 7.7 ± 0.3 Ω
Presumed cause and standard value in normalcy
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
5 (Disconnection or Wiring harness from FB1-2 outlet to J03 and R22 (female) (3) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between R22 (female) (5) and V07 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 Between wiring harness between C01 (female) (20) and E12 Resistance
Above 1 MΩ
wiring harness (female) (B) and grounding value
6
(Contact with Between wiring harness from FB1-2 outlet to J03, to R22 Resistance
grounding circuit) Above 1 MΩ
(female) (3), and to other relative circuits and grounding value
Between wiring harness between R22 (female) (5) and V07 Resistance
Above 1 MΩ
and grounding value
!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)
Engine water temperature Resistance value
P02 (female)
Between C01 (20) and P02 - 30 – 0°C 57 k – 10 kΩ
(13) 5 – 100°C 10 k – 0.3 kΩ
Between C01 (20) and
- 30 – 100°C 57 k – 0.3 kΩ
grounding
Governor • pump
7 !Turn the engine starting switch OFF for the preparations, and conduct troubleshooting
controller defective
when it is turned from the OFF position to the ON position (Troubleshooting on the output
side).
C02 Engine water temperature Voltage
Below 0°C 20 – 30 V
Between (9) and grounding (or disconnect E12) (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 abnor-
mal, the controller is defective.
PC160LC-7 20-407
(1)
TROUBLESHOOTING E-1
20-408 PC160LC-7
(4)
TROUBLESHOOTING E-2
Failure
• Engine stops while in operation. Engine stops while in operation.
information
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: governor potentiometer voltage)
Grounding fault of !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3
(Contact with Between wiring harness between C01 (female) (13) and E10 Resistance
grounding circuit) Above 1 MΩ
(female) (B) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C01 Voltage
4
controller defective
Between (22) and (21) 4.5 – 5.5 V
Between (13) and (21) 0.5 – 4.5 V
PC160LC-7 20-409
(1)
TROUBLESHOOTING E-3
If the monitoring display is abnormal, conduct troubleshooting for error code [E217].
Defective adjustment
2 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, gov-
3 ernor 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
4 See Shop Manual for 102 Series Engine.
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.
5 (Disconnection or
Wiring harness from C01 (female) (23) to J07 and H15 Resistance
defective contact Below 1 Ω
with connector) (female) (5) 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.
6
(Contact with Between wiring harness from C01 (female) (23) to J07 and Resistance
grounding circuit) Above 1 MΩ
H15 (female) (5) and to other relative circuits and grounding value
Governor • pump As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
7
controller defective causes listed in Item 1 through 6, the controller is judged as defective.)
20-410 PC160LC-7
(1)
TROUBLESHOOTING E-3
PC160LC-7 20-411
(1)
TROUBLESHOOTING E-4
Failure
• Engine does not stop.
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
Relative
until the engine stops.
information
• It can be confirmed in the monitor function how the battery relay works (ON or OFF)
(Code No. 037: Controller output)
Assembled-type !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 fault during the troubleshooting.
2
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) 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 wir- Resistance
ing harness Wiring harness between C03 (female) (4) and D01 (female) (5) Below 1 Ω
value
3 (Disconnection or
Resistance
defective contact Wiring harness from D01 (female) (1) to J01 and A21 (BR) Below 1 Ω
with connector) value
Resistance
Wiring harness between A20 (E1) and grounding Below 1 Ω
value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump
4 C03 Engine starting switch Voltage
controller defective
20 – 30 V
Between (4) and grounding ON→OFF
(for 4 to 7 seconds)
20-412 PC160LC-7
(1)
TROUBLESHOOTING E-4
PC160LC-7 20-413
(1)
TROUBLESHOOTING E-5
Failure
• Auto-decelerator does not work.
information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
Relative
auto-decelerator does not work.
information
• Confirm the display on the monitor panel, when the engine is running.
20-414 PC160LC-7
(1)
TROUBLESHOOTING E-6
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C,
Relative and raise the engine rotation up to 1,200 rpm.
information • 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.
PC160LC-7 20-415
(1)
TROUBLESHOOTING E-7
1
tem defective troubleshooting (2).
Disconnection of wir- !Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
value in normalcy
Continuity • Resistance
tive Heater relay Starting switch
2 value
(Internal disconnec-
value in normalcy
Intake air heater !Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
defective tion during the troubleshooting.
3
(Internal disconnec- Intake air heater Continuity
tion) Between E01 and grounding There is continuity
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Disconnection of wir- Resistance
ing harness Wiring harness from H15 (female) (3) to J02 and A25 Below 1 Ω
value
4 (Disconnection or
Resistance
defective contact Wiring harness between A22 and heater relay Below 1 Ω
with connector) value
Resistance
Between A26 and E01 Below 1 Ω
value
20-416 PC160LC-7
(1)
TROUBLESHOOTING E-7
PC160LC-7 20-417
(1)
TROUBLESHOOTING E-8
Failure
• All work equipment, swing and travel do not move.
information
Relative
—
information
Assembled-type aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 fault during the troubleshooting.
4
(Internal short-cir- D01 (male) Resistance value
cuiting) 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 wir- Resistance
ing harness Wiring harness between FB1-3 outlet and S14 (male) (1) Below 1 z
value
5 (Disconnection or
defective contact Resistance
Wiring harness from S14 (male) (2) to J02 and V01 (female) (1) Below 1 z
with connector) value
Resistance
Wiring harness between V01 (female) (2) and grounding Below 1 z
value
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of during the troubleshooting.
wiring harness Between wiring harness between FB1-3 outlet and S14 Resistance
Above 1 Mz
6 (Contact with (male) (1) and grounding value
grounding (GND) Wiring harness from S14 (male) (2) to J02 and V01 (female)
circuit) Resistance
(1), or between wiring harness between S14 (male) (2) and Above 1 Mz
value
D01 (female) (4) and grounding
20-418 PC160LC-7
(4)
TROUBLESHOOTING E-8
PC160LC-7 20-419
(4)
TROUBLESHOOTING E-9
Failure
• One-touch power max. switch does not work.
information
• If the one-touch power max switch is pressed while the engine is running in mode A or E, the one-touch
Relative power max monitor is displayed on the monitor panel.
information • Input from the one-touch power max. switch (left knob switch) can be confirmed in the monitor function.
(Code No. 022: Switch input 1)
2
(Internal disconnec-
tion) Release Above 1 MΩ
Between (1) and (2)
Depress Below 1 Ω
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
3 (Disconnection or Wiring harness between FB1-9 outlet and M23 (female) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between M23 (female) (2) and C01 (female) (11) Below 1 Ω
value
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of during the troubleshooting.
wiring harness
Between wiring harness between FB1-9 outlet and M23 Resistance
4 (Contact with Above 1 MΩ
(female) (1) and grounding value
grounding (GND)
circuit) Between wiring harness between M23 (female) (2) and C01 Resistance
Above 1 MΩ
(female) (11) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C01 One-touch power max. switch Voltage
5
controller defective
Release Below 1 V
Between (11) and grounding
Depress 20 – 30 V
20-420 PC160LC-7
(1)
TROUBLESHOOTING E-10
PC160LC-7 20-421
(1)
TROUBLESHOOTING E-11
Failure • No display in monitor panel at all • When the engine starting switch is turned ON,
information there appears no display at all in the monitor panel.
Relative
—
information
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness from P01 (female) (1) (2) to J07 to FB1-12 Below 1 z
value
defect contact with
connector) Resistance
Wiring harness between P01 (female) (6) (7) and grounding Below 1 z
value
Grounding fault of aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness from P01 (female) (1) (2) to J07 to Resistance
Above 1 Mz
circuit) FB1-12 outlet and grounding value
20-422 PC160LC-7
(4)
TROUBLESHOOTING E-11
PC160LC-7 20-422-1
(4)
TROUBLESHOOTING E-12, E-13
Monitor panel LCD When the switch is operated as follows, if the all panel LCD goes off (if the all screen
1
defective becomes white), the monitor panel LCD is normal.
• Press switches [ ] + [ A ] simultaneously.
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is none of
2
defective the causes listed above, the monitor panel is judged as defective.)
Failure
• Contents of monitor panel are different from mounted model.
information
Relative
—
information
PC160LC-7 20-423
(1)
TROUBLESHOOTING E-14
Failure
• Fuel level monitor lights up in red while engine is running.
information
• If the fuel level gauge of the monitor panel enters the red range, the fuel level monitor lights up in red.
Relative
• Input (Voltage) from the fuel level sensor can be confirmed in the monitor function.
information
(Code No. 042: Fuel level sensor voltage)
1 Check the fuel level in the fuel tank and add fuel, if necessary.
(System is normal)
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Fuel level sensor during the troubleshooting.
defective A60 (male) Fuel level Resistance value
2
(Internal disconnec-
tion) FULL (Upper limit) Approx. 12 Ω
Between (1) and grounding
EMPTY (Lower limit) 85 – 110 Ω
Disconnection of !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Disconnection or
Wiring harness between P02 (female) (2) and A60 (female) Resistance
defective contact Below 1 Ω
with connector) (1) value
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel P02 (female) Fuel level Resistance value
4
defective
FULL (Upper limit) Approx. 12 Ω
Between (2) and grounding
EMPTY (Lower limit) 85 – 110 Ω
20-424 PC160LC-7
(1)
TROUBLESHOOTING E-15
E-15 Engine cooling water temperature gauge does not indicate correctly
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) (1) and E05 (female) (2) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between P02 (female) (13) and E05 (female) (1) Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (1) and E05 Resistance
Above 1 MΩ
circuit) (female) (2) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) (1) and E05
circuit) Voltage Below 1 V
(female) (2) and grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel Engine cooling water
5 P02 (female) Resistance value
defective temperature
Between (1) and (13) 90 – 3.5 kΩ
10 – 100 °C
Between (1) and grounding 90 – 3.5 kΩ
PC160LC-7 20-425
(1)
TROUBLESHOOTING E-16
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) (12) and A61 (female) (2) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between P02 (female) (13) and A61 (female) (1) Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (12) and A61 Resistance
Above 1 MΩ
circuit) (female) (2) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) (12) and A61
circuit) Voltage Below 1 V
(female) (2) and grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel Engine cooling water
5 P02 (female) Resistance value
defective temperature
Between (12) and (13) 90 – 3.5 kΩ
10 – 100 °C
Between (12) and grounding 90 – 3.5 kΩ
20-426 PC160LC-7
(1)
TROUBLESHOOTING E-17
Grounding fault of !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (2) and A60 Resistance
Above 1 MΩ
circuit) (female) (1) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) (2) and A60
circuit) Voltage Below 1 V
(female) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel P02 (female) Fuel level Resistance value
5
defective
FULL (Upper limit) Approx. 12 Ω
Between (2) and grounding
EMPTY (Lower limit) 85 – 110 Ω
PC160LC-7 20-427
(1)
TROUBLESHOOTING E-18
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness from P02 (female) (17) to J02 to X05 (male) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) (2) to J05 to grounding Below 1 Ω
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.
3 (Contact with Between wiring harness from P02 (female) (17) to J02 and
grounding (GND) Resistance
X05 (male) (1), or P02 (female) (17) to C02 (female) (38) and Above 1 MΩ
circuit) value
grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness
4 Between wiring harness from P02 (female) (17) to J02 and
(Contact with 24 V
circuit) X05 (male) (1), or P02 (female) (17) to C02 (female) (38) and Voltage Below 1 V
grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Monitor panel P02 Swing lock switch Voltage
5
defective
OFF 20 – 30 V
Between (17) and grounding
ON Below 1 V
20-428 PC160LC-7
(1)
TROUBLESHOOTING E-18
PC160LC-7 20-429
(1)
TROUBLESHOOTING E-19
Failure • When monitor switch is operated, nothing is dis- (1) When mode selector switch is operated, working
information played. mode monitor is not displayed.
Relative
—
information
Failure • When monitor switch is operated, nothing is dis- (2) When LCD monitor adjustment switch is oper-
information played. ated, mode selection screen is not displayed.
Relative
—
information
Failure • When monitor switch is operated, nothing is dis- (4) When maintenance switch is operated, item
information played. selection screen is not displayed.
Relative
—
information
Failure • When monitor switch is operated, nothing is dis- (5) When automatic deceleration switch is operated,
information played. automatic deceleration monitor is not displayed.
Relative
• When the automatic decelerator does not operate either, conduct the troubleshooting for E-5.
information
20-430 PC160LC-7
(1)
TROUBLESHOOTING E-19
Failure • When monitor switch is operated, nothing is dis- (6) When travel speed selector switch is operated,
information played. travel speed monitor is not displayed.
Relative
• When the travel speed does not change either, conduct the troubleshooting for H-2.
information
Failure • When monitor switch is operated, nothing is dis- (7) When wiper switch is operated, wiper monitor is
information played. not displayed.
Relative
• When the wiper does not operate either, conduct the troubleshooting for E-20.
information
PC160LC-7 20-431
(1)
TROUBLESHOOTING E-20
tion or short-circuit-
ing) 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 wir- during the troubleshooting.
ing harness
Wiring harness between P01 (female) (9) and W04 (female) Resistance
3 (Disconnection or Below 1 Ω
(3) value
defective contact
with connector) Wiring harness between P01 (female) (10) and W04 (female) Resistance
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.
4 (Contact with
grounding (GND) cir- Between wiring harness between P02 (female) (15) and W03 Resistance
Above 1 MΩ
cuit) (female) (1) value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Monitor panel fault
(window rear limit P02 Front window Voltage
switch system) When installed at front 20 – 30 V
Between (15) and grounding
When retracted at rear Below 1 V
5 !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Monitor panel fault P01 Windshield wiper switch Resistance value
(Windshield wiper
motor system) OFF Below 3 V
Between (9) and grounding
Between (10) and grounding Below 3 V ⇔ 20 – 30 V
ON
(Constant cycle)
20-432 PC160LC-7
(1)
TROUBLESHOOTING E-20
PC160LC-7 20-433
(1)
TROUBLESHOOTING E-20
fault)
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 wir- during the troubleshooting.
ing harness
Resistance
3 (Disconnection or Wiring harness from FB1-4 to J03 to J06 and A50 (female) (1) Below 1 z
value
defective contact
with connector) Wiring harness from A50 (female) (2) to J04 and P01 Resistance
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 Between wiring harness from FB1-4 to J03 to J06 and A50
Resistance
wiring harness (female) (1), or FB1-4 to D04 (female) (4), and to other rela- Above 1 Mz
4 value
(Contact with tive circuits and grounding
grounding circuit) Between wiring harness from A50 (female) (2) to J04 and
Resistance
P01 (female) (3), or A50 (female) (2) to D04 (female) (8) and Above 1 Mz
value
grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel P01 Windshield washer switch Voltage
5
defective
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
20-434 PC160LC-7
(4)
TROUBLESHOOTING E-20
PC160LC-7 20-435
(1)
TROUBLESHOOTING E-20
fault)
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 wir- during the troubleshooting.
ing harness
Resistance
3 (Disconnection or Wiring harness from FB1-4 to J03 to J06 and A50 (female) (1) Below 1 z
value
defective contact
with connector) Wiring harness from A50 (female) (2) to J04 and P01 Resistance
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 Between wiring harness from FB1-4 to J03 to J06 and A50
Resistance
wiring harness (female) (1), or FB1-4 to D02 (female) (3), and to other rela- Above 1 Mz
4 value
(Contact with tive circuits and grounding
grounding circuit) Between wiring harness from A50 (female) (2) to J04 and
Resistance
P01 (female) (3), or A50 (female) (2) to D02 (female) (7) and Above 1 Mz
value
grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel P01 Windshield washer switch Voltage
5
defective
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
20-435-1 PC160LC-7
(4)
TROUBLESHOOTING E-20
PC160LC-7 20-435-2
(4)
TROUBLESHOOTING E-21
Failure
• Alarming buzzer cannot be cancelled.
information
Relative • Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)
(Internal disconnec-
tion) Release Above 1 MΩ
Between (1) and (2)
Depress Below 1 Ω
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) (16) and P03 (male) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from P03 (male) (2) to J05 and grounding Below 1 Ω
value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
3
(Contact with 24 V Between wiring harness between P02 (female) (16) and P03
circuit) Voltage Below 1 V
(male) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Alarming buzzer
4 Monitor panel fault P02 Voltage
cancellation switch
Release 20 – 30 V
Between (16) and grounding
Depress Below 1 V
20-436 PC160LC-7
(1)
TROUBLESHOOTING E-22
Failure • "Boom RAISE" is not correctly displayed in mon- • "Boom RAISE" is not correctly displayed in the
information itor function. monitor function on the monitor panel.
Relative
—
information
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (10) and S06 (female) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S06 (female) (2) and grounding Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (10) and S06 Resistance
Above 1 MΩ
circuit) (female) (1) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (10) and S06
circuit) Voltage Below 1 V
(female) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting.
Governor • pump Right work equipment
5 C03 Voltage
controller defective control lever
NEUTRAL 20 – 30 V
Between (10) and grounding
RAISE Below 1 V
PC160LC-7 20-437
(1)
TROUBLESHOOTING E-23
Failure • "Boom LOWER" is not correctly displayed in • "Boom LOWER" is not correctly displayed in the
information monitor function. monitor function on the monitor panel.
Relative
—
information
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (20) and S02 (female) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S02 (female) (2) and grounding Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (20) and S02 Resistance
Above 1 MΩ
circuit) (female) (1) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (20) and S02
circuit) Voltage Below 1 V
(female) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting.
Governor • pump Right work equipment
5 C03 Voltage
controller defective control lever
NEUTRAL 20 – 30 V
Between (20) and grounding
LOWER Below 1 V
20-438 PC160LC-7
(1)
TROUBLESHOOTING E-24
Failure • "Arm IN" is not correctly displayed in monitor • "Arm IN" is not correctly displayed in the monitor
information function. function (special function) on the monitor panel.
Relative
—
information
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (30) and S04 (female) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S04 (female) (2) and grounding Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (30) and S04 Resistance
Above 1 MΩ
circuit) (female) (1) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (30) and S04
circuit) Voltage Below 1 V
(female) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting.
Governor • pump Left work equipment
5 C03 Voltage
controller defective control lever
NEUTRAL 20 – 30 V
Between (30) and grounding
IN Below 1 V
PC160LC-7 20-439
(1)
TROUBLESHOOTING E-25
Failure • "Arm OUT" is not correctly displayed in monitor • "Arm OUT" is not correctly displayed in the monitor
information function. function (special function) on the monitor panel.
Relative
—
information
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (40) and S08 (female) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S08 (female) (2) and grounding Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (40) and S08 Resistance
Above 1 MΩ
circuit) (female) (1) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (40) and S08
circuit) Voltage Below 1 V
(female) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting.
Governor • pump Left work equipment
5 C03 Voltage
controller defective control lever
NEUTRAL 20 – 30 V
Between (40) and grounding
OUT Below 1 V
20-440 PC160LC-7
(1)
TROUBLESHOOTING E-26
Failure • "Bucket CURL" is not correctly displayed in moni- • "Bucket CURL" is not correctly displayed in the mon-
information tor function. itor function (special function) on the monitor panel.
Relative
—
information
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (9) and S01 (female) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S01 (female) (2) and grounding Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (9) and S01 Resistance
Above 1 MΩ
circuit) (female) (1) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (9) and S01
circuit) Voltage Below 1 V
(female) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting.
Governor • pump Right work equipment
5 C03 Voltage
controller defective control lever
NEUTRAL 20 – 30 V
Between (9) and grounding
CURL Below 1 V
PC160LC-7 20-441
(1)
TROUBLESHOOTING E-27
Failure • "Bucket DUMP" is not correctly displayed in moni- • "Bucket DUMP" is not correctly displayed in the mon-
information tor function. itor function (special function) on the monitor panel.
Relative
—
information
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (19) and S05 (female) (1) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S05 (female) (2) and grounding Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (19) and S05 Resistance
Above 1 MΩ
circuit) (female) (1) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (19) and S05
circuit) Voltage Below 1 V
(female) (1) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting.
Governor • pump Right work equipment
5 C03 Voltage
controller defective control lever
NEUTRAL 20 – 30 V
Between (19) and grounding
DUMP Below 1 V
20-442 PC160LC-7
(1)
TROUBLESHOOTING E-28
Failure • "SWING" is not correctly displayed in monitor • "SWING" is not correctly displayed in the monitor
information function. function (special function) on the monitor panel.
Relative
—
information
PC160LC-7 20-443
(4)
TROUBLESHOOTING E-28
20-444 PC160LC-7
(1)
TROUBLESHOOTING E-29
Failure • "TRAVEL" is not correctly displayed in monitor • "TRAVEL" is not correctly displayed in the monitor
information function. function (special function) on the monitor panel.
Relative
—
information
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness from C03 (female) (39) to J01 and S30 Resistance
2 (Disconnection or Below 1 Ω
(female) (2) value
defective contact
with connector) Resistance
Wiring harness from S30 (female) (1) to J05 and grounding Below 1 Ω
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.
3 (Contact with
grounding (GND) Wiring harness from C03 (female) (39) to J01 to S30 (female) Resistance
Above 1 MΩ
circuit) (2) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Wiring harness from C03 (female) (39) to J01 to S30 (female)
circuit) Voltage Below 1 V
(2) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting.
Governor • pump C03 Travel control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (39) and grounding
Forward or reverse Below 1 V
20-446 PC160LC-7
(1)
TROUBLESHOOTING E-29
PC160LC-7 20-447
(1)
TROUBLESHOOTING E-30
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C02 (female) (16) and S31 (female) (2) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from S31 (female) (2) to J05 and grounding Below 1 Ω
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.
3 (Contact with
grounding (GND) Between wiring harness between C02 (female) (16) and S31 Resistance
Above 1 MΩ
circuit) (female) (2) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C02 (female) (16) and S31
circuit) Voltage Below 1 V
(female) (2) and grounding
!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting.
Governor • pump C02 Travel control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (16) and grounding
One side of right or left only Below 1 V
20-448 PC160LC-7
(1)
TROUBLESHOOTING E-30
PC160LC-7 20-449
(1)
TROUBLESHOOTING E-31
Failure • "Service" is not correctly displayed in monitor func- • "Service" is not correctly displayed in the monitor
information tion. function (special function) on the monitor panel.
Relative
—
information
20-450 PC160LC-7
(1)
TROUBLESHOOTING E-31
PC160LC-7 20-451
(1)
TROUBLESHOOTING E-32
Failure
• Air conditioner does not work.
information
Relative • For the electric circuit diagram inside air conditioner unit, see "Electric circuit diagram of air conditioner"
information in the collected circuit diagrams.
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Air conditioner unit M26 Voltage
4
defective
Between (4) (5) and (8) 20 – 30 V
If the result is as above, the air conditioner unit is defective.
20-452 PC160LC-7
(4)
TROUBLESHOOTING E-32
PC160LC-7 20-453
(1)
TROUBLESHOOTING E-32
20-453-1 PC160LC-7
(4)
TROUBLESHOOTING E-32
Self-diagnosis
notice Trouble Disconnection in recirculated air sensor
E11
Contents of
• Disconnection in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
(Internal disconnection)
Between (1) and (2) 300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12
Contents of
• Short circuit in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
cuit)
Between (1) and (2) 300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC160LC-7 20-453-2
(4)
TROUBLESHOOTING E-32
Self-diagnosis
notice Trouble Disconnection in water temperature sensor
E15
Contents of
• Disconnection in the water temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
connection)
Between (1) and (2) 95 z – 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (14) and THW
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in water temperature sensor
E16
Contents of
• Short circuit in the water temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
short circuit)
Between (1) and (2) 95 z – 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (14) and THW
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-453-3 PC160LC-7
(4)
TROUBLESHOOTING E-32
Self-diagnosis
notice Trouble Short circuit in daylight sensor
E18
Contents of
• Short circuit in the daylight sensor system is detected.
trouble
• Assumes that the daylight sensor is not installed for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (16) and P15
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M30 (female) (3) and P15
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Abnormality in air outlet damper
E43
Contents of
• Abnormality in air outlet servomotor system is detected.
trouble
• Stops the air outlet servomotor.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel • <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.
Resistance Max. 1 z
(female) (3)
Disconnection in wiring Wiring harness between MV1 (female) (3) and M29
harness (Disconnection Resistance Max. 1 z
(female) (11)
2 in wiring harness or
defective contact in con- Wiring harness between MV1 (female) (5) and M30
Resistance Max. 1 z
nector) (female) (9)
Wiring harness between MV1 (female) (6) and M29
Resistance Max. 1 z
(female) (8)
Wiring harness between MV1 (female) (7) and M29
Resistance Max. 1 z
(female) (9)
Defective air conditioner If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may
3
system be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC160LC-7 20-453-4
(4)
TROUBLESHOOTING E-32
Self-diagnosis
notice Trouble Abnormality in air mix damper
E44
Contents of
• Abnormality in air mix servomotor system is detected.
trouble
• Stops the air mix servomotor.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.
Resistance Max. 1 z
(female) (11)
Disconnection in wiring Wiring harness between MAM (female) (3) and M30
harness (Disconnection Resistance Max. 1 z
(female) (3)
2 in wiring harness or
defective contact in con- Wiring harness between MAM (female) (5) and M30
Resistance Max. 1 z
nector) (female) (2)
Wiring harness between MAM (female) (6) and M29
Resistance Max. 1 z
(female) (4)
Wiring harness between MAM (female) (7) and M29
Resistance Max. 1 z
(female) (5)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-453-5 PC160LC-7
(4)
TROUBLESHOOTING E-32
Self-diagnosis
notice Trouble Abnormality in recirculated and fresh air damper
E45
Contents of
• Abnormality in recirculated and fresh air servomotor system is detected.
trouble
• Stops the recirculated and fresh air servomotor.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.
2 Defective fuse (in unit)
Possible causes and
PC160LC-7 20-453-6
(4)
TROUBLESHOOTING E-32
20-453-7 PC160LC-7
(4)
TROUBLESHOOTING E-32
Trouble • The air conditioner does not operate. (1) The air conditioner does not operate at all.
Related
information
Resistance Max. 1z
ground
Possible causes and
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch ON.
ground in wiring harness Between wiring harness between circuit breaker fuse 11
3 Resistance Min. 1 Mz
(Contact with ground cir- outlet and M33 (male) (3) and chassis ground
cuit) Between wiring harness between M27 (female) (14) and
Resistance Min. 1 Mz
M30 (female) (6) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Defective air conditioner M33 Voltage
4
unit Between (2) and (3) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air condi-
tioner is defective.
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
M30, M29 Voltage
5 Defective control panel
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)
TROUBLESHOOTING E-32
Trouble • The air conditioner does not operate. (2) Air does not come out (Air flow is insufficient).
Related
information
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Possible causes and
20-453-9 PC160LC-7
(4)
TROUBLESHOOTING E-32
Trouble • The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
Related
information
PC160LC-7 20-453-10
(4)
TROUBLESHOOTING E-32
20-453-11 PC160LC-7
(4)
TROUBLESHOOTING E-33
E-33 Travel alarm does not sound or does not stop sounding
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes
5 Travel alarm fault
listed in Item 1 through 4 above is found, the travel alarm is judged as defective)
20-454 PC160LC-7
(1)
TROUBLESHOOTING E-33
PC160LC-7 20-455
(1)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)
PC160LC-7 20-501
(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
2
Cause for presumed
failure <Contents>
(The attached No. for • The standard values in normalcy by which to judge "good" or "no good" about
3
filing and reference presumed causes.
purpose only. It does not stand • References for making judgement of "good" or "no good"
for any priority)
4
PC160LC-7 20-503
(1)
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
20-504 PC160LC-7
(1)
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)
TROUBLESHOOTING H-1
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.
20-506 PC160LC-7
(1)
TROUBLESHOOTING H-2
tioning 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 mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
2
functioning of PC valve PC valve output pressure Arm IN relief Approx. 0.6(Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of the PC valve or its internal failure is suspected. In that case, check the
valve itself.
Oil pressure ratio
Oil pressure to be mea-
sured All control levers in Bucket curled
NEUTRAL (control lever full stroke)
Improper adjustment or mal- Pump delivery pressure 1
3 Nearly equal pressure
functioning of LS valve LS valve output pressure Approx. 0.6(Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of the LS valve or its internal failure is suspected. In that case, check the
valve itself.
Orifice or filter in servo equip- The orifice or filter in the pump servo equipment is suspected of clogging. Check
4
ment clogged the equipment itself.
5 Malfunction of servo piston The servo piston is suspected of malfunction. Check the piston itself.
PC160LC-7 20-507
(1)
TROUBLESHOOTING H-3, H-4
Failure information • An abnormal noise is heard from around the hydraulic pump.
Relative information —
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
3
clogged causing negative pressure inside the tank. Make a visual check.
Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
4
clogged negative pressure in the suction circuit. Make a visual check.
5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.
20-508 PC160LC-7
(1)
TROUBLESHOOTING H-5, H-6
PC160LC-7 20-509
(1)
TROUBLESHOOTING H-7
Malfunction of right PPC valve Right work equipment control lever PPC valve output pressure
1
(boom circuit) NEUTRAL 0 MPa {0 kg/cm2}
Boom RAISE position Above 2.7 MPa
Boom LOWER position {Above 28 kg/cm2}
!Keep the engine stopped for the preparations, and keep it running at high idling
during the troubleshooting.
20-510 PC160LC-7
(1)
TROUBLESHOOTING H-8
Malfunction of left PPC valve Left work equipment control lever PPC valve output pressure
1
(arm circuit) NEUTRAL 0 MPa {0 kg/cm2}
Arm IN position Above 2.7 MPa
Arm OUT position {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
PC160LC-7 20-511
(1)
TROUBLESHOOTING H-9
Malfunction of right PPC valve Right work equipment control lever PPC valve output pressure
1
(bucket circuit) NEUTRAL 0 MPa {0 kg/cm2}
Bucket CURL position Above 2.7 MPa
Bucket DUMP position {Above 28 kg/cm2}
!Keep the engine stopped for the preparations, and keep it running at high
idling during the troubleshooting.
20-512 PC160LC-7
(1)
TROUBLESHOOTING H-10
PC160LC-7 20-513
(1)
TROUBLESHOOTING H-11
Failure information • Hydraulic drift of work equipment is large. (1) Hydraulic drift of boom is large.
Relative information • Conduct the troubleshooting in working mode A.
!Keep the engine stopped for the preparations, and keep it running at high
idling during the troubleshooting.
1 Boom cylinder defective
Boom cylinder Leakage from cylinder
Relieved in RAISE direction 20 cc/min
Defective sealing of boom Sealing of the lock valve of the boom control valve may be defective. Check
2
control valve (lock valve) it directly.
Defective sealing of central- Sealing of the centralized safety-suction valve of the control valve may be
3
ized safety-suction valve defective. Check it directly.
Failure information • Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large.
Relative information • Conduct the troubleshooting in working mode A.
Failure information • Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large.
Relative information • Conduct the troubleshooting in working mode A.
20-514 PC160LC-7
(1)
TROUBLESHOOTING H-12, H-13
Malfunction of control valve The suction valve of the control valve (on the head side) may have a mal-
2
(suction valve). function. Check it directly.
!Keep the engine stopped for the preparations, and keep it running at high
dard value in normalcy
PC160LC-7 20-515
(1)
TROUBLESHOOTING H-14, H-15
Failure information • Work equipment loaded more is slower during compound operation.
Relative information —
The pressure compensation valve of the work equipment loaded less may
dard value in normalcy
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE
Failure information • Boom RAISE speed is low in compound operation of swing + boom RAISE.
• If the speed of single operation of the boom RAISE speed is slow, conduct troubleshooting for H-
Relative information
7 first.
Malfunction or defective seal- The LS selector valve of the control valve may have a malfunction or its
1
ing of LS selector valve sealing may be defective. Check it directly.
20-516 PC160LC-7
(1)
TROUBLESHOOTING H-16
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.
PC160LC-7 20-517
(1)
TROUBLESHOOTING H-17
20-518 PC160LC-7
(1)
TROUBLESHOOTING H-18
PC160LC-7 20-519
(1)
TROUBLESHOOTING H-19
20-520 PC160LC-7
(1)
TROUBLESHOOTING H-20, H-21
Failure information • Travel speed does not change or it is kept low or high.
Relative information • Conduct the troubleshooting in working mode A.
Defective seat of travel control The safety and check valve seat of the travel control lever may be defective.
dard value in normalcy
2
valve (Safety and check valve) Check it directly.
Malfunction of travel motor The counterbalance valve of the travel motor may have a malfunction.
3
(counterbalance valve) Check it directly.
!Keep the engine stopped for the preparations, and keep it running at high
idling during the troubleshooting.
4 Travel motor 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
5 Final drive defective
by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
PC160LC-7 20-521
(1)
TROUBLESHOOTING H-22
Failure information • Machine does not swing. (1) Machine does not swing in either direction.
Relative information • Conduct the troubleshooting in working mode A.
!Keep the engine stopped for the preparations, and keep it running at high idling
during the troubleshooting.
Malfunction of swing holding Right work equipment control lever Solenoid valve output pressure
1
brake solenoid valve
In NEUTRAL 0 MPa {0 kg/cm2}
Operated for swing 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunction of swing motor
2 The holding brake of the swing motor may have a malfunction. Check it directly.
(holding brake)
!Keep the engine stopped for the preparations, and keep it running at high idling
during the troubleshooting.
3 Swing motor 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
4 Swing machinery defective
checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
Failure information • Machine does not swing. (2) Machine does not swing in only one direction.
Relative information • Conduct the troubleshooting in working mode A.
!Keep the engine stopped for the preparations, and keep it running at high idling
during the troubleshooting.
Malfunction of swing PPC Left work equipment control lever PPC valve output pressure
1
valve
In NEUTRAL 0 MPa {0 kg/cm2}
Operated for swing Above 2.7 MPa {Above 28 kg/cm2}
Malfunction of swing control
2 The spool of the swing control valve may have a malfunction. Check it directly.
valve (spool)
!Keep the engine stopped for the preparations, and keep it running at high idling
during the troubleshooting.
Defective adjustment or mal- Left work equipment
3 function of swing motor (safety Swing lock switch Swing relief pressure
control lever
valve)
Swing circuits relieved 28.9 – 32.9 MPa
ON
(separately on both sides) {295 – 335 kg/cm2}
Defective sealing of swing Sealing of the suction valve of the swing motor may be defective. Check it
4
motor (suction valve) directly.
20-522 PC160LC-7
(1)
TROUBLESHOOTING H-23
valve)
Malfunction of swing motor The holding brake of the swing motor may have a malfunction. Check it
2
(holding brake) directly.
!Keep the engine stopped for the preparations, and keep it running at high
idling during the troubleshooting.
3 Swing motor 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
4 Swing machinery defective
checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
In NEUTRAL
dard value in normalcy
PC160LC-7 20-523
(1)
TROUBLESHOOTING H-24
!Keep the engine stopped for the preparations, and keep it running at high
in normalcy
1 Swing motor defective Left work equipment control lever Leakage from swing motor
The swing PPC slow return valves may be clogged. Check them directly.
Clogging of swing PPC slow
2 (They may be checked by exchanging with each other and checking change
return valves
of the phenomenon.)
Malfunction of swing control The spool of the swing control valve may have a malfunction. Check it
3
valve (spool) directly.
!Keep the engine stopped for the preparations, and keep it running at high
idling during the troubleshooting.
Defective adjustment or mal- Left work equipment
4 function of swing motor (safety Swing lock switch Swing relief pressure
control lever
valve)
Swing circuits relieved 28.9 – 32.9 MPa
ON
(separately on both sides) {295 – 335 kg/cm2}
Defective sealing of swing Sealing of the suction valve of the swing motor may be defective. Check it
5
motor (suction valve) directly.
20-524 PC160LC-7
(1)
TROUBLESHOOTING H-25, H-26
Failure information • When upper structure stops swinging, it makes large shock.
Relative information • Conduct the troubleshooting in working mode A.
Malfunction of swing PPC Left work equipment control lever PPC valve output pressure
1
valve
In NEUTRAL 0 MPa {0 kg/cm2}
Operated for swing Above 2.7 MPa {Above 28 kg/cm2}
The swing PPC slow return valves may have a malfunction. Check them
Malfunction of swing PPC slow
2 directly. (They may be checked by exchanging with each other and check-
return valves
ing change of the phenomenon.)
Malfunction of swing motor The shockless valve of the swing motor may have malfunction. Check it
3
(shockless valve) directly.
Failure information • When upper structure stops swinging, it makes large sound.
Relative information • Conduct the troubleshooting in working mode A.
1 The back pressure check valve may have a malfunction. Check it directly.
dard value in normalcy
check valve
The swing motor (safety valves) may have a malfunction. Check the valves
Malfunction of swing motor
2 directly. (They may be checked by exchanging with each other and check-
(safety valve)
ing change of the phenomenon.)
The swing motor (suction valves) may have a malfunction. Check the
Malfunction of swing motor
3 valves directly. (They may be checked by exchanging with each other and
(suction valves)
checking change of the phenomenon.)
The swing machinery may have a defect in it. Check it directly. (It may be
4 Swing machinery defective
checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
PC160LC-7 20-525
(1)
TROUBLESHOOTING H-27
Failure information • Hydraulic drift of swing is large. (1) When swing holding brake is operated
• If the swing lock switch is turned ON or the swing holding brake release switch is in the normal
Relative information position, the swing brake operates and the disc brake holds the upper structure.
• Conduct the troubleshooting in working mode A.
!Keep the engine stopped for the preparations, and keep it running at high
dard value in normalcy
Malfunction of swing holding Right work equipment control lever Solenoid valve output pressure
1
brake solenoid valve In NEUTRAL 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Operated for swing
{29 – 35 kg/cm2}
Malfunction or internal defect The holding brake of the swing motor may have a malfunction or an internal
2
of swing motor (holding brake) defect. Check it directly.
Failure information • Hydraulic drift of swing is large. (2) When swing holding brake is released
• If the swing holding brake release is in the emergency position, the swing holding brake is re-
Relative information leased and the upper structure is held with only hydraulic pressure.
• Conduct the troubleshooting in working mode A.
The safety valves of the swing motor may have a malfunction. Check them
Defective sealing of swing
2 directly. (They may be checked by exchanging with each other and check-
motor (safety valve)
ing change of the phenomenon.)
The suction valves of the swing motor may have a malfunction. Check them
Defective sealing of swing
3 directly. (They may be checked by exchanging with each other and check-
motor (suction valve)
ing change of the phenomenon.)
Malfunction or defective seal-
The shockless valve of the swing motor may have a malfunction or its seal-
4 ing of swing motor (shockless
ing may be defective. Check it directly.
valve)
20-526 PC160LC-7
(1)
TROUBLESHOOTING H-28, H-29
1
dard value in normalcy
PC160LC-7 20-527
(1)
TROUBLESHOOTING OF ENGINE
(S-MODE)
PC160LC-7 20-601
(4)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds 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 nar-
row 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 proba-
bility, starting with the causes that have been marked
as having the highest probability from information
gained from [Questions] and [Check items].
20-602 PC160LC-7
(4)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
PC160LC-7 20-603
(4)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-604 PC160LC-7
(4)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
PC160LC-7 20-605
(4)
TROUBLESHOOTING S-1
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 100 % 90 % 80 % 75 % 70 %
temperature
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
20-606 PC160LC-7
(4)
TROUBLESHOOTING S-1
PC160LC-7 20-607
(4)
TROUBLESHOOTING S-2
20-608 PC160LC-7
(4)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
PC160LC-7 20-609
(4)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
20-610 PC160LC-7
(4)
TROUBLESHOOTING S-3
PC160LC-7 20-611
(4)
TROUBLESHOOTING S-4
20-612 PC160LC-7
(4)
TROUBLESHOOTING S-5
PC160LC-7 20-613
(4)
TROUBLESHOOTING S-6
20-614 PC160LC-7
(4)
TROUBLESHOOTING S-7
PC160LC-7 20-615
(4)
TROUBLESHOOTING S-8
20-616 PC160LC-7
(4)
TROUBLESHOOTING S-9
PC160LC-7 20-617
(4)
TROUBLESHOOTING S-10
• Leakage of fuel
• Improper condition of fuel injection
• Excessive injection of fuel
20-618 PC160LC-7
(4)
TROUBLESHOOTING S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
PC160LC-7 20-619
(4)
TROUBLESHOOTING S-12
20-620 PC160LC-7
(4)
TROUBLESHOOTING S-13
PC160LC-7 20-621
(4)
TROUBLESHOOTING S-14
20-622 PC160LC-7
(4)
TROUBLESHOOTING S-15
PC160LC-7 20-623
(4)
TROUBLESHOOTING S-16
20-624 PC160LC-7
(4)
30 DISASSEMBLY AND ASSEMBLY
PC160LC-7 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 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing part
kind of information are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
t: Special tools which cannot be substi- are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
q: Speciall tools which are very useful if stand for the following.
k
available, can be substituted with com-
This mark indicates safety-related pre-
mercially available tools.
cautions, which must be followed when
2) Distinction of new and existing special tools. doing the work.
N: Tools with new part numbers, newly a This marks gives guidance or precau-
developed for this model. tions when doing the procedure.
5
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the spe- This mark indicates an amount of oil or
cial tool is presented in the section of water to be added.
Sketches for Special Tools.
a Part No. of special tools starting with 79*T SKETCHES OF SPECIAL TOOLS
means that they are locally made parts and as
such not interchangeable with those made by • Various special tools are illustrated for the con-
Komatsu in Japan e.g. 79*T---×××---××××. venience of local manufacture.
REMOVAL OF PARTS
PC160LC-7 30-3
(2)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
SPECIAL TOOLS
5
for other models.
Blank: Tools already available for other models, This mark indicates an amount of oil or
used without any modification. water to be added.
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of SKETCHES OF SPECIAL TOOLS
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T 1) Vartious special tools are illustrated for the
means that they are locally made parts and convenience of local manufacture.
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T---×××--
-××××.
DISASSEMBLY
30-4 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
C. If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PC160LC-7 30-5
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
30-6 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
Center swivel joint Disassembly of center swivel
E • 790-101-2540 • Washer 1
assembly joint assembly
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
792-104-3940 Bolt t 2
01613-31645 Washer t 2
790-105-2100 Jack t 1
790-101-1102 Pump t 1
PC160LC-7 30-7
(4)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
1 KBATZ080080 Wrench t 1 N
Swing motor and swing Removal, installation of
machinery assembly
G 2 KBATZ030190 Adapter t 1 N
ring nut
3 KBATZ060400 Stopper t 1 N
• 790-101-5221 • Grip
1 Press fitting of bushing
• 01010-51225 • Bolt
Idler assembly H
• 790-101-5271 • Plate
791-685-8006 Compressor t 1
790-201-2780 Spacer t 1
791-635-3160 Extension t 1
Disassembly, assembly of
1
Cylinder recoil spring assembly
790-101-1600
(686 kN {70t}) t 1
790-101-1102 Pump t 1
Recoil spring assembly J
791-640-2180 Guide bolt t 1
• 790-201-1620 • Plate
2 Installation of dust seal
• 790-101-5021 • Grip
• 01010-50816 • Bolt
• 790-101-5081 • Plate
1 Press fitting of bushing
• 790-101-5021 • Grip
Carrier roller assembly K
• 01010-50816 • Bolt
• 790-101-5221 • Grip
1 Press fitting of bushing
• 01010-51225 • Bolt
Track roller assembly L
• 790-101-5261 • Plate
30-8 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Necessity
Remodel
Sketch
Q’ty
New/
Component Symbol Part No. Part Name Nature of work, remarks
790-331-1110 Wrench t 1
3 790-720-1000 Expander q 1
Ring (for boom
796-720-1660
and bucket) q 1
• 01010-50816 • Bolt 1
790-201-5021 • Grip 1
• 01010-50816 • Bolt 1
790-201-5021 Grip q 1
01010-50816 Bolt q 1
796-900-1200 Remover t 1
Puller
Work equipment assembly R 790-101-4000
(490 kN {50 t}, long) t 1 Removal of foot pin
Pump
790-101-1102
(294 kN {30}) t 1
PC160LC-7 30-9
(4)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Necessity
Remodel
Sketch
Q’ty
New/
Component Symbol Part No. Part Name Nature of work, remarks
30-9-1 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
F2 PUSH TOOL
30-10 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*2]
a Apply gasket sealant (LG-1) to the starting
motor gasket.
a Apply the gasket sealant in the form of a con-
tinuous 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)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
A 1 795-799-1390 Puller t 1
REMOVAL
k Disconnect the cable from the negative (–) ter- 8. Remove 4 delivery tubes (7).
minal of the battery.
9. Remove fuel tubes (8) and (9) between the fuel
1. Close the fuel stop valve. 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).
30-12 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
13. Turn and remove cap (14). 16. Remove fuel injection pump lower bracket (17)
a Use a filter wrench, etc. to remove the cap. and mounting bolts and nuts (18).
PC160LC-7 30-13
(2)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
[*1]
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 accord-
ing to the following procedure.
30-14 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
Bleeding air
• Bleed air from the fuel piping according to the fol-
lowing procedure.
1. Fill the fuel tank with fuel (until the float reaches
the highest level).
PC160LC-7 30-15
(2)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND INSTALLATION k Take care not to catch your hands between
the tensioner and pulley.
OF ENGINE FRONT SEAL
9. Remove fan pulley (9).
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 795-799-2610 Installer t 1
B
2 795-799-2620 Installer t 1
REMOVAL
30-16 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
PC160LC-7 30-17
(4)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
3 Mounting bolt:
the specified torque.
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
30-17-1 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
PC160LC-7 30-17-2
(4)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
C 795-931-1100 Seal puller q 1
REMOVAL
30-18 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
INSTALLATION 2) Insert rear oil seal (4) and pilot [2] together
in the crankshaft and push the seal carrier of
• Carry out installation in the reverse order to rear oil seal (4) into the flywheel housing.
removal. a Before inserting the rear oil seal, clean,
degrease, and dry the seal contact surface
[*1] of the crankshaft.
a Tighten the mounting bolts of the flywheel 3) Pull out pilot [2] and push in rear oil seal (4)
further.
3 Mounting bolt of flywheel assembly:
assembly in the following numerical order.
PC160LC-7 30-19
(4)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
New/Remodel
Symbol
11. Remove tubes (7) and (8) between fuel filter and
Necessity
Part No. Part name
Sketch
fuel injection pump.
Q'ty
12. Remove bracket (9) and fuel filter as a unit. [*3]
2 795-799-1171 Puller t 1
A
3 790-331-1110 Wrench t 1
13. Remove air intake connector (10) and ribbon
heater (11). [*4]
REMOVAL a Cover the openings with adhesive tapes, etc.
6 Coolant: 18.6 l
30-20 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
PC160LC-7 30-21
(2)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
a Cover the nozzle holder assembly mounting 30. Remove push rods (31). [*13]
parts to prevent foreign matter from entering
the engine.
30-22 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
3 Hose clamp
[*1]
[*2] [*9]
a Install the air conditioner compressor belt. a Tighten the mounting bolts in the following
For details, see TESTING AND ADJUSTING,
3 Mounting bolt:
numerical order.
Inspection and adjustment of air compressor
belt tension. 1st time : Tighten all the bolts to
43 ± 6 Nm {4.38 ± 0.61 kgm}.
[*3] 2nd time: Tighten only bolts 1 – 4 to
a Apply gasket sealant to the threads of the 43 ± 6 Nm {4.38 ± 0.61 kgm}.
bolt (only 1 piece) on the head cover side
among the 3 fuel filter bracket mounting
bolts.
[*4]
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
3 Mounting bolt:
[*11]
PC160LC-7 30-23
(2)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
2) Sling cylinder head assembly (32) and set it 3 Cylinder head bolt:
to the cylinder block. 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 numeri-
cal 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).
30-24 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
• Bleeding air
Bleed air from the fuel piping. For details, see
REMOVAL AND INSTALLATION OF FUEL INJEC-
TION PUMP ASSEMBLY.
PC160LC-7 30-25
(2)
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL AND INSTALLATION 5. Remove the 2 mounting bolts and lift off radiator
assembly (6).
OF RADIATOR ASSEMBLY a You can lift up and remove the radiator
assembly with the hands.
4 Radiator assembly: 11 kg
REMOVAL
INSTALLATION
• Carry out installation in the reverse order to
removal.
30-26 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
INSTALLATION
[*1]
a Tighten the hose clamp with the bolt right
2. Open the engine hood, remove clamp (2), and
3 Hose clamp:
down.
disconnect hose (3). [*2]
1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
3. Remove the mounting bolts of cover (4) and
2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
move the cover toward the engine.
PC160LC-7 30-27
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
NSTALLATION
• Carry out installation in the reverse order to
removal.
30-28 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
796-460-1210 Oil stopper q 1
D
796-770-1320 Adapter q 1
k Disconnect the cable from the negative (–) ter- 6. Disconnect hoses (4), (5), and (6) from the
minal of the battery. engine. [*3]
k Lower the work equipment to the ground and
7. Remove fan guards (7) and (8).
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
8. Remove the air conditioner compressor belt and
of the hydraulic tank.
disconnect connector E06 (9). Remove air con-
ditioner compressor (10) and bracket and move
a Put tags to the disconnected hoses and tubes to
them toward the counterweight. [*4]
prevent a mistake in re-connecting them.
a Do not disconnect the air conditioner piping.
1. Drain the coolant.
9. Remove the cooling fan.
6 Coolant: 18.6 l
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]
PC160LC-7 30-29
(2)
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
11. Remove plates (12) and (13) and covers (14) 15. Disconnect fuel hoses (21) and 22.
and (15). a Plug the hoses to prevent fuel from leaking.
30-30 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
20. Disconnect connectors E01 (27) and E05 (28) 23. Disconnect connectors V21 (33) and A61 (34)
and remove the wiring harness clamp. and remove the wiring harness clamp.
PC160LC-7 30-31
(2)
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
[*4]
a Install the air conditioner compressor belt.
For details, see TESTING AND ADJUSTING,
Inspection and adjustment of air compressor
belt tension.
30-32 PC160LC-7
(2)
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)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
EXPANSION AND 3. Using tool M, pull out master pin (2). [*2]
INSTALLATION OF TRACK
SHOE ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
Remover and
791-630-3000
installer t 1
M
790-101-1300 Cylinder t 1
790-101-1102 Pump t 1
790-331-1110 Wrench t 1 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].
EXPANSION
5. Pull out temporary pin [1] and remove the dust
1. Stop the machine so that the master pin will be seal. Move the machine in reverse to expand
between the idler and carrier roller and the track track shoe (3). [*3]
shoe can be expanded in the forward and back-
ward directions.
30-34 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION [*2]
a Using tool M, press fit the master pin so that
• Carry out installation in the reverse order to its projection a will be as follows.
removal. • Dimension a: 2.5 ± 1 mm
[*1]
a Adjust the tension of the track shoe. For
detail, see TESTING AND ADJUSTING,
Inspection and adjustment of track shoe ten-
sion.
PC160LC-7 30-35
(2)
DISASSEMBLY AND ASSEMBLY SPROCKET
30-36 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY FIANAL DRIVE
REMOVAL AND INSTALLATION 4. Remove the 18 mounting bolts from final drive
assembly (6) and lift if off to remove. [*1]
OF FINAL DRIVE ASSEMBLY a Be careful. Do not damage the face of the fit-
ting seal at the base of the hose.
REMOVAL 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.
INSTALLATION
• Install in reverse order to removal.
3. Disconnect four travel motor hoses (2), (3), (4) 245 – 309 Nm {25 – 31.5 kgm}
and (5).
• 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.
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
PC160LC-7 30-37
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY AND
ASSEMBLY OF FINAL
DRIVE ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 796-427-1200 Wrench t 1
796T-427-1220 Push tool t 1 Q
790-101-2510 Block t 1
792-104-3940 Bolt t 2
4. No. 1 carrier assembly
F 2 01580-11613 Nut t 2 1) Remove No. 1 carrier assembly (3).
01613-31645 Washer t 2
790-105-2100 Jack t 1
790-101-1102 Pump t 1
3 791-545-1510 Installer t 1
DISASSEMBLY
1. Draining oil
Remove the drain plug to drain the oil from the
final drive case.
3. Washer
Remove washer (2).
5. No. 1 sun gear shaft
Remove No. 1 sun gear shaft (11).
30-38 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
6. Thrust washer
Remove thrust washer (13).
9. Nut
7. No. 2 sun gear 1) Remove lock plate (24).
Remove No. 2 sun gear (14). 2) Using tool F1, remove nut (25).
PC160LC-7 30-39
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
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 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
PC160LC-7 30-41
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
Adhesive (LT-2)
a Do not apply adhesive (LT-2) to the
threads of the mating nut.
30-42 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
5. Thrust washer
Install thrust washer (13).
PC160LC-7 30-43
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
8. Washer
Install washer (2).
9. Cover
Using eyebolts [1], install cover (1) and tighten
3 Mounting bolt:
Gasket sealant (LG-6)
30-44 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY AND 3. Detach idler (4) from shaft (5) and support asem-
bly (7).
ASSEMBLY OF IDLER a The idler contains 70 – 80 cc of oil. Drain the
ASSEMBLY oil at this stage if disassembly. Take care and
spread a cloth on the floor to prevent smear-
SPECIAL TOOLS ing the floor with flushing oil.
New/Remodel
4. Remove floating seal (6) on the opposite side
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5201 Push tool KIT q 1
• 790-101-5221 • Grip
• 01010-51225 • Bolt
H
• 790-101-5271 • Plate
790-434-1630 Installer t 1
790-601-1000 Oil pump q 1
DISASSEMBLY
PC160LC-7 30-45
(2)
DISASSEMBLY AND ASSEMBLY IDLER
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 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY IDLER
5. Using tool H2 install floating seal (3) to idler (4) 6. Install O-ring then install support (2) with dowel
and support (2). pin (1).
a Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or 7. Using tool H3, add oil and tighten the plug.
PC160LC-7 30-47
(2)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
New/Remodel
load, so be very sure to set the tool
Symbol
Necessity
Part No. Part name properly.
Sketch
Failure to do this is dangerous.
Q'ty
a Installed load of spring: 108.8 kN {11,100 kg}
791-685-8006 Compressor t 1
790-201-2780 Spacer t 1
791-635-3160 Extension t 1
1 Cylinder
790-101-1600 (686 kN {70t}) t 1
J
790-101-1102 Pump t 1
791-640-2180 Guide bolt t 1
790-201-1500 Push tool KIT q 1
• 790-201-1620 • Plate 1
2
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
30-48 PC160LC-7
(6)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
Grease (G2-LI)
PC160LC-7 30-49
(2)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY AND
ASSEMBLY OF TRACK a When installing floating seals (5) and (6), thor-
ROLLER ASSEMBLY oughly clean, degrease, and dry the contact sur-
faces of the O-rings and floating seals (hatched
SPECIAL TOOLS parts). Take care that dirt will not stick to the
floating seal contact surfaces.
a After installing the floating seals, check that their
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
– 11 mm.
Q'ty
790-101-5201 Push tool KIT q 1
• 790-101-5221 • Grip
1
• 01010-51225 • Bolt
L
• 790-101-5261 • Plate
2 790-434-1640 Installer t 1
3 791-601-1000 Oil pump q 1
DISASSEMBLY
ASSEMBLY a Using tool L3, fill the track roller assembly with
oil and tighten plug (8).
5 Track roller:
a Assemble according to the following figure.
a Only precautions for assembly are explained
30-50 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISASSEMBLY AND a When installing floating seals (7) and (8), thor-
oughly clean, degrease, and dry the contact sur-
ASSEMBLY OF CARRIER faces of the O-rings and floating seals (hatched
ROLLER ASSEMBLY parts). Take care that dirt will not stick to the
floating seal contact surfaces.
SPECIAL TOOLS a After installing the floating seals, check that their
slant is less than 1 mm and their projection a is 5
New/Remodel
– 7 mm.
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-5001 Push tool KIT q 1
• 790-101-5081 • Plate
1
• 790-101-5021 • Grip
K
• 01010-50816 • Bolt
2 790-434-1660 Installer t 1
3 791-601-1000 Oil pump q 1
DISASSEMBLY
a Assemble according to the following figure. a Using tool K3, fill the carrier roller assembly with
oil and tighten plug (10).
PC160LC-7 30-51
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
INSTALLATION
30-52 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
DISASSEMBLY AND
ASSEMBLY OF SWING
MOTOR AND SWING
MACHINERY ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 KBATZ080080 Wrench t 1 N
G 2 KBATZ030190 Adapter t 1 N
3 KBATZ060400 Stopper t 1 N 2) Remove No. 1 carrier assembly (6).
a Insert a flat-head screwdriver, etc. under
planetary gear (7) to float and remove
DISASSEMBLY the planetary gear.
1. Draining oil
Loosen the drain plug and drain the oil from the
swing machinery case.
PC160LC-7 30-53
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
7. Ring nut
2) Using a bar, etc., float and remove No. 2 carrier 1) Using punch [1], etc., straighten the bent
assembly (18). parts (3 places) of ring nut (27) around the
pinion shaft spline.
6. Ring gear
Remove ring gear (26). 2) Place the flange of housing (28) on a block
a Make match marks on ring gear (26) and and float the pinion shaft at the center.
housing (28) for reassembly. 3) Install tool G1 to the pinion shaft and install
tool G2 to the ring nut.
30-54 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
PC160LC-7 30-55
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
30-56 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
2 Bearing:Grease
end reaches the spacer. a Press fit the bearing until the end of bear-
ing (30) reaches the end of housing (28).
(SHELL RETINAX HD-2 or
equivalent)
2 Mounting screw:
8) Tighten 6 front cover mounting screws (32).
HD-2 or equivalent)
PC160LC-7 30-57
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
3 Ring nut:
2. Ring nut nut.
1) Install ring nut (27) to the pinion shaft.
1100 – 1200 Nm {112.2 – 122.3 kgm}
30-58 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
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
3 Mounting bolt:
swing motor assembly was removed.
3 Pipe:
gauge (1).
30-60 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
D1 799-301-1600 Oil leak tester kit t 1
DISASSEMBLY
1. Set the swing motor and swing machinery 3) Remove 2 plugs (4), 2 springs (5), and 2
assembly on blocks. poppets (6).
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.
6. Collar
Using a puller, etc., remove collar (13).
a Remove 1 disc (14) so that you can remove
the collar easily.
30-62 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
9. Thrust plate
Remove thrust plate (19).
5) Remove retainer holder (16).
PC160LC-7 30-63
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
30-64 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
3) Press the end of shaft (23) with a press, etc. 3. Cylinder block assembly
to press fit it to case (21). 1) Install collar (33), spring (32), and collar (30).
a Press fit the shaft until the end of the 2) Press down collar (30) with a press, etc., and
bearing outer race reaches the case end. install snap ring (31).
4) Install snap ring (22).
2. Thrust plate
Install thrust plate (19).
a Install the thrust plate with small hole side b 4) Install retainer holder (16).
up.
PC160LC-7 30-65
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
30-66 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
6. Brake piston
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)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
3 Mounting bolt:
7) Tighten the mounting bolts.
3 Mounting bolt:
Install reverse prevention valve assembly (1).
5) Install valve plate (3).
a When installing the valve plate, set its cir- 32.4 ± 2.0 Nm {3.3 ± 0.2 kgm}
cularly grooved side toward the cover
and match the cut on its periphery to the
dowel pin.
a Apply grease (G2-LI) to the cover mount-
ing face so that the valve plate will not fall
when the cover assembly is installed.
30-68 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
PC160LC-7 30-69
(2)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
30-70 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY AND 3. Using tool E, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
ASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY 4. Remove seal (6) from swivel shaft (5).
SPECIAL TOOLS 5. Remove O-ring (7) and slipper seal (8) from
swivel rotor (4).
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-2501 Push puller q 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
E • 790-101-2540 • Washer 1
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
ASSEMBLY
DISASSEMBLY
1. Assemble slipper seal (8) and O-ring (7) to
swivel rotor (4).
Grease (G2-LI)
a When installing the rotor, be extremely care-
ful not to damage the slipper seal and the O-
ring.
3 Mounting bolt:
5. Fit O-ring and install cover (1).
PC160LC-7 30-71
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
796-900-1200 Remover t 1
R 790-101-4000
Puller
(490 kN {50t} long) t 1
790-101-1102
Pump
(294 kN {30t}) t 1
4. Start the engine and retract the piston rod.
a Fasten the piston rod with wire so that it will
REMOVAL not slip out and lower the cylinder onto a
30-72 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
6. Disconnect connector A42 (8). 8. Lift work equipment assembly (11) and disas-
semble it.
4 Work equipment assembly: 2,700 kg
PC160LC-7 30-73
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
bling pin:
Grease (LM-G)
30-74 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL AND INSTALLATION 7. Remove plate (3) and pin (4) and lift off boom
cylinder assembly (2).
OF REVOLVING FRAME a Remove the boom cylinder on the opposite
ASSEMBLY side simultaneously.
4 Boom cylinder assembly: 130 kg
REMOVAL
PC160LC-7 30-75
(2)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
10. Remove the 32 mounting bolts and lift off revolv- INSTALLATION
ing frame assembly (12). [*1]
a Using a lever block, etc., balance the revolv- • Carry out installation in the reverse order to
ing frame assembly in longitudinal and lateral removal.
directions, and then remove the all mounting
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
30-76 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
[*2]
a Set the soft zone (marked with S) of the inner
race on the right side of the machine. (The
PC160LC-7 30-77
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
OF HYDRAULIC TANK
ASSEMBLY
REMOVAL
30-78 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
10. Remove cover (9) and plates (10) and (11). 14. Disconnect 7 hoses (16) – (22).
PC160LC-7 30-79
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION
[*2]
a Tighten hose clamp screws (24) at 180° to
3 Mounting bolt:
[*3]
Bleeding air
• Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
30-80 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL AND INSTALLATION 3. Disconnect the following hoses from the front of
the control valve.
OF CONTROL VALVE • (1) : Bucket cylinder (Head side)
ASSEMBLY • (2) : Bucket cylinder (Bottom side)
• (3) : Arm cylinder (Head side)
REMOVAL • (4): Arm cylinder (Bottom side)
• (5): Travel PPC valve
k Lower the work equipment to the ground and • (6): Travel PPC valve
stop the engine. Then, loosen the hydraulic oil • (7): Hydraulic tank
filler cap slowly to release the internal pressure • (8): Pump LS valve
of the hydraulic tank. • (9): Right travel motor
PC160LC-7 30-81
(4)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
4. Disconnect the following hoses and wiring con- 5. Disconnect the following hoses and wiring con-
nector from the left of the control valve. nector from the right of the control valve.
• (15) : Bucket CURL PPC valve • (26) : Main pump
(Hose band: White) • (27) : Bucket DUMP PPC valve
• (16) : Arm IN PPC valve (Hose band: Blue) (Hose band: Black)
• (17) : Boom LOWER PPC valve • (28) : Arm OUT PPC valve (Hose band: Yellow)
(Hose band: Blown) • (29) : Boom RAISE PPC valve
• (18) : Boom cylinder (Head side) (Hose band: Green)
• (19) : Oil cooler • (30) : Boom cylinder (Bottom side)
• (20) : Pump merge-divider valve solenoid valve • (31) : Hydraulic tank
• (21) : Travel junction valve solenoid valve • (32) : 2-stage relief solenoid valve
• (22) : Left travel REVERSE PPC valve • (33) : Left travel FORWARD PPC valve
• (23) : Right travel REVERSE PPC valve (Hose band: Red)
(Hose band: Blue) • (34) : Right travel FORWARD PPC valve
• (24) : Swing RIGHT PPC valve (Hose band: Green)
• (25) : R pump pressure sensor connector A52 • (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)
30-82 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
PC160LC-7 30-83
(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
INSTALLATION
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
30-84 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
ASSEMBLY
PC160LC-7 30-85
(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
3 Combination nut:
machine.
3 Combination bolt:
machine.
30-86 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
796-460-1210 Oil stopper q 1
D
796-770-1320 Adapter q 1
REMOVAL 4. Remove plates (2) and (3) and covers (4) and
PC160LC-7 30-87
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
30-88 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP INPUT SHAFT OIL SEAL
New/Remodel
Symbol
Necessity
Part No. Part name Grease (G2-LI)
Sketch
a Apply grease thinly to the periphery of the oil
Q'ty
seal.
791-463-1350 Push tool t 1
N
790-201-2740 Spacer t 1
REMOVAL
PC160LC-7 30-89
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
DISASSEMBLY AND ASSEM- a When installing pistons (10), apply grease (G2-
LI) to their outside and the inside of the valve
BLY OF WORK EQUIPMENT body holes.
PPC VALVE ASSEMBLY
a Tighten mounting bolts (16) of plates (14) and
DISASSEMBLY (15) (to be tightened together) to the following
torque.
3 Mounting bolt:
a Disassemble according to the following figure.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
ASSEMBLY
a Assemble according to the following figure. a Apply grease (G2 -LI) to the rocking parts of joint
a Only precautions for assembly are explained (17) and contact surfaces of disc (18) and pis-
below. tons (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
30-90 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
ASSEMBLY
PC160LC-7 30-91
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 790-502-1003 Cylinder repair stand t 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
4) Set piston rod assembly (2) to tool Q1.
796-720-1660
Ring
(for boom and bucket) q 1
4
07281-01159
Clamp
(for boom and bucket) q 1
DISASSEMBLY
30-92 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
6) Using tool Q2, remove piston assembly (4). 2. Disassembly of piston assembly
1) Remove rings (11), wear rings (12), and pis-
ton ring (13).
2) Remove the O-ring and backup rings (14).
PC160LC-7 30-93
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
30-94 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
PC160LC-7 30-95
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
• When replacing either or both of the rod and pis- 12) Tighten screw (3).
2 Threads of screw:
ton assembly (2), assemble the new parts
according to the following procedure.
Adhesive (LOCTITE No. 262)
3 Screw:
a Make a mark of the cushion plug position on the
end of the rod having the bottom cushion. (Per-
form this work for only the arm cylinder.) 58.9 – 73.6 Nm {6 – 7.5 kgm}
9) Using tool Q2, tighten piston assembly (4) 13) Caulk the threaded part by 4 places with a
until it reaches end b of the rod. punch.
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.
30-96 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
PC160LC-7 30-97
(2)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
3 Counterweight: 2,900 kg
the engine. [*2]
INSTALLATION
Adhesive (LT-2)
3 Mounting bolt:
2,160 – 2,450 Nm {220 – 250 kgm}
[*2]
a Install the counterweight so that the clear-
ance between it and the revolving frame and
the clearance between it and exterior door
will be 10 ± 5 mm on each side.
30-98 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL AND INSTALLATION 3. Pull dowm outside air filler cover operating clos-
ing lever (2).
OF AIR CONDITIONER UNIT
ASSEMBLY
Serial No.: 10001 – 11000
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
799-703-1200 Service tool KIT t 1
799-703-1100 Vacuum pump (100V) t 1
S 799-703-1111 Vacuum pump (220V) t 1
799-703-1121 Vacuum pump (240V) t 1 4. Remove outside air filter (3).
799-703-1401 Gas leak detector t 1
REMOVAL
1. Drain coolant.
PC160LC-7 30-99
(4)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
7. Remove covers (7), (8) and (9). 12. Disconnect cab intermediate connectors (18) at
the following two points.
• H09: Upper side
• H08: Lower sid
30-100 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
[*1]
a Coat the threads of the refrigerant piping at
the connecting part with compressor oil (ND-
OIL8), and then tighten the piping with a dou-
ble-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:
20. Disconnect air conditioner hoses (30) and (31)
as well as air conditioner tubes (32) and (33). [*1]
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
21. Remove the eight mounting bolts and remove air
conditioner unit assembly (34). • Filling air conditioner gas.
a When removing the air conditioner unit Fill the air conditioner circuit with air conditioner
assembly, do not forget to disconnect the two gas (R134a), using tool S.
air conditioner hoses connected to the bot-
tom.
PC160LC-7 30-101
(4)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
Serial No.: 11001 and up 4. Remove duct (5), cover (6), and plate (7).
New/Remodel
6. Remove ducts (10) and (11).
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
799-703-1200 Service tool KIT t 1
799-703-1100 Vacuum pump (100V) t 1
S 799-703-1111 Vacuum pump (220V) t 1
799-703-1121 Vacuum pump (240V) t 1
799-703-1401 Gas leak detector t 1
REMOVAL
30-101-1 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
[*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):
12. Remove mounting bolt (24) and connector (25). 8 – 12 Nm {0.8 – 1.2 kgm}
[*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:
13. Disconnect heater hoses (22) and (23) and air
conditioner tube (26). [*1]
a Put tags to the disconnected hoses and 20 – 25 Nm {2.0 – 2.5 kgm}
tubes to prevent a mistake in re-connecting 3 Hose screw of M24 x 1.5:
them. 30 – 35 Nm {3.0 – 3.5 kgm}
PC160LC-7 30-101-2
(4)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
REMOVAL
30-102 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
PC160LC-7 30-103
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
INSTALLATION
30-104 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
Serial No.: 11001 and up 5. Remove air conditioner connector plate (14).
REMOVAL
PC160LC-7 30-104-1
(4)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
10. Move right console (24) into the 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).
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
30-104-2 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
PC160LC-7 30-104-3
(4)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
* Among the panes of window glass on the 4 sides (1) : Right side window glass
of the operator's cab, 4 panes (1) – (4) are stuck. (2) : Left side rear window glass
In this section, the procedure for replacing the (3) : Door lower window glass
stuck glass is explained. (4) : Front window glass
When replacing front window glass (4), remove (5) : Front window assembly
front window assembly (5). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the (6) : Both-sided adhesive tape
front window assembly is installed to the opera- (16): Center trim seal
tor's cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
PC160LC-7 30-105
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 793-498-1210 Lifter (Suction cup) t 2
X
2 20Y-54-13180 Adapter t 2
REMOVAL
30-106 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
PC160LC-7 30-107
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
3) Evenly apply paint primer to the surfaces to a In addition to the above parts, apply the
stick both-sided adhesive tapes and the sur- primer to right side window glass (1) and
faces out of those surfaces on operator's cab door lower window glass (3).
(8) which will be coated with the adhesive. • Range to apply primer additionally for right
2 Paint primer:
side window glass (1): (b)
• Range to apply primer additionally for door
SUNSTAR PAINT PRIMER 580
lower window glass (3): (c)
SUPER or equivalent
a After applying the primer, leave it for at least
a Do not apply the primer more than 2
5 minutes (within 8 hours) to dry.
times. (If it is applied more than 2 times,
its performance will be lowered.)
30-108 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
4) Evenly apply glass primer to the sticking sur- 4. Stick both-sided adhesive tape (6) along the
2 Glass primer:
faces of window glass (9). inside edge of the glass sticking section.
a Do not remove the release tape of the both-
SUNSTAR GLASS PRIMER 580 sided adhesive tape on the glass sticking
SUPER or equivalent side before sticking the glass.
a Do not apply the primer more than 2 a When sticking the both-sided adhesive tape,
times. (If it is applied more than 2 times, do not touch the cleaned surface as long as
its performance will be lowered.) possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
PC160LC-7 30-109
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
a Stick both-sided adhesive tape (6a) addi- 3) Stick both-sided adhesive tape (6) for door
tionally for right side window glass (1). lower window glass (3) as shown in the fig-
• Positions to stick additional both-sided ure.
adhesive tape for right side window
glass:
(f) : 50 mm
(g) : 90 mm
(h) : 250 mm
30-110 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
4) Stick both-sided adhesive tape (6) for front 5. Position the new window glass.
window glass (4) as shown in the figure. 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 win-
a Stick both-sided adhesive tape (6c) of dow glass and operator's cab before
the lower side of the front window glass installing the window glass.
along the outside edge of the lower line,
differently from other both-sided adhe-
sive tapes (6). (If it is stuck along the
inside, it will be seen through the trans-
parent part of the glass.)
PC160LC-7 30-111
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
a When positioning front window glass (4), 2) Cut the tip of the adhesive nozzle (14) so
set its horizontal position to the frame that dimensions (q) and (r) will be as follows.
width and set its vertical position so that • Dimension (q) : 10 mm
height difference (p) between it and the • Dimension (r) : 15 mm
frame top will be 3 mm.
2 Adhesive (Winter):
SUPER "S"
30-112 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
5) Apply adhesive (15) to the outside of both- a Apply adhesive (15) additionally for addi-
sided adhesive tape (6) of the operator's cab. tional both-sided adhesive tape (6a) of
the right side window glass and addi-
tional both-sided adhesive tape (6b) of
door lower window glass.
PC160LC-7 30-113
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
7. Install the window glass. a After installing front window glass (4), fill
1) Install window glass (9), matching it to the the clearances between it and center trim
lines of the positioning tapes drawn in step 5. seal (16) with caulking material in range
a Since the window glass cannot be (s) to dimensions (t) and (u).
removed and stuck again, stick it very After applying the primer to glass (4) of
carefully. section A – A, apply adhesive as caulk-
a Stick the glass within 5 minutes after ing material.
applying the adhesive. • Caulking dimension (t) : 2 mm
2) After sticking window glass (9), press all • Caulking dimension (u): 5 mm
around it until it is stuck to the both-sided a When caulking, mask the glass side and
adhesive tape. form the adhesive with a rubber spatula
a Press the corners of the window glass as shown in the figure.
firmly. a Wipe off projected adhesive.
2 Glass primer:
SUNSTAR GLASS PRIMER 580
2 Adhesive:
SUPER
30-114 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right window glass (1) to the primer and adhesive from the operator's cab and
operator's cab, insert stopper rubbers X2 to 2 window glass.
places (v) at the bottom of the glass to fix the a Using white gasoline, wipe off the adhesive
glass. before it is dried up.
a When cleaning the glass, do not give an
impact to it.
PC160LC-7 30-115
(2)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
REMOVAL AND INSTALLATION 7. Remove rollers (8) and (9) under the both sides
of the front window.
OF FRONT WINDOW
ASSEMBLY
k Lower the work equipment to the ground and
stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor'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).
30-116 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
PC160LC-7 30-117
(4)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
INSTALLATION 4. Install right corner block (3) and fix right corner
block bracket (7) with right striker bolt (5).
• Carry out installation in the reverse order to a Tighten the striker bolt securely after adjust-
removal. ing it in step 6.
a Install the right corner block so that there will
[*1] [*2] be no level difference at part a.
• Adjust opening and closing of the front window a Install the right corner block so that level dif-
assembly according to the following procedure. ference b between the rail and right corner
block (3) at part PF will be 0 – 1.0 mm.
1. Open and close the front window to check that it Check that the right corner block is not pro-
does not interfere with the rails and the rollers jected from the rail at the rolling surface of
are not hitch. the roller.
a Secure roller clearance c at part PJ.
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.
3 Mounting bolt: 98 Nm {1.0 kgm}
30-118 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
5. Install left corner blocks (1) and (2) and secure 6. Adjust the striker bolts according to the following
left corner bracket (6) with left striker bolt (4). procedure (Adjust the "CLOSE" positions of the
a Tighten the striker bolt securely after adjust- front window assembly locks).
ing it in step 6. 1) Tighten left striker bolt (4) and right striker
a Install the left corner blocks so that there will bolt (5) at roughly right positions so that front
be no level difference at 2 part d. window glass (18) will be fitted to cab-side
a Secure roller clearance e. trim seal (19).
PC160LC-7 30-119
(4)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
7. After adjusting the striker bolts, splash water 9. Adjust the front window stoppers.
heavily over the front window glass and check 1) After adjusting "closing" lock of the front win-
that the water does not leak into the cab. dow assembly in step 8, check the contact of
both front window stoppers (23).
8. Adjust the "opening" lock of the front window 2) If both stoppers (23) do not contact normally,
assembly. adjust and fix them at places where they con-
1) After adjusting the "closing" lock of the front tact normally.
window in steps 6 and 7, raise the front win-
dow 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 follow-
ing 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 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW, MONITOR
10. Check the latching effort of the front window REMOVAL AND INSTALLATION
assembly.
1) After finishing steps 6 – 9, check that latching OF MONITOR ASSEMBLY
efforts of both locks (20) and (21) are even.
a Check the latching efforts on both "clos- REMOVAL
ing" side (in the front of the operator's k First, disconnect the cable from the negative
cab) and "opening" side (in the rear of terminal (–) of the battery.
the operator's cab).
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
• Install in reverse order of removal.
PC160LC-7 30-121
(4)
DISASSEMBLY AND ASSEMBLY GOVERNOR, PUMP CONTROLLER
REMOVAL REMOVAL
k First, disconnect the cable from the negative k First, disconnect the cable from the negative
terminal (–) of the battery. terminal (–) of the battery.
2. Disconnect governor, pump controller wiring con- 2. Disconnect governor, pump controller wiring con-
nectors C01 (2), C02 (3) and C03 (4). nectors C01 (4), C02 (5) and C03 (6).
3. Remove the four mounting bolts and remove 3. Remove the four mounting bolts and remove
governor, pump controller assembly (5). governor, pump controller assembly (7).
INSTALLATION INSTALLATION
• Install in reverse order of removal. • Install in reverse order of removal.
30-122 PC160LC-7
(4)
90 OTHERS
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)