Day: June 9, 2025

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC118MR, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC118MR workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

WEBM008700 – Hydraulic Excavator PC118MR-8 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 872 pages
File Format: PDF
Language: English
00 Index and foreword…3
Table of contents…4
Foreword and general information…12
Safety notice…12
How to read the shop manual…17
Explanation of terms for maintenance standard…19
Handling of hydraulic components…21
Method of disconnecting and connecting push-pull type coupler…23
Handling of electric equipment…26
How to read electric wire code…36
Precautions when performing work…39
Standard tightening torque table…42
List of abbreviation…46
Conversion table…50
Shop Manual…55
01 Specification…55
Contents…56
Specifications…57
Specifications drawing…57
Specifications…60
Table of weight…63
Table of fuel, coolant and lubricants…65
Shop Manual…67
10 Structure and function…67
Contents…68
Engine and cooling system…70
Engine mount…70
PTO…71
Cooling system…72
Power train…74
Power train…74
Swing circle…75
Swing machinery…76
Undercarriage and frame…77
Track frame…77
Idler and recoil spring…78
Carrier roller…79
Track roller…80
Track shoe…81
Hydraulic system…82
Hydraulic equipment layout drawing…82
Valve control…83
Hydraulic tank and filter…84
Hydraulic pump…86
Blade specification…86
Control valve…98
Outline…98
11-spool valve…99
CLSS…110
Outline of CLSS…110
Basic principle…111
Function and operation by valve…114
Hydraulic circuit diagram and name of valves…114
1. Unload valve…116
2. Introduction of LS pressure…119
3. LS bypass plug…121
4. Pressure compensation valve…122
5. Surface area ratio of pressure compensation valve…123
6. Right and left travel junction circuit…124
7. Travel LS bypass circuit…126
8. Boom regeneration circuit…128
PPC valve…131
Work equipment and swing PPC valve…131
Travel PPC valve…137
Blade and boom swing PPC valve…140
Swing motor…142
Safety valve with suction…144
Operation of the modulating relief valve…145
Operation of swing brake…146
Actuation of hydraulic timer valve…147
Travel motor…148
Center swivel joint…150
Solenoid valve…151
Attachment oil flow adjuster EPC valve…152
PPC accumulator…156
For PPC circuit…156
Anti-drop valve…157
Work equipment…163
Work equipment…163
Dimensions of components…166
1,850 mm arm…166
2,000 mm arm…168
2,300 mm arm…170
Bucket…172
Work equipment cylinder…174
Boom cylinder…174
2-piece boom cylinder…174
Arm cylinder…174
Bucket cylinder…175
Boom swing cylinder…175
Blade cylinder…175
Cab and its attachments…178
Air conditioner…178
Air conditioner piping diagram…178
Air conditioner unit…182
Air conditioner controller…185
Compressor…186
Condenser…187
Sensor…188
Electrical system…189
Electrical control system…189
Machine control system diagram…189
Engine control function…191
Engine and pump mutual control function…193
Auto-deceleration function…197
Engine automatic warm-up function…199
Swing control function…203
Travel control function…205
PPC lock function…207
Oil flow adjuster function for attachment…208
System components…210
Monitor system…219
Machine monitor…220
Display…222
Switches…226
Operator mode function…230
Service mode function…232
KOMTRAX system…233
Sensor…236
Atmospheric pressure sensor…236
Boost pressure and temperature sensor…236
Coolant temperature sensor…237
Crankshaft speed sensor…237
Common rail pressure sensor…238
Hydraulic oil temperature sensor…238
Fuel level sensor…239
Pump oil pressure sensor…240
PPC oil pressure sensor…241
Shop Manual…243
20 Standard value table…243
Contents…244
Standard value table…245
Standard value table for engine…245
Standard value table for chassis…246
30 Testing and adjusting…255
Contents…256
Testing and adjusting…257
Testing engine speed…257
Testing exhaust temperature…258
Checking exhaust gas colour…259
Adjusting valve clearance…260
Testing compression pressure…262
Testing blow-by pressure…264
Testing engine oil pressure…265
Handling fuel system parts…266
Releasing residual pressure from fuel system…266
Testing fuel pressure…267
Testing fuel return rate and fuel leakage…268
Bleeding air from fuel circuit…270
Checking fuel circuit for leakage…272
Testing and adjusting alternator belt tension…273
Testing…273
Adjusting…273
Measuring the swing circle axial clearance…274
Testing and adjusting track-shoe tension…275
Checking and regulating pressure in the hydraulic circuits…276
Testing and adjusting oil pressure in work equipment and travel circuits…277
Testing and adjusting swing and blade circuit oil pressure…279
Testing control circuit basic pressure…281
Testing and adjusting oil pressure in pump PC control circuit…282
Testing LS differential pressure and adjusting LS valve…284
Testing solenoid valve output pressure…286
Testing main pump flow rate…289
Checking parts which cause hydraulic drift of work equipment…290
Measuring travel deviation…292
Adjusting the maximum speed of the travel motors…293
Releasing residual pressure from hydraulic circuit…294
Testing oil leakage…295
Air bleeding from hydraulic circuits…298
Order for operations…298
Special functions of machine monitor…300
Handling voltage circuit of engine controller…349
Preparation work for troubleshooting of electrical system…350
Procedure for testing diodes…355
Pm Clinic service…356
40 Troubleshooting…361
Contents…362
Failure code table and fuse locations…366
Failure code table…366
Fuse locations…369
General information on troubleshooting…371
Points to remember when troubleshooting…371
Sequence of events in troubleshooting…372
Checks before troubleshooting…373
Classification and procedures for troubleshooting…374
Information in troubleshooting table…375
Phenomena looking like troubles and troubleshooting Nos…377
Connection table for connector pin numbers…380
T- branch box and T- branch adapter table…416
Troubleshooting by failure code…419
Failure code [989L00] Engine controller lock caution 1…419
Failure code [989M00] Engine controller lock caution 2…420
Failure code [989N00] Engine controller lock caution 3…421
Failure code [AB00KE] Charge voltage low…422
Failure code [B@BAZG] Eng oil press. low…424
Failure code [B@BCNS] Eng coolant overheat…425
Failure code [B@HANS] Hyd. oil overheat…426
Failure code [CA111] ECM critical internal failure…427
Failure code [CA115] Eng. Ne and Bkup speed sensor error…430
Failure code [CA122] Charge air press sensor high error…431
Failure code [CA123] Charge air press sensor low error…433
Failure code [CA131] Throttle sensor high error…434
Failure code [CA132] Throttle sensor low error…436
Failure code [CA144] Coolant temp. sensor high error…438
Failure code [CA145] Coolant temp. sensor low error…440
Failure code [CA153] Charge air temp. sensor high error…442
Failure code [CA154] Charge air temp. sensor low error…444
Failure code [CA155] Charge air temperature high speed derate…445
Failure code [CA187] Sensor sup. 2 volt. low error…446
Failure code [CA221] Ambient air press. sensor high error…448
Failure code [CA222] Ambient air press. sensor low error…450
Failure code [CA234] Eng. overspeed…451
Failure code [CA238] Ne speed sensor sup. volt. error…452
Failure code [CA271] IMV/PCV1 short error…454
Failure code [CA272] IMV/PCV1 open error…455
Failure code [CA322] Injector #1 (L #1) system open/short error…456
Failure code [CA324] Injector #3 (L #3) system open/short error…458
Failure code [CA331] Injector #2 (L #2) system open/short error…460
Failure code [CA332] Injector #4 (L #4) system open/short error…462
Failure code [CA342] Calibration code incompatibility…464
Failure code [CA351] Inj. drive circuit error…465
Failure code [CA352] Sensor sup. 1 volt. low error…468
Failure code [CA386] Sensor sup. 1 volt. high error…470
Failure code [CA435] Abnormality in engine oil pressure switch…472
Failure code [CA441] Battery voltage low error…473
Failure code [CA442] Battery voltage high error…474
Failure code [CA449] Rail press. very high error…475
Failure code [CA451] Rail press. sensor high error…476
Failure code [CA488] Charge air temperature high torque derate…478
Failure code [CA452] Rail press. sensor low error…479
Failure code [CA553] Rail press. high error…480
Failure code [CA559] Rail press. low error…481
Failure code [CA689] Eng. Ne speed sensor error…484
Failure code [CA731] Eng. Bkup speed sensor phase error…486
Failure code [CA757] All persistent data lost error…487
Failure code [CA778] Eng. Bkup speed sensor error…488
Failure code [CA1633] KOMNET datalink timeout error…490
Failure code [CA2185] Throttle sens. sup. volt. high error…492
Failure code [CA2186] Throttle sens. sup. volt. low error…494
Failure code [CA2249] Rail press. very low error…495
Failure code [CA2311] Abnormality in IMV solenoid…496
Failure code [D110KB] Battery relay drive short…498
Failure code [D19JKZ] Personal code relay abnormality…500
Failure code [D862KA] GPS antenna discon…502
Failure code [DA22KK] Pump solenoid power low error…504
Failure code [DA25KP] 5 V sensor 1 power abnormality…507
Failure code [DA26KP] 5 V sensor 2 power abnormality…510
Failure code [DA2RMC] CAN discon (Pump controller detected)…512
Failure code [DAF8KB] Camera Power Supply Short Circuit…514
Failure code [DAFGMC] GPS module error…516
Failure code [DAFRMC] CAN discon (Monitor detected)…518
Failure code [DFB1KZ] Service lever pot. 1 abnormality…520
Failure code [DFB2KZ] Service lever pot. 2 abnormality…522
Failure code [DFB3L8] Service lever1 potentio error…524
Failure code [DFB4L8] Service lever2 potentio error…526
Failure code [DFB5KZ] Service lever sPot. 1 abnormality…528
Failure code [DFB6KZ] Service lever sPot. 2 abnormality…530
Failure code [DGH2KB] Hydr oil sensor short…532
Failure code [DHPAMA] Pump press sensor abnormality…534
Failure code [DHS5KX] Travel PPC sensor abnormality…536
Failure code [DHX1MA] Overload sensor abnormality…538
Failure code [DV20KB] Travel alarm short circuit…539
Failure code [DW43KA] Travel speed sol discon…540
Failure code [DW43KB] Travel speed sol short…541
Failure code [DW45KA] Swing brake sol discon…542
Failure code [DW45KB] Swing brake sol short…544
Failure code [DXA8KA] PC-EPC sol discon…546
Failure code [DXA8KB] PC-EPC sol short…548
Failure code [DXE7KA] Service current EPC2 open circuit…550
Failure code [DXE7KB] Service current EPC2 short circuit…552
Failure code [DXE8KA] Service current EPC3 open circuit…554
Failure code [DXE8KB] Service current EPC3 short circuit…556
Failure code [DXE9KA] Service current EPC4 open circuit…558
Failure code [DXE9KB] Service current EPC4 short circuit…560
Failure code [DXEAKA] Service current EPC1 open circuit…562
Failure code [DXEAKB] Service current EPC1 short circuit…564
Failure code [DY20KA] Wiper working abnormality…566
Failure code [DY20MA] Wiper parking abnormality…568
Failure code [DY2CKA] Washer drive open circuit…570
Failure code [DY2CKB] Washer drive short circuit…572
Failure code [DY2DKB] Wiper drive (fwd) short circuit…574
Failure code [DY2EKB] Wiper drive (rev) short circuit…576
Troubleshooting of electrical system…579
Before carrying out troubleshooting of electrical system…579
Information in troubleshooting table…581
E-1 When starting switch is turned ON, machine monitor displays nothing…582
E-2 Engine does not start (Engine does not turn)…585
E-3 Preheater does not operate…588
E-4 Automatic warm-up system does not operate (in cold season)…590
E-5 All work equipment, swing, and travel mechanism do not move or cannot be locked…591
E-6 Precaution lights up while engine is running…594
E-7 Emergency stop item lights up while engine is running…597
E-8 Engine coolant temperature gauge does not indicate normally…598
E-9 Hydraulic oil temperature gauge does not indicate normally…600
E-10 Fuel level gauge does not indicate normally…603
E-11 Contents of display by machine monitor are different from applicable machine…605
E-12 Machine monitor does not display some items…606
E-13 Function switch does not work…607
E-14 Auto-decelerator does not operate normally…608
E-15 Working mode does not change…609
E-16 Travel speed does not change…610
E-17 Alarm buzzer cannot be stopped…611
E-18 Windshield wiper and window washer do not operate…612
E-19 Swing holding brake does not operate normally…616
E-20 Travel alarm does not sound or does not stop sounding…618
E-21 Air conditioner does not operate normally (including air conditioner abnormality record)…619
E-22 While starting switch is in OFF position, service meter is not displayed…632
E-23 Machine monitor cannot be set in service mode…633
E-24 Monitoring function does not display lever control signal normally…634
E-25 KOMTRAX system does not operate normally…658
Troubleshooting of hydraulic and mechanical system (H-mode)…659
Information contained in troubleshooting table…659
H-1 Speed or power of all work equipment, swing, and travel are low…660
H-2 Engine speed sharply drops or engine stalls…661
H-3 No work equipment, travel and swing move…662
H-4 Abnormal noise is heard from around hydraulic pump…663
H-5 Fine control performance or response of work equipment and travel is low…664
H-6 Speed or power of boom is low…665
H-7 Speed or power of arm is low…666
H-8 Speed or power of bucket is low…667
H-9 Speed or power of boom swing is low…668
H-10 Speed or power of blade is low…669
H-11 Work equipment does not move in its single operation…670
H-12 Hydraulic drift of work equipment is large…671
H-13 Time lag of work equipment is large…673
H-14 Work equipment loaded more is slower during compound operation…674
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE…675
H-16 Travel speed lowers significantly during compound operation of work equipment/swing + travel…676
H-17 Machine deviates during travel…677
H-18 Travel speed is low…678
H-19 Machine cannot be steered easily or steering power is low…679
H-20 Travel speed does not change or it is kept low or high…680
H-21 Track does not move (only either side)…681
H-22 Machine does not swing…682
H-23 Swing acceleration, swing speed and swing power are low…683
H-24 Excessive overrun when stopping swing…685
H-25 When upper structure stops swinging, it makes large shock…686
H-26 When upper structure stops swinging, it makes large sound…687
H-27 Hydraulic drift of swing is large…688
H-28 Flow rate in attachment circuit cannot be adjusted…689
Troubleshooting of engine (S-mode)…690
Method of using troubleshooting chart…690
S-1 Starting performance is poor…694
S-2 Engine does not start…695
S-3 Engine does not pick up smoothly…698
S-4 Engine stops during operations…699
S-5 Engine does not rotate smoothly…700
S-6 Engine lacks output (or lacks power)…701
S-7 Exhaust smoke is black (incomplete combustion)…702
S-8 Oil consumption is excessive (or exhaust smoke is blue)…703
S-9 Oil becomes contaminated quickly…704
S-10 Fuel consumption is excessive…705
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…706
S-12 Oil pressure drops…707
S-13 Oil level rises (Entry of coolant or fuel)…708
S-14 Coolant temperature becomes too high (overheating)…709
S-15 Abnormal noise is made…710
S-16 Vibration is excessive…711
50 Disassembly and assembly…713
Contents…714
How to read this manual…716
Coating materials list…718
Engine and cooling system…721
Removal and installation of fuel supply pump assembly…721
Removal…721
Installation…722
Removal and installation of fuel injector assembly…723
Removal…723
Installation…724
Removal and installation of front oil seal…725
Special tools…725
Removal…725
Installation…726
Removal and installation of rear oil seal…727
Special tools…727
Removal…727
Installation…728
Removal and installation of cylinder head assembly…730
Removal…730
Installation…734
Removal and installation of radiator assembly…737
Removal…737
Installation…738
Removal and installation of aftercooler assembly…739
Removal…739
Installation…740
Removal and installation of work equipment oil cooler assembly…741
Special tools…741
Installation…742
Removal and installation of engine and work equipment pump assembly…743
Special tools…743
Removal…743
Installation…747
Removal and installation of fuel tank assembly…748
Removal…748
Installation…750
Power train…751
Removal and installation of the final drive…751
Removal…751
Installation…751
Removal and installation of swing motor…752
Removal…752
Installation…752
Removal and installation of swing machinery…753
Removal…753
Installation…754
Disassembly and assembly of swing machinery…755
Special tools…755
Disassembly…755
Assembly…758
Removal and installation of swing circle…764
Removal…764
Installation…764
Undercarriage and frame…765
Removal and installation of track roller…765
Removal…765
Installation…765
Disassembly of idler assembly…766
Removal and installation of idler and recoil spring assembly…767
Removal…767
Installation…767
Disassembly of recoil spring…768
Removal and installation of track shoes…769
Removal…769
Installation…769
Removal and installation of sprocket assembly…770
Removal…770
Installation…770
Removal and installation of carrier roller…771
Removal…771
Installation…771
Removal and installation of revolving frame…772
Removal…772
Installation…773
Removal and installation of counterweight assembly…775
Removal…775
Installation…776
Removal and installation of additional counterweight assembly…777
Removal…777
Installation…778
Hydraulic system…779
Removal and installation of center swivel joint assembly…779
Removal…779
Installation…780
Disassembly and assembly of center swivel joint assembly…781
Special tools…781
Disassembly…781
Removal and installation of hydraulic tank assembly…783
Special tools…783
Removal…783
Installation…785
Removal and installation of hydraulic pump assembly…786
Special tools…786
Installation…788
Removal and installation of control valve assembly…789
Special tools…789
Removal…789
Installation…792
Disassembly and assembly control valve…794
Disassembly and assembly of work equipment PPC valve assembly…795
Disassembly…795
Assembly…795
Disassembly and assembly of travel PPC valve assembly…797
Special tools…797
Assembly…797
Removal and installation of boom swing cylinder assembly…799
Removal…799
Installation…800
Removal and installation boom cylinder (version with 2-piece boom)…801
Removal…801
Installation…803
Removal and installation of blade cylinder…804
Removal…804
Installation…804
Disassembly and assembly of hydraulic cylinder assembly…805
Special tools…805
Disassembly…805
Assembly…807
Work equipment…811
Removal and installation work equipment assembly (for 1-piece boom)…811
Removal…811
Installation…813
Removal and installation work equipment assembly (2-piece boom)…814
Removal…814
Installation…815
Removal and installation of boom swing bracket…816
Removal…816
Installation…818
Cab and its attachments…819
Removal and installation of operator cab assembly…819
Removal…819
Installation…823
Removal and installation of operator's cab glass (Stuck glass)…824
Special tools…825
Removal…825
Installation…825
Removal and installation of front window assembly…834
Removal…834
Installation…834
Removal and installation of floor frame assembly…835
Removal…835
Installation…840
Electrical system…841
Removal and installation of air compressor assembly…841
Special tools…841
Removal…841
Installation…842
Removal and installation of air conditioner condenser…843
Removal…843
Installation…844
Removal and installation of air conditioner unit assembly…845
Removal…845
Installation…848
Removal and installation of machine monitor assembly…850
Installation…851
Removal and installation of pump controller assembly…852
Removal…852
Installation…853
Removal and installation of engine controller assembly…855
Removal…855
Installation…855
Removal and installation of KOMTRAX terminal assembly…856
Removal…856
Installation…856
90 Diagrams and drawings…857
Contents…858
Hydraulic diagram…859
Electrical diagram…861
Electrical diagram (1/6)…861
Electrical diagram (2/6)…863
Electrical diagram (3/6)…865
Electrical diagram (4/6)…867
Electrical diagram (5/6)…869
Electrical diagram (6/6)…871

Komatsu Hydraulic Excavator PC118MR Repair Service Manuals

---

INSTANT DOWNLOAD

---

---

INSTANT DOWNLOAD

---

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC170LC-10, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC170LC-10 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEN06367-02 – Hydraulic Excavator PC170LC-10 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,450 pages
File Format: PDF
Language: English

COVER..1
00 Index and foreword ..3
Index ..4
Foreword, safety and general information ..15
Important safety notice ..15
How to read the shop manual ..22
Explanation of terms for maintenance standard ..24
Handling equipment of fuel system devices ..26
Handling of intake system parts ..27
Handling of hydraulic equipment ..28
Method of disconnecting and connecting of push-pull type coupler ..30
Handling of electrical equipment ..33
How to read electric wire code ..41
Precautions when performing operation ..44
Practical use of KOMTRAX ..49
Standard tightening torque table ..50
List of abbreviation ..56
Conversion table ..61
01 Specification ..67
Table of contents ..68
Specifications ..69
Specification drawing ..69
Working range drawings ..70
Specifications ..71
Weight table ..74
Table of fuel, coolant, and lubricants ..75
10 Structure and function ..77
Table of contents ..78
Engine and cooling system ..79
Engine related parts ..79
VFT ..81
EGR system piping drawing ..85
EGR system circuit diagram ..87
EGR valve ..88
EGR cooler ..90
KCCV layout drawing ..92
KCCV ventilator ..95
KDOC muffler ..97
Cooling system ..99
Power train ..101
Power train system ..101
Swing circle ..103
Swing machinery ..104
Final drive ..106
Undercarriage and frame ..108
Track frame and idler cushion ..108
Hydraulic system ..110
Hydraulic component layout ..110
Valve control ..113
Hydraulic tank ..115
CLSS ..117
Main pump ..121
Control valve ..147
Swing motor ..195
Travel motor ..197
PPC valve ..212
Solenoid valve ..234
Attachment circuit selector valve (for high pressure circuit) ..238
Attachment circuit selector valve (for low pressure circuit) ..240
Center swivel joint ..243
Accumulator ..245
Work equipment ..246
Work equipment ..246
Work equipment shim ..247
Bucket play adjustment shim ..248
Cab and its attachments ..249
Cab mount and cab tipping stopper ..249
ROPS cab ..250
Electrical system ..251
Electrical control system ..251
Machine monitor system ..296
KOMTRAX system ..318
Sensor ..321
20 Standard value tables ..339
Table of contents ..340
Standard service value table ..341
Standard value table for engine ..341
Standard value table for machine ..343
Standard value table for electrical system ..357
30 Testing and adjusting ..365
Table of contents ..366
Related information on testing and adjusting ..367
Tools for testing and adjusting ..367
Sketch of tools for testing and adjusting ..370
Engine and cooling system ..371
Testing engine speed ..371
Testing boost pressure ..372
Testing exhaust gas color ..374
Testing and adjusting valve clearance ..375
Testing compression pressure ..378
Testing blowby pressure ..382
Testing engine oil pressure ..383
Testing fuel pressure ..384
Testing fuel discharge, return and leakage ..389
Bleeding air from fuel system ..394
Testing fuel circuit for leakage ..396
Handling cylinder cutout mode operation ..397
Handling no-injection cranking operation ..398
Checking and adjusting air conditioner compressor belt tension ..399
Replacing fan belt ..400
Power train ..401
Testing swing circle bearing clearance ..401
Undercarriage and frame ..402
Testing and adjusting track tension ..402
Hydraulic system ..403
Releasing remaining pressure from hydraulic circuit ..403
Testing oil pressure of control circuit ..404
Testing and adjusting oil pressure in work equipment, swing, and travel circuits ..405
Testing and adjusting oil pressure in pump PC control circuit ..409
Testing and adjusting oil pressure in pump LS control circuit ..412
Testing outlet pressure of solenoid valve ..416
Testing PPC valve outlet pressure ..419
Adjusting play of work equipment and swing PPC valves ..421
Testing pump swash plate sensor ..422
Isolating the parts causing hydraulic drift in work equipment ..423
Testing and adjusting travel deviation ..425
Testing oil leakage ..427
Bleeding air from hydraulic circuit ..430
Cab and its attachments ..432
Checking cab tipping stopper ..432
Adjusting mirrors ..433
Electrical system ..435
Special functions of machine monitor ..435
KOMTRAX terminal start-up procedure ..493
Adjusting rearview camera angle ..496
Handling voltage circuit of engine controller ..498
Handling battery disconnect switch ..499
Testing diodes ..500
Pm clinic ..501
Pm Clinic service ..501
40 Troubleshooting ..511
Table of contents ..512
Related information on troubleshooting ..518
Troubleshooting points ..518
Sequence of events in troubleshooting ..520
Checks before troubleshooting ..522
Inspection procedure before troubleshooting ..524
Preparation work for troubleshooting of electrical system ..542
Classification and procedure for troubleshooting ..547
Symptom and troubleshooting numbers ..550
Information in troubleshooting table ..553
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ..555
Connector list and layout ..558
Connector contact identification ..568
T-branch box and T-branch adapter table ..606
Fuse location table ..611
Failure codes table ..613
Troubleshooting by failure code (Display of code) ..620
Failure code [879AKA] A/C Inner Sensor Open Circuit ..620
Failure code [879AKB] A/C Inner Sensor Short Circuit ..621
Failure code [879BKA] A/C Outer Sensor Open Circuit ..622
Failure code [879BKB] A/C Outer Sensor Short Circuit ..623
Failure code [879CKA] Ventilating Sensor Open Circuit ..624
Failure code [879CKB] Ventilating Sensor Short Circuit ..625
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ..626
Failure code [879EMC] Ventilation Damper Abnormality ..627
Failure code [879FMC] Air Mix Damper Abnormality ..628
Failure code [879GKX] Refrigerant Abnormality ..629
Failure code [989L00] Engine Controller Lock Caution 1 ..630
Failure code [989M00] Engine Controller Lock Caution 2 ..631
Failure code [989N00] Engine Controller Lock Caution 3 ..632
Failure code [AA10NX] Air Cleaner Clogging ..633
Failure code [AB00KE] Charge Voltage Low ..635
Failure code [B@BAZG] Eng Oil Press Low ..637
Failure code [B@BAZK] Eng Oil Level Low ..638
Failure code [B@BCNS] Eng Water Overheat ..639
Failure code [B@BCZK] Eng Water Level Low ..640
Failure code [B@HANS] Hyd Oil Overheat ..642
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ..643
Failure code [CA122] Chg Air Press Sensor High Error ..644
Failure code [CA123] Chg Air Press Sensor Low Error ..646
Failure code [CA131] Throttle Sensor High Error ..648
Failure code [CA132] Throttle Sensor Low Error ..650
Failure code [CA144] Coolant Temp Sens High Error ..652
Failure code [CA145] Coolant Temp Sens Low Error ..654
Failure code [CA153] Chg Air Temp Sensor High Error ..656
Failure code [CA154] Chg Air Temp Sensor Low Error ..658
Failure code [CA187] Sensor 2 Supply Volt Low Error ..660
Failure code [CA221] Ambient Press Sensor High Error ..662
Failure code [CA222] Ambient Press Sens Low Error ..664
Failure code [CA227] Sensor 2 Supply Volt High Error ..666
Failure code [CA234] Eng Overspeed ..667
Failure code [CA238] Ne Speed Sensor Supply Volt Error ..668
Failure code [CA239] Ne Speed Sens Supply Volt High Error ..669
Failure code [CA271] IMV/PCV1 Short Error ..670
Failure code [CA272] IMV/PCV1 Open Error ..672
Failure code [CA295] Ambient Press Sens In Range Error ..674
Failure code [CA322] Inj #1(L#1) Open/Short Error ..675
Failure code [CA324] Inj #3(L#3) Open/Short Error ..677
Failure code [CA331] Inj #2(L#2) Open/Short Error ..679
Failure code [CA332] Inj #4(L#4) Open/Short Error ..681
Failure code [CA343] ECM Critical Internal Failure ..683
Failure code [CA351] Injectors Drive Circuit Error ..684
Failure code [CA352] Sensor 1 Supply Volt Low Error ..685
Failure code [CA356] Mass Air Flow Sensor High Error ..687
Failure code [CA357] Mass Air Flow Sensor Low Error ..689
Failure code [CA386] Sensor 1 Supply Volt High Error ..691
Failure code [CA428] Water in Fuel Sensor High Error ..692
Failure code [CA429] Water in Fuel Sensor Low Error ..694
Failure code [CA435] Eng Oil Press Sw Error ..696
Failure code [CA441] Battery Voltage Low Error ..697
Failure code [CA442] Battery Voltage High Error ..699
Failure code [CA449] Rail Press Very High Error ..700
Failure code [CA451] Rail Press Sensor High Error ..701
Failure code [CA452] Rail Press Sensor Low Error ..703
Failure code [CA466] KVGT Motor Driver Position Error ..705
Failure code [CA488] Chg Air Temp High Torque Derate ..707
Failure code [CA515] Rail Press Sens Sup Volt High Error ..708
Failure code [CA516] Rail Press Sens Sup Volt Low Error ..710
Failure code [CA553] Rail Press High Error ..712
Failure code [CA555] Crankcase Press High Error 1 ..713
Failure code [CA556] Crankcase Press High Error 2 ..714
Failure code [CA559] Rail Press Low Error ..715
Failure code [CA689] Eng Ne Speed Sensor Error ..719
Failure code [CA691] Intake Air Temp Sens High Error ..721
Failure code [CA692] Intake Air Temp Sens Low Error ..723
Failure code [CA697] ECM Internal Temp Sensor High Error ..725
Failure code [CA698] ECM Int Temp Sensor Low Error ..726
Failure code [CA731] Eng Bkup Speed Sens Phase Error ..727
Failure code [CA778] Eng Bkup Speed Sensor Error ..728
Failure code [CA1117] Persistent Data Lost Error ..731
Failure code [CA1695] Sensor 5 Supply Volt High Error ..732
Failure code [CA1696] Sensor 5 Supply Volt Low Error ..733
Failure code [CA1843] Crankcase Press Sens High Error ..734
Failure code [CA1844] Crankcase Press Sens Low Error ..736
Failure code [CA1896] EGR Valve Stuck Error ..738
Failure code [CA1942] Crankcase Press Sens In Range Error ..739
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error ..740
Failure code [CA2185] Throt Sensor Sup Volt High Error ..741
Failure code [CA2186] Throt Sensor Sup Volt Low Error ..743
Failure code [CA2249] Rail Press Very Low Error ..745
Failure code [CA2272] EGR Valve Pos Sens Low Error ..746
Failure code [CA2311] IMV Solenoid Error ..748
Failure code [CA2349] EGR Valve Solenoid Open Error ..749
Failure code [CA2353] EGR Valve Solenoid Short Error ..751
Failure code [CA2357] EGR Valve Servo Error ..753
Failure code [CA2373] Exhaust Manifold Press Sens High Error ..754
Failure code [CA2374] Exhaust Manifold Press Sens Low Error ..756
Failure code [CA2375] EGR Orifice Temp Sens High Error ..758
Failure code [CA2376] EGR Orifice Temp Sens Low Error ..760
Failure code [CA2554] Exh Manifold Press Sens In Range Error ..762
Failure code [CA2555] Grid Htr Relay Volt Low Error ..763
Failure code [CA2556] Grid Htr Relay Volt High Error ..765
Failure code [CA2961] EGR Orifice Temp High Error 1 ..767
Failure code [CA2973] Chg Air Press Sensor In Range Error ..768
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ..769
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ..771
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error ..773
Failure code [CA3741] Rail Press Valve Trip Error ..775
Failure code [CA3918] KVGT Stuck Error ..776
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ..777
Failure code [CA3921] KVGT Servo Error 2 ..778
Failure code [CA3922] KVGT Motor Driver Open Error ..779
Failure code [CA3923] KVGT Motor Driver Short Error ..781
Failure code [D110KB] Battery Relay Drive Short Circuit ..783
Failure code [D19JKZ] Personal Code Relay Abnormality ..785
Failure code [D811MC] KOMTRAX Error ..788
Failure code [D862KA] GPS Antenna Open Circuit ..789
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX) ..790
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) ..792
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..793
Failure code [DA20MC] Pump Controller Malfunction ..795
Failure code [DA22KK] Pump Solenoid Power Low Error ..796
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ..798
Failure code [DA29KQ] Model Selection Abnormality ..800
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ..802
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ..804
Failure code [DA2QKR] CAN2 Discon (Pump Con) ..805
Failure code [DA2RKR] CAN1 Discon (Pump Con) ..807
Failure code [DAF0MB] Monitor ROM Abnormality ..808
Failure code [DAF0MC] Monitor Error ..809
Failure code [DAF8KB] Camera Power Supply Short Circuit ..810
Failure code [DAF9KQ] Model Selection Abnormality ..812
Failure code [DAFGMC] GPS Module Error ..813
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ..814
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor) ..816
Failure code [DAFQKR] CAN2 Discon (Monitor) ..817
Failure code [DAZ9KQ] A/C Model Selection Abnormality ..818
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ..819
Failure code [DB2QKR] CAN2 Discon (Engine Con) ..823
Failure code [DB2RKR] CAN1 Discon (Engine Con) ..827
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ..832
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ..834
Failure code [DHPAMA] F Pump Press Sensor Abnormality ..836
Failure code [DHPBMA] R Pump Press Sensor Abnormality ..838
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ..840
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ..842
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ..844
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ..846
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ..848
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ..850
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ..852
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ..854
Failure code [DKR0MA] Pump Swash Plate Sensor Abnormality ..856
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ..858
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ..860
Failure code [DV20KB] Travel Alarm Short Circuit ..861
Failure code [DW43KA] Travel Speed Sol Open Circuit ..863
Failure code [DW43KB] Travel Speed Sol Short Circuit ..865
Failure code [DW45KA] Swing Brake Sol Open Circuit ..867
Failure code [DW45KB] Swing Brake Sol Short Circuit ..870
Failure code [DW91KA] Travel Junction Sol Open Circuit ..872
Failure code [DW91KB] Travel Junction Sol Short Circuit ..874
Failure code [DWA2KA] Attachment Sol Open Circuit ..876
Failure code [DWA2KB] Attachment Sol Short Circuit ..878
Failure code [DWJ0KA] Merge-divider Sol Open Circuit ..879
Failure code [DWJ0KB] Merge-divider Sol Short Circuit ..880
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..881
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit ..883
Failure code [DXA8KA] PC-EPC Sol Open Circuit ..884
Failure code [DXA8KB] PC-EPC Sol Short Circuit ..886
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ..888
Failure code [DXE4KB] Attachment Flow EPC Short Circuit ..890
Failure code [DY20KA] Wiper Working Abnormality ..891
Failure code [DY20MA] Wiper Parking Abnormality ..893
Failure code [DY2CKB] Washer Drive Short Circuit ..895
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ..897
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ..899
Troubleshooting of electrical system (E-mode) ..901
E-1 Engine does not start (Engine does not crank) ..901
E-2 Manual preheating system does not work ..907
E-3 Automatic preheating system does not work ..910
E-4 While preheating is working, preheating monitor does not light up ..912
E-5 When starting switch is turned to ON position, machine monitor displays nothing ..914
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow ..917
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow ..918
E-8 Engine coolant temperature monitor lights up in red while engine is running ..919
E-9 Hydraulic oil temperature monitor lights up in red while engine is running ..920
E-10 Charge level monitor lights up in red while engine is running ..921
E-11 Fuel level monitor lights up in red while engine is running ..922
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ..923
E-13 Water separator monitor lights up in red while engine is running ..924
E-14 Engine coolant temperature monitor lights up in red while engine is running ..925
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ..926
E-16 Engine oil pressure monitor lights up in red while engine is running ..927
E-17 Fuel gauge display does not move from minimum or maximum ..928
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) ..929
E-19 Engine coolant temperature gauge display does not move from minimum or maximum ..930
E-20 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) ..931
E-21 Hydraulic oil temperature gauge does not move from minimum or maximum ..932
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) ..934
E-23 Contents of display on machine monitor is different from actual machine condition ..935
E-24 Some areas of machine monitor screen are not displayed ..936
E-25 Function switch does not work ..937
E-26 Automatic warm-up system does not operate (in cold season) ..938
E-27 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated ..939
E-28 Auto-deceleration function does not operate or is not canceled while lever is operated ..940
E-29 Working mode selection screen is not displayed while working mode selector switch is operated ..941
E-30 Setting of engine and hydraulic pump is not changed while working mode is changed ..942
E-31 Travel speed monitor does not change when travel speed switch is operated ..943
E-32 Travel speed does not change while travel speed selection is changed ..944
E-33 Alarm buzzer does not stop sounding ..945
E-34 Service meter is not displayed, while starting switch is in OFF position ..946
E-35 Service mode cannot be selected ..947
E-36 Any of work equipment, swing and travel does not work ..948
E-37 Any of work equipment, swing and travel cannot be locked ..950
E-38 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position ..952
E-39 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position ..954
E-40 One-touch power maximizing function does not operate, or indicator is not displayed on monitor ..956
E-41 One-touch power maximizing function cannot be canceled ..958
E-42 Alarm does not sound during travel ..959
E-43 Alarm does not stop sounding while machine is stopped ..960
E-44 Horn does not sound ..961
E-45 Horn does not stop sounding ..963
E-46 Wiper monitor does not light up, or does not go out, while wiper switch is operated ..964
E-47 Wiper does not operate while wiper switch is operated ..965
E-48 Window washer does not operate while window washer switch is operated ..967
E-49 Boom LOWER is not displayed correctly with monitoring function ..968
E-50 Arm OUT is not displayed correctly with monitoring function ..969
E-51 Arm IN is not displayed correctly with monitoring function ..970
E-52 Boom RAISE is not displayed correctly with monitoring function ..971
E-53 Bucket CURL is not displayed correctly with monitoring function ..972
E-54 Bucket DUMP is not displayed correctly with monitoring function ..973
E-55 Swing is not displayed correctly with monitoring function ..974
E-56 Travel is not displayed correctly with monitoring function ..975
E-57 Service is not displayed correctly with monitoring function ..977
E-58 Attachment hydraulic circuit cannot be changed ..979
E-59 KOMTRAX system does not operate normally ..980
Troubleshooting of hydraulic and mechanical system (H-mode) ..981
Information described in troubleshooting table (H-mode) ..981
System chart of hydraulic and mechanical systems ..982
Failure mode and cause table ..984
H-1 All of work equipments, swing and travel operations lack speed or power ..992
H-2 Engine speed drops significantly or engine stalls ..994
H-3 All work equipment, swing and travel does not work ..995
H-4 Unusual sound is heard from around hydraulic pump ..996
H-5 Fine control performance or response is poor ..997
H-6 Boom speed or power is low ..998
H-7 Arm speed or power is low ..1001
H-8 Bucket speed or power is low ..1004
H-9 Work equipment does not move in single operation ..1006
H-10 Hydraulic drift of boom is large ..1007
H-11 Hydraulic drift of arm is large ..1008
H-12 Hydraulic drift of bucket is large ..1009
H-13 Time lag of work equipment is large ..1010
H-14 When part of work equipment is relieved singly, other parts of work equipment move ..1012
H-15 One-touch power maximizing function does not operate ..1013
H-16 In combined operation of work equipment, equipment having heavier load moves slower ..1014
H-17 In combined operations of swing and boom RAISE, boom rising speed is low ..1015
H-18 In combined operation of swing and travel, travel speed drops largely ..1016
H-19 Machine does not travel straight ..1017
H-20 Travel speed is slow ..1019
H-21 Machine is hard to steer or travel power is low ..1021
H-22 Travel speed does not change, or travel speed is too slow or fast ..1024
H-23 One of tracks does not run ..1025
H-24 Upper structure does not swing to the right or left ..1027
H-25 Upper structure swing only to the right or left ..1028
H-26 Swing acceleration or swing speed is low in both directions (right and left) ..1029
H-27 Swing acceleration performance is poor or swing speed is slow in only one direction ..1030
H-28 Upper structure overruns excessively when it stops swinging (both right and left) ..1031
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ..1032
H-30 Shock is large when upper structure stops swinging ..1033
H-31 Large unusual noise is heard when upper structure stops swinging ..1034
H-32 Swing drift on a slope is large while swing parking brake is applied ..1035
H-33 Swing drift on a slope is large while swing parking brake is released ..1036
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed ..1037
H-35 Oil flow in attachment circuit cannot be controlled ..1038
Troubleshooting of engine (S-mode) ..1039
Information mentioned in troubleshooting table (S mode) ..1039
S-1 Engine does not crank when starting switch is turned to START position ..1040
S-2 Engine cranks but no exhaust smoke comes out ..1041
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ..1042
S-4 Engine startability is poor ..1043
S-5 Engine does not pick up smoothly ..1045
S-6 Engine stops during operation ..1047
S-7 Engine runs rough or is unstable ..1049
S-8 Engine lacks power ..1050
S-9 Exhaust smoke is black ..1052
S-10 Engine oil consumption is excessive ..1054
S-11 Oil becomes contaminated quickly ..1055
S-12 Fuel consumption is excessive ..1056
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ..1057
S-14 Oil pressure drops ..1058
S-15 Fuel mixes into engine oil ..1059
S-16 Water mixes into engine oil (milky) ..1060
S-17 Coolant temperature rises too high (overheating) ..1061
S-18 Unusual noise is heard ..1062
S-19 Vibration is excessive ..1063
S-20 Air cannot be bled from fuel circuit ..1064
50 Disassembly and assembly ..1065
Table of contents ..1066
Related information on disassembly and assembly ..1068
How to read this manual ..1068
Coating materials list ..1070
Special tools list ..1074
Sketches of special tools ..1079
Engine and cooling system ..1083
Removal and installation of supply pump assembly ..1083
Removal and installation of injector assembly ..1087
Removal and installation of cylinder head assembly ..1093
Removal and installation of radiator assembly ..1110
Removal and installation of hydraulic oil cooler assembly ..1112
Removal and installation of aftercooler assembly ..1115
Removal and installation of engine and main pump assembly ..1117
Removal and installation of engine front oil seal ..1124
Removal and installation of engine rear oil seal ..1128
Removal and installation of fuel cooler assembly ..1131
Removal and installation of fuel tank assembly ..1133
Removal and installation of engine hood assembly ..1135
Removal and installation of KDOC assembly ..1137
Removal and installation of KCCV assembly ..1139
Removal and installation of air cleaner assembly ..1144
Power train ..1146
Removal and installation of travel motor and final drive assembly ..1146
Disassembly and assembly of final drive assembly ..1147
Removal and installation of swing motor and swing machinery assembly ..1156
Disassembly and assembly of swing machinery assembly ..1158
Removal and installation of swing circle assembly ..1165
Undercarriage and frame ..1166
Separation and connection of track shoe assembly ..1166
Removal and installation of sprocket ..1168
Removal and installation of idler and idler cushion assembly ..1169
Disassembly and assembly of idler assembly ..1170
Disassembly and assembly of idler cushion assembly ..1173
Disassembly and assembly of track roller assembly ..1175
Disassembly and assembly of carrier roller assembly ..1177
Removal and installation of revolving frame assembly ..1180
Removal and installation of counterweight assembly ..1182
Hydraulic system ..1184
Removal and installation of center swivel joint assembly ..1184
Disassembly and assembly of center swivel joint assembly ..1187
Removal and installation of hydraulic tank assembly ..1188
Removal and installation of main pump assembly ..1192
Removal and installation of main pump input shaft oil seal ..1195
Removal and installation of control valve assembly ..1196
Disassembly and assembly of control valve assembly ..1200
Disassembly and assembly of work equipment PPC valve assembly ..1202
Disassembly and assembly of travel PPC valve assembly ..1204
Work equipment ..1206
Removal and installation of work equipment assembly ..1206
Disassembly and assembly of work equipment cylinder assembly ..1209
Cab and its attachments ..1215
Removal and installation of operator's cab assembly ..1215
Removal and installation of operator cab glass (adhered glass) ..1220
Removal and installation of front window assembly ..1230
Removal and installation of floor frame assembly ..1236
Removal and installation of air conditioner unit assembly ..1241
Removal and installation of operator's seat ..1245
Removal and installation of seat belt ..1247
Removal and installation of front wiper assembly ..1249
Electrical system ..1256
Removal and installation of air conditioner compressor assembly ..1256
Removal and installation of air conditioner condenser assembly ..1258
Removal and installation of engine controller assembly ..1260
Removal and installation of pump controller assembly ..1262
Removal and installation of machine monitor assembly ..1265
Removal and installation of pump swash plate sensor ..1267
Removal and installation of mass air flow and temperature sensor ..1268
Removal and installation of KOMTRAX terminal assembly ..1269
60 Maintenance standard ..1271
Table of contents ..1272
Engine and cooling system ..1273
Engine mount ..1273
Cooling system ..1274
Power train ..1275
Swing circle ..1275
Swing machinery ..1276
Final drive ..1277
Sprocket ..1279
Undercarriage and frame ..1281
Track frame and idler cushion ..1281
Idler ..1283
Track roller ..1285
Carrier roller ..1286
Track shoe ..1287
Hydraulic system ..1291
Hydraulic tank ..1291
Main pump ..1292
Control valve ..1295
Travel motor ..1306
Work equipment and swing PPC valve ..1309
Travel PPC valve ..1312
1st-line attachment PPC valve (with EPC valve) ..1315
2nd-line attachment PPC valve ..1318
Solenoid valve ..1320
Attachment circuit selector valve (for high-pressure circuit) ..1321
Attachment circuit selector valve (for low-pressure circuit) ..1322
Center swivel joint ..1323
Work equipment ..1324
Work equipment ..1324
Boom cylinder ..1333
Arm cylinder ..1334
Bucket cylinder ..1335
80 Appendix ..1337
Table of contents ..1338
Air conditioner components ..1339
Precautions for refrigerant ..1339
Air conditioner component ..1340
Configuration and function of refrigeration cycle ..1343
Outline of refrigeration cycle ..1344
Air conditioner unit ..1346
Dual pressure switch ..1353
Air conditioner controller ..1354
Compressor ..1355
Air conditioner condenser ..1356
Sunlight sensor ..1358
Outer temperature sensor (outside air temperature sensor) ..1359
Procedure for testing and troubleshooting ..1360
Circuit diagram and arrangement of connector pins ..1362
System diagram ..1364
Input and output signals of the air conditioner controller ..1365
Parts and connectors layout ..1367
Testing air leakage (duct) ..1371
Testing with self-diagnosis function ..1374
Testing vent (mode) changeover ..1377
Testing FRESH/RECIRC air changeover ..1379
Testing sunlight sensor ..1380
Testing (dual) pressure switch for refrigerant ..1381
Testing relays ..1382
Troubleshooting chart 1 ..1383
Troubleshooting chart 2 ..1384
Information in troubleshooting table ..1387
Failure code list related to air conditioner ..1388
Failure code [879AKA] A/C Inner Sensor Open Circuit ..1389
Failure code [879AKB] A/C Inner Sensor Short Circuit ..1390
Failure code [879BKA] A/C Outer sensor Open Circuit ..1391
Failure code [879BKB] A/C Outer sensor Short Circuit ..1393
Failure code [879CKA] Ventilating Sensor Open Circuit ..1395
Failure code [879CKB] Ventilating Sensor Short Circuit ..1396
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ..1397
Failure code [879EMC] Ventilation Damper Abnormality ..1399
Failure code [879FMC] Air Mix Damper Abnormality ..1400
Failure code [879GKX] Refrigerant Abnormality ..1401
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..1402
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ..1404
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..1407
A-4 Troubleshooting for FRESH/RECIRC air changeover ..1409
Troubleshooting with gauge pressure ..1411
Connection of service tool ..1414
Precautions for disconnecting and connecting air conditioner piping ..1416
Handling of compressor oil ..1418
Desiccant replacement ..1420
90 Diagrams and drawings ..1423
Table of contents ..1424
Hydraulic circuit diagram ..1425
Symbols in hydraulic circuit diagram ..1425
Hydraulic circuit diagram ..1428
Electric circuit diagram ..1430
Symbols in electric circuit diagram ..1430
Electrical circuit diagram ..1434
Electric circuit diagram for air conditioner unit ..1440
INDEX..1441

Komatsu Hydraulic Excavator PC170LC Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEN01892-05 – Hydraulic Excavator PC160LC-7E0 Shop Manual.pdf
UEN01892-04 – Hydraulic Excavator PC160LC-7E0, PC180LC-7E0, PC180NLC-7E0 Shop Manual.pdf
TEN00175-06 – Hydraulic Excavator GALEO PC160LC-7E0 Operation & Maintenance Manual.pdf
UEAM006800 – Hydraulic Excavator PC160LC-7E0 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 2,413 pages
File Format: PDF
Language: English

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

Komatsu Hydraulic Excavator PC160LC-E0, PC180LC-E0, PC180NLC-E0 Workshop Service Repair Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC160LC-7, PC160LC-8, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC160LC-7, PC160LC-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBM028606 – Hydraulic Excavator PC160LC-7 Shop Manual.pdf
SEN04566-00TH – Hydraulic Excavator PC160LC-8 Shop Manual.pdf
SEN04566-10 – Hydraulic Excavator PC160LC-8 Shop Manual.pdf
TEN00021-00 – Hydraulic Excavator GALEO PC160LC-7 Operation & Maintenance Manual.pdf
TEN00096-01 – Hydraulic Excavator GALEO PC160LC-7 Operation & Maintenance Manual.pdf
TEN00308-00TH – Hydraulic Excavator PC160LC-8 Operation & Maintenance Manual.pdf
TEN00308-03 – Hydraulic Excavator PC160LC-8 Operation & Maintenance Manual.pdf
TEN00473-02 – Hydraulic Excavator PC160LC-8 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 4,548 pages
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Language: English

SEBM028606 – Hydraulic Excavator PC160LC-7 Shop Manual….2
  COVER….2
  CONTENTS….3
  01 GENERAL….28
    SPECIFICATION DIMENSION DRAWINGS ….29
    SPECIFICATIONS….31
    WEIGHT TABLE….33
    FUEL,COOLANT,AND LUBRICANTS….35
  10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD….36
    ENGINE RELATED PARTS….37
    RADIATOR・OIL COOLER・AFTERCOOLER….38
    POWER TRAIN….39
    SWING MACHINERY….40
    SWING CIRCLE….41
    FINAL DRIVE….42
    TRACK FRAME・RECOIL SPRING….44
    IDLER….46
    CARRIER ROLLER….48
    TRACK ROLLER….49
    TRACK SHOE….50
    HYDRAULIC EQUIPMENT LAYOUT DRAWING….54
    VALVE CONTROL….56
    HYDRAULIC TANK….57
    HYDRAULIC PUMP….58
    PC-EPC VALVE….76
    CONTROL VALVE….81
    CLSS….94
    TRAVEL JUNCTION VALVE….124
    SELF-REDUCING PRESSURE VALVE….125
    CENTER SWIVEL JOINT….126
    SWING MOTOR ….127
    TRAVEL MOTOR….128
    WORK EQUIPMENT・SWING PPC VALVE….137
    TRAVEL PPC VALVE….141
    SERVICE PPC VALVE….150
    SOLENOID VALVE….153
    ACCUMULATOR….155
    RETURN OIL FILTER ….156
    ATTACHMENT CIRCUIT SELECTOR VALVE….157
    HYDRAULIC CYLINDER….159
    WORK EQUIPMENT….161
    AIR CONDITIONER….167
    ENGINE CONTROL….168
    ELECTRONIC CONTROL SYSTEM ….174
    MULTI MONITOR SYSTEM….199
    7-SEGMENT MONITOR SYSTEM….219
    SENSOR….226
  20 TESTING AND ADJUSTING….229
    STANDARD VALVE TABLE FOR ENGINE RELATED PARTS….230
    STANDARD VALVE TABLE FOR CHASSIS RELATED PARTS….231
    TESTING AND ADJUSTING….240
      TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING….241
      INSPECTION AND ADJUSTING OF ENGINE RPM….243
      MEASUREMENT OF EXHAUST GAS COLOR….245
      ADJUSTMENT OF VALVE CLEARANCE….246
      MEASUREMENT OF COMPRESSION PRESSURE….248
      MEASUREMENT OF BLOW-BY PRESSURE….249
      INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING….250
      MEASUREMENT OF ENGINE OIL PRESSURE….252
      ADJUSTMENT OF ENGINE SPEED SENSOR….253
      INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION….254
      MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS….255
      INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION….256
      INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT,SWING, AND TRAVEL CIRCUITS….257
      INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE….260
      INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE….261
      INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT OIL PRESSURE….264
      MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE….267
      MEASUREMENT OF PPC VALVE OUTPUT PRESSURE….270
      ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE….271
      INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT….272
      TESTING AND ADJUSTING TRAVEL DEVIATION ….274
      RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT….276
      MEASUREMENT OF OIL LEAKAGE ….277
      BLEEDING AIR FROM EACH PART….279
      INSPECTION PROCEDURES FOR DIODE….281
      SPECIAL FUNCTION OF MONITOR PANEL….282
      SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL….307
      PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM….323
      PM-TUNE UP SERVICE ….325
    TROUBLESHOOTING….330
      POINTS TO REMEMBER WHEN TROUBLESHOOTING….331
      SEQUENCE OF EVENTS IN TROUBLESHOOTING….332
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….333
      CHECKS BEFORE TROUBLESHOOTING ….341
      CLASSIFICATION AND STEPS FOR TROUBLESHOOTING….342
      CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM….346
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….379
      T-ADAPTER-BOXES AND T-ADAPTER TABLE ….402
      TROUBLESHOOTING ERROR CODE &quot;ELECTRICAL SYSTEM&quot; AND FAILURE CODE &quot;MECHANICAL SYSTEM&quot; ARE INDICATED….405
        BEFORE TROUBLESHOOTING FOR DISPLAYED CODE….407
        INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….412
        ERROR CODE IN ELECTRICAL SYSTEM[E101](ABNORMAL DATA IN ERROR HISTORY)….414
        ERROR CODE IN ELECTRICAL SYSTEM[E112](SHORT-CIRCUITING IN NORMAL ROTATOIN SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)….416
        ERROR CODE IN ELECTRICAL SYSTEM[E113](SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)….418
        ERROR CODE IN ELECTRICAL SYSTEM[E114](SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM)….420
        ERROR CODE IN ELECTRICAL SYSTEM[E115](ABNORMAL OPERATION OF WINDSHIELD WIPER)….424
        ERROR CODE IN ELECTRICAL SYSTEM[E116](ABNORMALITY OPERATION IN RETRACTING WINDSHIELD WIPER)….426
        ERROR CODE IN ELECTRICAL SYSTEM[E201](SHORT-CIRCUITING IN TRAVEL JUNCTION SOLENOID)….428
        ERROR CODE IN ELECTRICAL SYSTEM[E203](SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)….432
        ERROR CODE IN ELECTRICAL SYSTEM[E204](SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)….436
        ERROR CODE IN ELECTRICAL SYSTEM[E205](SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)….440
        ERROR CODE IN ELECTRICAL SYSTEM[E206](SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID)….444
        ERROR CODE IN ELECTRICAL SYSTEM[E211](DISCONNECTION IN TRAVEL JUNCTION SOLENOID)….448
        ERROR CODE IN ELECTRICAL SYSTEM[E213](DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)….452
        ERROR CODE IN ELECTRICAL SYSTEM[E214](DISCONNECTION OF MERGE/DIVIDE SOLENOID)….456
        ERROR CODE IN ELECTRICAL SYSTEM[E215](DISCONNECTION IN 2-STAGE RELIEF SOLENOID)….460
        ERROR CODE IN ELECTRICAL SYSTEM[E216](DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)….464
        ERROR CODE IN ELECTRICAL SYSTEM[E217](ABNORMALITY IN INPUTTING MODEL CODE)….468
        ERROR CODE IN ELECTRICAL SYSTEM[E218](DISCONNECTION OF S-NET SIGNAL)….470
        ERROR CODE IN ELECTRICAL SYSTEM[E224](ABNORMALITY IN F PUMP PRESSURE SENSOR)….472
        ERROR CODE IN ELECTRICAL SYSTEM[E225](ABNORMALITY IN R PUMP PRESSURE SENSOR)….474
        ERROR CODE IN ELECTRICAL SYSTEM[E226](ABNORMALITY IN PRESSURE SENSOR POWER SOURCE)….476
        ERROR CODE IN ELECTRICAL SYSTEM[E227](ABNORMALITY IN ENGINE ROTATION SENSOR)….478
        ERROR CODE IN ELECTRICAL SYSTEM[E228](SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)….480
        ERROR CODE IN ELECTRICAL SYSTEM[E232](SHORT-CIRCUITING IN PC-EPC SOLENOID)….482
        ERROR CODE IN ELECTRICAL SYSTEM[E233](DISCONNECTION IN PC-EPC SOLENOID)….484
        ERROR CODE IN ELECTRICAL SYSTEM[E238](DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY)….486
        ERROR CODE IN ELECTRICAL SYSTEM[E245](SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SOLENOID)….488
        ERROR CODE IN ELECTRICAL SYSTEM[E246](DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SOLENOID)….489
        ERROR CODE IN ELECTRICAL SYSTEM[E306](ABNORMALITY IN GOVERNOR POTENTIOMETER)….490
        ERROR CODE IN ELECTRICAL SYSTEM[E308](ABNORMALITY IN FUEL DIAL)….492
        ERROR CODE IN ELECTRICAL SYSTEM[E311](SHORT-CIRCUITING IN COLD STARTING SOLENOID RELAY)….494
        ERROR CODE IN ELECTRICAL SYSTEM[E312](DISCONNECTION IN COLD STARTING SOLENOID RELAY)….496
        ERROR CODE IN ELECTRICAL SYSTEM[E315](SHORT-CIRCUITING IN BATTERY RELAY)….498
        ERROR CODE IN ELECTRICAL SYSTEM[E316](STEP-OUT IN GOVERNOR MOTOR)….500
        ERROR CODE IN ELECTRICAL SYSTEM[E317](DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)….501
        ERROR CODE IN ELECTRICAL SYSTEM[E318](SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PRASE B)….503
        FAILURE CODE IN MECHANICAL SYSTEM[A000N1](OUT-OF-RATE ENGINE ROTATION AT HIGH IDLING)….505
        FAILURE CODE IN MECHANICAL SYSTEM[A000N2](OUT-OF-RATE ENGINE ROTATION AT LOW IDLING)….505
        FAILURE CODE IN MECHANICAL SYSTEM[AA10NX](AIR CLEANER CLOGGING)….506
        FAILURE CODE IN MECHANICAL SYSTEM[ABOOKE](ABNORMALLY LOWERED CHARGING VOLTAGE)….507
        FAILURE CODE IN MECHANICAL SYSTEM[B@BAZG](ABNORMALLY LOWERED ENGINE OIL PRESSURE)….509
        FAILURE CODE IN MECHANICAL SYSTEM[B@BAZK](ABNORMALLY LOWERED ENGINE OIL LEVEL)….510
        FAILURE CODE IN MECHANICAL SYSTEM[B@BCNS](ENGINE COOLING WATER OVERHEATING)….511
        FAILURE CODE IN MECHANICAL SYSTEM[B@BAZK](ABNORMALLY LOWERED RADIATOR WATER LEVEL)….512
        FAILURE CODE IN MECHANICAL SYSTEM[B@HANS](HYDRAULIC OIL OVERHEATING)….513
      TROUBLESHOOTING OF ELECTRICAL SYSTEM(E-MODE)….514
        BEFORE CONDUCTING E-MODE TROUBLESHOOTING ….515
        INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….516
        E-1 ENGINE DOES NOT START….517
        E-2 ENGINE STOPS WHILE IN OPERATION….522
        E-3 ENGINE ROTATES UNSTABLY OR HUNTING ….523
        E-4 ENGINE DOES NOT STOP….525
        E-5 AUTO-DECELERATOR DOES NOT WORK….527
        E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK….528
        E-7 PREHEATER DOES NOT OPERATE….529
        E-8 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE….531
        E-9 ONE-TOUCH POWER MAX SWITCH DOES NOT WORK….533
        E-10 ATTACHMENT CIRCUIT DOES NOT CHANGE ….534
        E-11 NO DISPLAY IN MONITOR PANEL AT ALL ….535
        E-12 MONITOR PANEL DOES NOT DISPLAY PARTIALLY ….537
        E-13 CONTENTS OF MONITOR PANEL ARE DIFFERENT FROM MOUNTED MODEL….537
        E-14 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ….538
        E-15 ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY….539
        E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY….540
        E-17 FUEL GAUGE DOES NOT DISPLAY CORRECTLY….541
        E-18 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY….542
        E-19 WHEN MONITOR SWITCH IS OPERATED,NOTHING IS DISPLAYED….544
        E-20 WINDSHIELD WIPER AND WINDOW WASHER DOES NOT WORK….546
        E-21 ALARMING BUZZER CANNOT BE CANCELLED….552
        E-22 &quot;BOOM RAISE&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….553
        E-23 &quot;BOOM LOWER&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….554
        E-24 &quot;ARM IN&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….555
        E-25 &quot;ARM OUT&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….556
        E-26 &quot;BUCKET CURL&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….557
        E-27 &quot;BUCKET DUMP&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….558
        E-28 &quot;SWING&quot; IS NOT CORRECTLY DISPLAYED IS MONITOR FUNCTION….559
        E-29 &quot;TRAVEL&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION ….561
        E-30 &quot;TRAVEL DIFFERENTIAL PRESSURE&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….563
        E-31 &quot;SERVICE&quot; IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….565
        E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM….567
        E-33 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING….580
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)….582
        INFORMATION CONTAINED IN TROUBLESHOOTING TABLE….583
        SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS….584
        H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, SWING, AND TRAVEL ARE LOW….586
        H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS….587
        H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE ….588
        H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP….588
        H-5 AUTO-DECELERATOR DOES NOT WORK….589
        H-6 FINE CONTROL MODE DOES NOT FUNCTION….589
        H-7 SPEED OR POWER OF BOOM IS LOW….590
        H-8 SPEED OR POWER OF ARM IS LOW….591
        H-9 SPEED OR POWER OF BUCKET IS LOW ….592
        H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION….593
        H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE ….594
        H-12 TIME LAG OF WORK EQUIPMENT IS LARGE….595
        H-13 ONE-TOUCH POWER MAX SYSTEM DOES NOT OPERATE….595
        H-14 WORK EQUIPMENT LOADED MORE IS LOWER DURING COMPOUND OPERATION ….596
        H-15 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING+BOOM RAISE….596
        H-16 TRAVEL SPEED LOWERS LARGELY DURING COMPOUND OPERATION OF WORK EQUIPMENT/SWING+TRAVEL ….597
        H-17 MACHINE DEVIATES DURING TRAVEL ….598
        H-18 TRAVEL SPEED IS LOW ….599
        H-19 MACHINE CANNOT BE STEERED EASILY OR STEERING POWER IS LOW….600
        H-20 TRAVEL SPEED DOES NOT CHANGE, OR IT IS KEPT LOW OR HIGH….601
        H-21 TRACK DOES NOT MOVE (ONLY EITHER SIDE)….601
        H-22 MACHINE DOES NOT SWING ….602
        H-23 SWING ACCELERATION OR SWING SPEED IS LOW….603
        H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING ….604
        H-25 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SHOCK ….605
        H-26 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND….605
        H-27 HYDRAULIC DRIFT OF SWING IS LARGE ….606
        H-28 ATTACHMENT CIRCUIT DOES NOT CHANGE ….607
        H-29 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED….607
      TROUBLESHOOTING OF ENGINE (S-MODE)….608
        METHOD OF USING TROUBLESHOOTING CHARTS….609
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)….613
        S-2 ENGINE DOES NOT START….615
          (1) ENGINE DOES NOT TURN….615
          (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)….616
          (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)….617
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)….618
        S-4 ENGINE STOPS DURING OPERATIONS….619
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)….620
        S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)….621
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)….622
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)….623
        S-9 OIL BECOMES CONTAMINATED QUICKLY….624
        S-10 FUEL CONSUMPTION IS EXCESSIVE….625
        S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN….626
        S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)….627
        S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)….628
        S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)….629
        S-15 ABNORMAL NOISE IS MADE….630
        S-16 VIBRATION IS EXCESSIVE….631
  30 DISASSEMBLY AND ASSEMBLY….632
    HOW TO READ THIS MANUAL ….634
    PRECAUTIONS WHEN PERFORMING OPERATION ….636
    SPECIAL TOOL LIST ….638
    SKETCHES OF SPECIAL TOOLS ….642
    STARTING MOTOR ….643
      REMOVAL AND INSTALLATION ….643
    FUEL INJECTION PUMP ….644
      SPECIAL TOOLS ….644
      REMOVAL….644
      INSTALLATION ….646
    ENGINE FRONT SEAL….648
      REMOVAL ….648
      INSTALLATION ….650
    ENGINE REAR SEAL….652
      REMOVAL….652
      INSTALLATION….653
    CYLINDER HEAD ….654
      SPECIAL TOOLS….654
      REMOVAL….654
      INSTALLATION….657
    RADIATOR….660
      REMOVAL AND INSTALLATION ….660
    AFTERCOOLER ….661
      REMOVAL AND INSTALLATION ….661
    HYDRAULIC OIL COOLER ….662
      REMOVAL AND INSTALLATION ….662
    ENGINE AND HYDRAULIC PUMP ….663
      SPECIAL TOOLS….663
      REMOVAL ….663
      INSTALLATION ….666
    TRACK SHOE ….668
      SPECIAL TOOLS ….668
      EXPANSION ….668
      INSTALLATION ….669
    SPROCKET ….670
      REMOVAL AND INSTALLATION ….670
    FINAL DRIVE ….671
      REMOVAL AND INSTALLATION ….671
      SPECIAL TOOLS ….672
      DISASSEMBLY ….672
      ASSEMBLY….674
    IDLER….679
      SPECIAL TOOLS ….679
      DISASSEMBLY ….679
      ASSEMBLY….680
    RECOIL SPRING ….682
      SPECIAL TOOLS ….682
      DISASSEMBLY….682
      ASSEMBLY ….683
    TRACK ROLLER….684
      SPECIAL TOOLS ….684
      DISASSEMBLY AND ASSEMBLY ….684
    CARRIER ROLLER….685
      SPECIAL TOOLS ….685
      DISASSEMBLY AND ASSEMBLY ….685
    SWING MOTOR AND SWING MACHINERY ….686
      REMOVAL AND INSTALLATION ….686
      SPECIAL TOOLS ….687
      DISASSEMBLY….687
      ASSEMBLY ….690
    SWING MOTOR ….695
      SPECIAL TOOLS ….695
      DISASSEMBLY ….695
      ASSEMBLY….698
    CENTER SWIVEL JOINT ….703
      REMOVAL….703
      INSTALLATION ….704
      SPECIAL TOOLS ….705
      DISASSEMBLY AND ASSEMBLY….705
    WORK EQUIPMENT….706
      SPECIAL TOOLS….706
      REMOVAL ….706
      INSTALLATION ….708
    REVOLVING FRAME ….709
      REMOVAL ….709
      INSTALLATION ….710
    SWING CIRCLE ….711
      REMOVAL AND INSTALLATION ….711
    HYDRAULIC TANK ….712
      REMOVAL….712
      INSTALLATION ….714
    CONTROL VALVE….715
      REMOVAL ….715
      INSTALLATION ….718
      DISASSEMBLY AND ASSEMBLY….719
    HYDRAULIC PUMP ….721
      SPECIAL TOOLS ….721
      REMOVAL ….721
      INSTALLATION ….722
    HYDRAULIC PUMP INPUT SHAFT OIL SEAL….723
      SPECIAL TOOLS ….723
      REMOVAL AND INSTALLATION….723
    WORK EQUIPMENT PPC VALVE ….724
      DISASSEMBLY AND ASSEMBLY ….724
    TRAVEL PPC VALVE ….725
      DISASSEMBLY AND ASSEMBLY ….725
    HYDRAULIC CYLINDER ….726
      SPECIAL TOOLS ….726
      DISASSEMBLY ….726
      ASSEMBLY ….728
    COUNTERWEIGHT….732
      REMOVAL AND INSTALLATION ….732
    AIR CONDITIONER UNIT ….733
      SPECIAL TOOLS ….733
      REMOVAL ….733
      INSTALLATION ….735
    OPERATOR&apos;S CAB ….738
      REMOVAL….738
      INSTALLATION ….740
    OPERATOR&apos;S CAB GLASS (STUCK GLASS)….744
      SPECIAL TOOLS….745
      REMOVAL ….745
      INSTALLATION ….746
    FRONT WINDOW ….755
      REMOVAL ….755
      INSTALLATION ….757
    MONITOR….760
      REMOVAL AND INSTALLATION ….760
    GOVERNOR,PUMP CONTROLLER ….761
      REMOVAL AND INSTALLATION ….761
  90 OTHERS….762
    HYDRAULIC CIRCUIT DIAGRAM….763
    SERIAL NO.:10001-11000….764
      ELECTRICAL CIRCUIT DIAGRAM (1/4)….764
      ELECTRICAL CIRCUIT DIAGRAM (2/4)….765
      ELECTRICAL CIRCUIT DIAGRAM (3/4)….766
      ELECTRICAL CIRCUIT DIAGRAM (4/4)….767
    SERIAL NO.:11001 AND UP….768
      ELECTRICAL CIRCUIT DIAGRAM (1/4)….768
      ELECTRICAL CIRCUIT DIAGRAM (2/4)….769
      ELECTRICAL CIRCUIT DIAGRAM (3/4)….770
      ELECTRICAL CIRCUIT DIAGRAM (4/4)….771
SEN04566-00TH – Hydraulic Excavator PC160LC-8 Shop Manual….772
  COVER….772
  00 Index and foreword….773
    100 Index….773
      Composition of Shop Manual….774
      Table of Contents….776
    200 Foreword and General Information….785
      Safety Notice….786
      How to read the  shop manual….791
      Explanation of terms for maintenance standard….793
      Handling of electric equipment and hydraulic component….795
      Handling of connectors newly used for engines….804
      How to read electric wire code….807
      Precautions when carrying out operation….810
      Methods of dissambling and connecting push-pull type coupler….813
      Standard tightening torque table….816
      Conversion table….820
      Temperature….824
  01 Specification….827
    Specification dimension drawings….828
    Specifications….830
    Weight table….832
    Table of fuel, coolant and lubricants….834
  10 Structure, function and maintenance standard….837
    100 Engine and cooling system….837
      Engine related parts….838
      Radiator, oil cooler, aftercooler and fuel cooler….839
    200 Power train system….841
      Power train….842
      Swing circle….843
      Swing machinery….844
      Final drive….846
      Sprocket….848
    300 Undercarriage and frame….851
    401 Hydraulic system, Part 1….863
    402 Hydraulic system, Part 2….895
    403 Hydraulic system, Part 3….951
    500 Work equipment….997
    600 Cab and its attachments….1005
    700 Electrical system….1009
  20 Standard value table….1081
    100 Standard service value table….1081
  30 Testing and adjusting….1095
    101 Testing and adjusting, Part 1….1095
    102 Testing and adjusting, Part 2….1155
    103 Testing and adjusting, Part 3….1207
  40 Troubleshooting….1221
    100 Failure code table and fuse locations….1221
    200 General information on troubleshooting….1229
    301 Troubleshooting by failure code, Part 1….1279
    302 Troubleshooting by failure code, Part 2….1335
    303 Troubleshooting by failure code, Part 3….1397
    304 Troubleshooting by failure code, Part 4….1443
    400 Troubleshooting of electrical system (E-mode)….1465
    500 Troubleshooting of hydraulic and mechanical system (H-mode)….1541
    600 Troubleshooting of engine (S-mode)….1569
  50 Disassembly and assembly….1595
    100 General information on disassembly and assembly….1595
    200 Engine and cooling system….1607
    300 Power train….1653
    400 Undercarriage and frame….1675
    500 Hydraulic system….1695
    600 Work equipment Body….1725
    700 Cab and its attachments….1731
    800 Electrical system….1761
  90 Diagrams and drawings….1771
    100 Hydraulic circuit diagram….1771
    200 Electrical diagrams and drawings….1776
SEN04566-10 – Hydraulic Excavator PC160LC-8 Shop Manual….1787
  COVER….1787
  00 Index and foreword….0
    100 Index….1789
      Composition of shop manual….1790
      Table of contents….1792
    200 Foreword and general information….1801
      Safety notice….1802
      How to read the shop manual….1807
      Explanation of terms for maintenance standard….1809
      Handling of electric equipment and hydraulic component….1811
      Handling of connectors newly used for engines….1820
      How to read electric wire code….1823
      Precautions when carrying out operation….1826
      Method of disassembling and connecting push-pull type coupler….1829
      Standard tightening torque table….1832
      Conversion table….1836
  01 Specification….0
    100 Specification and technical data….1843
      Specification dimension drawings….1844
      Specifications….1846
      Weight table….1848
      Table of fuel, coolant and lubricants….1850
  10 Structure, function and maintenance standard….0
    100 Engine and cooling system….1853
      Engine related parts….1854
      Radiator, oil cooler, aftercooler and fuel cooler….1855
    200 Power train system….1857
      Power train….1858
      Swing circle….1859
      Swing machinery….1860
      Final drive….1862
      Sprocket….1864
    300 Undercarriage and frame….1867
      Track frame, recoil spring….1868
      Idler….1870
      Carrier roller….1872
      Track roller….1873
      Track shoe….1874
    401 Hydraulic system, Part 1….1879
      Hydraulic equipment layout drawing….1880
      Hydraulic tank….1882
      Hydraulic pump….1884
    402 Hydraulic system, Part 2….1911
      Control valve….1912
      CLSS….1926
      Functions and operation by valve….1930
    403 Hydraulic system, Part 3….1967
      Valve control….1968
      PPC valve….1969
      Solenoid valve….1990
      Accumulator….1992
      Return oil filter….1993
      Center swivel joint….1994
      Travel motor….1995
      Swing motor….2005
      Attachment circuit selector valve….2006
      Hydraulic cylinder….2010
    500 Work equipment….2013
      Work equipment….2014
      Dimensions of components….2016
    600 Cab and its attachments….2021
      Air conditioner piping….2022
    700 Electrical system….2025
      Engine control system….2026
      Electronic control system….2036
      Monitor system….2064
      Sensor….2090
      KOMTRAX system….2094
  20 Standard value table….0
    100 Standard service value table….2097
      Standard value table for engine….2098
      Standard value table for chassis related parts….2099
  30 Testing and adjusting….0
    101 Testing and adjusting, Part 1….2111
      Tools for testing, adjusting and troubleshooting….2113
      Testing engine speed….2116
      Testing intake air pressure (boost pressure)….2117
      Testing exhaust gas color….2118
      Adjusting valve clearance….2119
      Testing compression pressure….2121
      Testing blow-by pressure….2123
      Testing engine oil pressure….2124
      Handling fuel system parts….2125
      Releasing residual pressure from fuel system….2125
      Testing fuel pressure….2126
      Measuring fuel discharge, return and leakage….2128
      Bleeding air from fuel circuit….2132
      Checking fuel circuit for leakage….2134
      Checking and adjusting air conditioner compressor belt tension….2135
      Replacing fan belt….2136
      Testing clearance in swing circle bearings….2137
      Testing and adjusting track shoe tension….2138
      Inspection and adjustment oil pressure in work equipment, swing, and travel circuits….2139
      Testing control circuit basic pressure….2142
      Testing and adjusting pump PC control circuit oil pressure….2143
      Testing and adjusting pump LS control circuit oil pressure….2146
      Testing solenoid valve output pressure….2150
      Testing PPC valve output pressure….2153
      Adjusting play of work equipment and swing PPC valves….2154
      Inspecting locations of hydraulic drift of work equipment….2155
      Testing and adjusting travel deviation….2157
      Releasing remaining pressure in hydraulic circuit….2159
      Measurement of oil leakage….2160
      Bleeding air from various parts….2162
      Inspection procedures for diode….2164
      Checking cab tipping stopper….2165
      Installation and adjustment of mirrors and camera….2166
      Inspection of air conditioner Recirc/Fresh air filter….2170
    102 Testing and adjusting, Part 2….2173
      Special functions of machine monitor….2174
    103 Testing and adjusting, Part 3….2227
      Handling voltage circuit of engine controller….2228
      Preparation work for troubleshooting of electrical system….2229
      Procedure for testing diodes….2234
      Pm-clinic service….2235
  40 Troubleshooting….0
    100 Failure code table and fuse locations….2241
      Failure code table….2242
      Fuse locations….2245
    200 General information on troubleshooting….2249
      Points to remember when troubleshooting….2250
      Sequence of events in troubleshooting….2251
      Checks before troubleshooting….2252
      Classification and troubleshooting steps….2253
      Information in troubleshooting table….2254
      Phenomena looking like troubles and troubleshooting Nos….2256
      Connection table for connector pin numbers….2259
      T- branch box and T- branch adapter table….2295
    301 Troubleshooting by failure code, Part 1….2299
      Failure code [989L00] Engine controller lock caution 1….2301
      Failure code [989M00] Engine controller lock caution 2….2301
      Failure code [989N00] Engine controller lock caution 3….2302
      Failure code [AA10NX] Air cleaner clogging….2303
      Failure code [AB00KE] Charge voltage low….2304
      Failure code [B@BAZG] Eng oil press. low….2306
      Failure code [B@BAZK] Eng oil level low….2307
      Failure code [B@BCNS] Eng coolant overheat….2308
      Failure code [B@BCZK] Eng water level low….2310
      Failure code [B@HANS] Hydr oil overheat….2312
      Failure code [CA111] ECM critical internal failure….2314
      Failure code [CA115] Eng Ne and bkup speed sens error….2315
      Failure code [CA122] Chg air press sensor high error….2316
      Failure code [CA123] Chg air press sensor low error….2318
      Failure code [CA131] Throttle sensor high error….2320
      Failure code [CA132] Throttle sensor low error….2322
      Failure code [CA144] Coolant temp sens high error….2324
      Failure code [CA145] Coolant temp sens low error….2326
      Failure code [CA153] Chg air temp sensor high error….2328
      Failure code [CA154] Chg air temp sensor low error….2330
      Failure code [CA155] Chg air temp high speed derate….2332
      Failure code [CA187] Sens supply 2 volt low error….2334
      Failure code [CA221] Ambient press sens high error….2336
      Failure code [CA222] Ambient press sens low error….2338
      Failure code [CA227] Sens supply 2 volt high error….2340
      Failure code [CA234] Eng. overspeed….2341
      Failure code [CA238] Ne speed sens supply volt error….2342
      Failure code [CA271] IMV/PCV1 short error….2343
      Failure code [CA272] IMV/PCV1 open error….2344
      Failure code [CA322] Inj #1 open/short error….2346
      Failure code [CA324] Inj #3 open/short error….2348
      Failure code [CA331] Inj #2 open/short error….2350
      Failure code [CA332] Inj #4 open/short error….2352
    302 Troubleshooting by failure code, Part 2….2355
      Failure code [CA342] Calibration code incompatibility….2357
      Failure code [CA351] Injectors Drive Circuit Error….2358
      Failure code [CA352] Sens supply 1 volt low error….2360
      Failure code [CA386] Sens supply 1 volt high error….2362
      Failure code [CA428] Water in fuel sensor high error….2364
      Failure code [CA429] Water in fuel sensor low error….2366
      Failure code [CA435] Eng oil press sw error….2368
      Failure code [CA441] Battery voltage low error….2370
      Failure code [CA442] Battery voltage high error….2372
      Failure code [CA449] Rail press very high error….2374
      Failure code [CA451] Rail press sensor high error….2376
      Failure code [CA452] Rail press sensor low error….2378
      Failure code [CA488] Chg air temp high torque derate….2380
      Failure code [CA553] Rail press high error….2380
      Failure code [CA559] Rail press low error….2381
      Failure code [CA689] Eng Ne speed sensor error….2382
      Failure code [CA731] Eng Bkup speed sens phase error….2384
      Failure code [CA757]  All persistent data lost error….2386
      Failure code [CA778] Eng Bkup speed sensor error….2388
      Failure code [CA1633] KOMNET datalink timeout error….2390
      Failure code [CA2185] Throttle sens. sup. volt. high error….2392
      Failure code [CA2186] Throttle sens. sup. volt. low error….2393
      Failure code [CA2249] Rail press very low error….2394
      Failure code [CA2311] IMV solenoid error….2396
      Failure code [CA2555] Grid htr relay volt high error….2398
      Failure code [CA2556] Grid htr relay volt low error….2400
      Failure code [D110KB] Battery relay drive short….2402
      Failure code [D19JKZ] Personal code relay abnormality….2404
      Failure code [D862KA] GPS antenna discon….2406
      Failure code [DA22KK] Pump solenoid power low error….2408
      Failure code [DA25KP] 5V sensor 1 power abnormality….2410
      Failure code [DA26KP] 5V sensor 2 power abnormality….2413
      Failure code [DA29KQ] Model selection abnormality….2414
    303 Troubleshooting by failure code, Part 3….2417
      Failure code [DA2RMC] CAN discon (Pump controller detected)….2420
      Failure code [DAF8KB] Short circuit in camera power supply….2422
      Failure code [DAFGMC] GPS module error….2424
      Failure code [DAFRMC] CAN discon (Monitor detected)….2426
      Failure code [DGH2KB] Hydr oil sensor short….2428
      Failure code [DHPAMA] F Pump press sensor abnormality….2430
      Failure code [DHPBMA] R Pump press sensor abnormality….2432
      Failure code [DHS5KX] Travel PPC press sensor abnormality….2434
      Failure code [DHSAMA] Sw RH PPC press sen. abnormality….2436
      Failure code [DHSBMA] Sw LH PPC press sen. abnormality….2438
      Failure code [DHX1MA] Overload sensor abnormality (Analog)….2440
      Failure code [DW43KA] Travel speed sol discon….2441
      Failure code [DW43KB] Travel speed sol short….2442
      Failure code [DW45KA] Swing brake sol discon….2444
      Failure code [DW45KB] Swing brake sol short….2446
      Failure code [DW91KA] Travel junction sol discon….2448
      Failure code [DW91KB] Travel junction sol short….2450
      Failure code [DWA2KA] Service sol discon….2452
      Failure code [DWA2KB] Service sol short….2453
      Failure code [DWJ0KA] Merge-divider sol discon….2454
      Failure code [DWJ0KB] Merge-divider sol short….2456
      Failure code [DWK0KA] 2-stage relief sol discon….2458
      Failure code [DWK0KB] 2-stage relief sol short….2460
    304 Troubleshooting by failure code, Part 4….2463
      Failure code [DXA8KA] PC-EPC sol discon….2464
      Failure code [DXA8KB] PC-EPC sol short….2466
      Failure code [DXE4KA] Service current EPC discon….2468
      Failure code [DXE4KB] Service current EPC short….2470
      Failure code [DY20KA] Wiper working abnormality….2472
      Failure code [DY20MA] Wiper parking abnormality….2474
      Failure code [DY2CKA] Washer drive discon….2476
      Failure code [DY2CKB] Washer drive short….2478
      Failure code [DY2DKB] Wiper drive (for) short….2480
      Failure code [DY2EKB] Wiper drive (rev) short….2482
    400 Troubleshooting of electrical system (E-mode)….2485
      Before carrying out troubleshooting of electrical system….2487
      Information in troubleshooting table….2489
      E-1 When starting switch turned ON, machine monitor displays nothing….2490
      E-2 When starting switch is turned to ON position (before starting engine), basic check item lights up….2492
      E-3 Engine does not start (Engine does not crank)….2495
      E-4 Preheater does not operate….2498
      E-5 Automatic warm-up system does not operate (in cold season)….2500
      E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked….2502
      E-7 Precaution lights up while engine is running….2504
      E-8 Emergency stop item lights up while engine is running….2508
      E-9 Engine coolant temperature gauge does not indicate normally….2509
      E-10 Hydraulic oil temperature gauge does not indicate normally….2510
      E-11 Fuel level gauge does not indicate normally….2512
      E-12 Contents of display by machine monitor are different from applicable machine….2514
      E-13 Machine monitor does not display some items….2514
      E-14 Function switch does not work….2514
      E-15 Auto-decelerator does not operate normally….2515
      E-16 Working mode does not change….2516
      E-17 Travel speed does not change….2517
      E-18 Alarm buzzer cannot be stopped….2518
      E-19 Windshield wiper and window washer do not operate….2519
      E-20 Power maximizing function does not operate normally….2521
      E-21 Swing holding brake does not operate normally….2523
      E-22 Travel alarm does not sound or does not stop sounding….2525
      E-23 Air conditioner does not operate normally (including air conditioner abnormality record)….2527
      E-24 While starting switch is in OFF position, service meter is not displayed….2538
      E-25 Machine monitor cannot be set in service mode….2538
      E-26 Monitoring function does not display lever control signal normally….2540
      E-27 KOMTRAX system does not operate normally….2550
    500 Troubleshooting of hydraulic and mechanical system (H-mode)….2553
      Information contained in troubleshooting table….2555
      System chart for hydraulic and mechanical systems….2556
      H-1 Speed or power of all work equipment, swing, and travel are low….2558
      H-2 Engine speed sharply drops or engine stalls….2559
      H-3 No work equipment, travel and swing move….2560
      H-4 Abnormal noise is heard from around hydraulic pump….2560
      H-5 Auto-decelerator does not work….2561
      H-6 Fine control mode does not function….2561
      H-7 Speed or power of boom is low….2562
      H-8 Speed or power of arm is low….2563
      H-9 Speed or power of bucket is low….2564
      H-10 Work equipment does not move in its single operation….2565
      H-11 Hydraulic drift of work equipment is large….2566
      H-12 Time lag of work equipment is large….2567
      H-13 One-touch power max system does not operate….2567
      H-14 Work equipment loaded more is slower during compound operation….2568
      H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE….2568
      H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel….2569
      H-17 Machine deviates during travel….2570
      H-18 Travel speed is low….2571
      H-19 Machine cannot be steered easily or steering power is low….2572
      H-20 Travel speed does not change or it is kept low or high….2573
      H-21 Track does not move (Only either side)….2573
      H-22 Machine does not swing….2574
      H-23 Swing acceleration or swing speed is low….2575
      H-24 Excessive overrun when stopping swing….2576
      H-25 When upper structure stops swinging, it makes large shock….2577
      H-26 When upper structure stops swinging, it makes large sound….2577
      H-27 Hydraulic drift of swing is large….2578
      H-28 Attachment circuit does not change….2579
      H-29 Flow rate in attachment circuit cannot be adjusted….2579
    600 Troubleshooting of engine (S-mode)….2581
      Method of using troubleshooting chart….2584
      S-1  Starting performance is poor….2588
      S-2  Engine does not start….2589
      S-3  Engine does not pick up smoothly….2592
      S-4  Engine stops during operations….2593
      S-5  Engine does not rotate smoothly….2594
      S-6  Engine lack output (or lacks power)….2595
      S-7  Exhaust smoke is black (incomplete combustion)….2596
      S-8  Oil consumption is excessive (or exhaust smoke is blue)….2597
      S-9  Oil becomes contaminated quickly….2598
      S-10  Fuel consumption is excessive….2599
      S-11  Oil is in coolant (or coolant spurts back or coolant level goes down)….2600
      S-12  Oil pressure drops….2601
      S-13  Oil level rises (Entry of coolant/fuel)….2602
      S-14  Coolant temperature becomes too high (overheating)….2603
      S-15  Abnormal noise is made….2604
      S-16  Vibration is excessive….2605
  50 Disassembly and assembly….0
    100 General information on disassembly and assembly….2607
      How to read this manual….2608
      Coating materials list….2610
      Special tool list….2613
      Sketches of special tools….2616
    200 Engine and cooling system….2619
      Removal and installation of fuel supply pump assembly….2620
      Removal and installation of fuel injector assembly….2624
      Removal and installation of cylinder head assembly….2631
      Removal and installation of front oil seal….2644
      Removal and installation of rear oil seal….2646
      Removal and installation of radiator assembly….2649
      Removal and installation of aftercooler assembly….2651
      Removal and installation of hydraulic oil cooler assembly….2653
      Removal and installation of engine and hydraulic pump assembly….2655
      Removal and installation of engine hood assembly….2663
      Removal and installation of fuel tank assembly….2665
    300 Power train….2669
      Removal and installation of travel motor and final drive assembly….2670
      Disassembly and assembly of final drive assembly….2672
      Removal and installation of swing motor and swing machinery assembly….2679
      Disassembly and assembly of swing motor and swing machinery assembly….2681
      Removal and installation of swing circle assembly….2688
    400 Undercarriage and frame….2691
      Disassembly and assembly of carrier roller….2692
      Disassembly and assembly of track roller assembly….2695
      Disassembly and assembly of idler assembly….2697
      Disassembly and assembly of recoil spring….2700
      Expansion and installation of track shoe assembly….2702
      Removal and installation of sprocket….2704
      Removal and installation of revolving frame assembly….2705
      Removal and installation of counterweight assembly….2707
    500 Hydraulic system….2711
      Removal and installation of center swivel joint assembly….2712
      Disassembly and assembly of center swivel joint assembly….2714
      Removal and installation of hydraulic tank assembly….2716
      Removal and installation of hydraulic pump assembly….2719
      Removal and installation of hydraulic pump input shaft oil seal….2722
      Removal and installation of control valve assembly….2723
      Disassembly and assembly of control valve assembly….2727
      Disassembly and assembly of work equipment PPC valve assembly….2729
      Disassembly and assembly of travel PPC valve assembly….2730
      Disassembly and assembly of hydraulic cylinder assembly….2733
    600 Work equipment Body….2741
      Removal and installation of work equipment assembly….2742
    700 Cab and its attachments….2747
      Removal and installation of operator’s cab assembly….2748
      Removal and installation of operator cab glass (stuck glass)….2752
      Removal and installation of front window assembly….2762
      Removal and installation of floor frame assembly….2769
      Removal and installation of air conditioner unit assembly….2773
    800 Electrical system….2777
      Removal and installation of monitor assembly….2778
      Removal and installation of pump controller assembly….2780
      Removal and installation of engine controller assembly….2783
      Removal and installation of KOMTRAX terminal….2785
  90 Diagrams and drawings….0
    100 Hydraulic circuit diagram….2787
      Hydraulic circuit diagram….2789
    200 Electrical diagrams and drawings….2792
      Electrical circuit diagram (1/6)….2794
      Electrical circuit diagram (2/6)….2795
      Electrical circuit diagram (3/6)….2796
      Electrical circuit diagram (4/6)….2797
      Electrical circuit diagram (5/6)….2798
      Electrical circuit diagram (6/6)….2799
      Connectors table and arrangement drawing….2800
TEN00021-00 – Hydraulic Excavator GALEO PC160LC-7 Operation &amp; Maintenance Manual….2803
  COVER….2803
  FOREWORD….2804
    FOREWORD….2805
    SAFETY INFORMATION….2808
    INTRODUCTION….2810
      DIRECTIONS OF MACHINE….2810
      BREAKING-IN THE NEW MACHINE….2810
    PRODUCT INFORMATION….2811
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….2811
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….2811
      SERVICE METER LOCATION….2812
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….2812
  CONTENTS….2813
  SAFETY….2816
    SAFETY INFORMATION….2817
    SAFETY LABELS….2819
      LOCATION OF SAFETY LABELS….2819
      SAFETY LABELS….2820
    SAFETY INFORMATION….2825
      SAFETY RULES….2825
      IF ABNORMALITIES ARE FOUND….2825
      WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….2825
      FIRE EXTINGUISHER AND FIRST AID KIT….2825
      SAFETY EQUIPMENT….2825
      KEEP MACHINE CLEAN….2826
      KEEP OPERATOR&apos;S COMPARTMENT CLEAN….2826
      LEAVING OPERATOR&apos;S SEAT WITH LOCK….2826
      HANDRAILS AND STEPS….2827
      MOUNTING AND DISMOUNTING….2827
      NO PERSONS ON ATTACHMENTS….2827
      BURN PREVENTION….2828
      FIRE PREVENTION AND EXPLOSION PREVENTION….2829
      ACTION IF FIRE OCCURS….2830
      WINDSHIELD WASHER FLUID….2830
      FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….2830
      ATTACHMENT INSTALLATION….2830
      ATTACHMENT COMBINATIONS….2830
      CAB WINDOW GLASSES….2830
      UNAUTHORIZED MODIFICATIONS….2831
      SAFETY AT JOBSITE….2831
      WORKING ON LOOSE GROUND….2831
      DISTANCE TO HIGH VOLTAGE CABLES….2831
      ENSURE GOOD VISIBILITY….2832
      VENTILATION FOR ENCLOSED AREA….2832
      SIGNALMAN&apos;S SIGNAL AND SIGNS….2832
      EMERGENCY EXIT FROM OPERATOR&apos;S CAB….2832
      ASBESTOS DUST HAZARD PREVENTION….2833
    SAFETY MACHINE OPERATION….2834
      STARTING ENGINE….2834
        CHECKS BEFORE STARTING ENGINE….2834
        SAFETY RULES FOR STARTING ENGINE….2835
        STARTING ENGINE IN COLD WEATHER….2835
      OPERATION….2836
        CHECKS BEFORE OPERATION….2836
        SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….2836
        SAFETY RULES FOR TRAVELING….2837
        TRAVELING ON SLOPES….2838
        OPERATIONS ON SLOPES….2839
        PROHIBITED OPERATIONS….2839
        OPERATIONS ON SNOW….2840
        PARKING MACHINE….2841
      TRANSPORTATION….2842
        SHIPPING THE MACHINE….2842
      BATTERY….2843
        BATTERY HAZARD PREVENTION….2843
        STARTING ENGINE WITH BOOSTER CABLES….2844
      TOWING….2845
        SAFETY RULES FOR TOWING….2845
      LIFTING OBJECTS WITH BUCKET….2846
        SAFETY RULES FOR LIFTING OBJECTS….2846
        LIFTING WORK USING BUCKET WITH HOOK….2846
    SAFETY MAINTENANCE INFORMATION….2847
      WARNING TAG….2847
      KEEP WORK PLACE CLEAN AND TIDY….2847
      APPOINT LEADER WHEN WORKING WITH OTHERS….2847
      STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….2848
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….2849
      PROPER TOOLS….2849
      ACCUMULATOR….2850
      PERSONNEL….2850
      WORK UNDER THE MACHINE….2850
      NOISE….2850
      WHEN USING HAMMER….2851
      WELDING WORKS….2851
      REMOVING BATTERY TERMINALS….2851
      SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….2851
      DO NOT DISASSEMBLE RECOIL SPRINGS….2851
      SAFETY RULES FOR HIGH-PRESSURE OIL….2852
      SAFETY HANDLING HIGH-PRESSURE HOSES….2852
      WASTE MATERIALS….2852
      AIR CONDITIONER MAINTENANCE….2852
      COMPRESSED AIR….2853
      PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….2853
  OPERATION….2854
    MACHINE VIEW ILLUSTRATIONS….2855
      OVERALL MACHINE VIEW….2855
      CONTROLS AND GAUGES….2856
    DETAILED CONTROLS AND GAUGES….2857
      MONITORING SYSTEM….2857
      SWITCHES….2881
      CONTROL LEVERS AND PEDALS….2886
      SUN ROOF….2889
      WINDSHIELD….2889
      EMERGENCY EXIT FROM OPERATOR&apos;S CAB….2894
      DOOR LOCK….2894
      CAP WITH LOCK….2895
      HOT AND COOL BOX….2896
      AIR CONDITIONER CONTROLS….2897
      RADIO….2912
      AUXILIARY ELECTRIC POWER….2916
      FUSE….2917
      FUSIBLE LINK….2918
      CONTROLLERS….2918
      TOOL BOX….2918
      GREASE GUN HOLDER….2918
      ACCUMULATOR….2919
    MACHINE OPERATIONS AND CONTROLS….2921
      BEFORE STARTING ENGINE….2921
      STARTING ENGINE….2936
      AFTER STARTING ENGINE….2940
      STOPPING THE ENGINE….2949
      MACHINE OPERATION….2950
      STEERING THE MACHINE….2954
      SWINGING….2956
      WORK EQUIPMENT CONTROLS AND OPERATIONS….2957
      WORKING MODE….2959
      PROHIBITED OPERATIONS….2960
      GENERAL OPERATION INFORMATION….2962
      TRAVELING ON SLOPES….2963
      ESCAPE FROM MUD….2965
      RECOMMENDED APPLICATIONS….2966
      BUCKET REPLACEMENT AND INVERSION….2968
      PARKING MACHINE….2971
      CHECK AFTER SHUT OFF ENGINE….2972
      MACHINE INSPECTION AFTER DAILY WORK….2972
      LOCKING….2973
    TRANSPORTATION….2974
      TRANSPORTATION PROCEDURE….2974
      LOADING AND UNLOADING WITH TRAILER….2974
      LIFTING MACHINE….2981
    COLD WEATHER OPERATION….2983
      COLD WEATHER OPERATION INFORMATION….2983
      AFTER DAILY WORK COMPLETION….2986
      AFTER COLD WEATHER SEASON….2986
    LONG TERM STORAGE….2987
      BEFORE STORAGE….2987
      DURING STORAGE….2987
      AFTER STORAGE….2987
      STARTING MACHINE AFTER LONG-TERM STORAGE….2988
    TROUBLES AND ACTIONS….2989
      RUNNING OUT OF FUEL….2989
      PHENOMENA THAT ARE NOT FAILURES….2989
      TOWING THE MACHINE….2990
      LIGHTWEIGHT TOWING HOLE….2990
      SEVERE JOB CONDITION….2990
      DISCHARGED BATTERY….2991
      OTHER TROUBLE….2995
  MAINTENANCE….3000
    MAINTENANCE INFORMATION….3001
    OUTLINE OF SERVICE….3003
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….3003
      ELECTRIC SYSTEM MAINTENANCE….3006
    WEAR PARTS….3007
      WEAR PARTS LIST….3007
    LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….3008
      PROPER SELECTION….3008
    TIGHTENING TORQUE SPECIFICATIONS….3012
      TIGHTENING TORQUE LIST….3012
    SAFETY CRITICAL PARTS….3013
      SAFETY CRITICAL PARTS LIST….3013
    MAINTENANCE SCHEDULE….3014
      MAINTENANCE SCHEDULE CHART….3014
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….3015
    MAINTENANCE PROCEDURE….3016
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….3016
        REPLACE FUEL FILTER CARTRIDGE….3054
      INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)….3016
        CHECK ENGINE VALVE CLEARANCE, ADJUST….3063
      WHEN REQUIRED….3017
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….3017
        CLEAN INSIDE OF COOLING SYSTEM….3022
        CHECK AND TIGHTEN TRACK SHOE BOLTS….3025
        CHECK AND ADJUST TRACK TENSION….3026
        CHECK ELECTRICAL INTAKE AIR HEATER….3027
        REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….3028
        REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….3031
        ADJUST BUCKET CLEARANCE….3032
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….3033
        CHECK AND MAINTENANCE AIR CONDITIONER….3034
        WASH WASHABLE FLOOR….3035
        BLEEDING AIR FROM HYDRAULIC SYSTEM….3038
        METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT….3040
        CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit)….3041
      CHECK BEFORE STARTING….3042
      EVERY 250 HOURS MAINTENANCE….3043
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….3044
        CHECK LEVEL OF BATTERY ELECTROLYTE….3045
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….3048
        CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL….3043
      EVERY 500 HOURS MAINTENANCE….3049
        LUBRICATING….3049
        LUBRICATE SWING CIRCLE….3051
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….3052
        REPLACE FUEL FILTER CARTRIDGE….3054
        CHECK SWING PINION GREASE LEVEL, ADD GREASE….3055
        CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS….3056
        CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….3057
        REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….3058
      EVERY 1000 HOURS MAINTENANCE….3059
        REPLACE HYDRAULIC OIL FILTER ELEMENT….3059
        CHANGE OIL IN SWING MACHINERY CASE….3060
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL….3061
        CHECK FAN BELT TENSION AND REPLACE FAN BELT….3061
      EVERY 2000 HOURS MAINTENANCE….3062
        CHANGE OIL IN FINAL DRIVE CASE….3062
        CLEAN HYDRAULIC TANK STRAINER….3063
        CHECK ALTERNATOR, STARTING MOTOR….3063
        CHECK ENGINE VALVE CLEARANCE, ADJUST….3063
      EVERY 4000 HOURS MAINTENANCE….3064
        CHECK WATER PUMP….3064
      EVERY 5000 HOURS MAINTENANCE….3065
        CHANGE OIL IN HYDRAULIC TANK….3065
  SPECIFICATIONS….3066
    SPECIFICATIONS….3067
  ATTACHMENTS, OPTIONS….3070
    GENERAL PRECAUTIONS FOR SAFETY….3071
      PRECAUTIONS WHEN SELECTING….3071
      READ THE INSTRUCTION MANUAL THOROUGHLY….3071
      PRECAUTIONS WHEN REMOVING OR INSTALLING….3071
      PRECAUTIONS WHEN USING….3071
    BUCKET WITH HOOK….3072
      HOOK CONDITION….3072
      PROHIBITED OPERATIONS….3072
    MACHINE READY FOR ATTACHMENT….3073
      LOCATIONS….3073
      HYDRAULIC CIRCUIT….3076
      ATTACHMENT REMOVAL AND INSTALLATION….3080
      ATTACHMENT OPERATIONS….3082
      LONG TERM STORAGE….3084
      SPECIFICATIONS….3084
    ATTACHMENT GUIDE….3085
      OTHER ATTACHMENTS….3085
      ATTACHMENT COMBINATIONS….3087
      TRACK SHOES SELECTION….3088
      BUCKET TEETH SELECTION….3089
    RECOMMENDED ATTACHMENT OPERATIONS….3090
      HYDRAULIC BREAKER….3090
  INDEX….3096
TEN00096-01 – Hydraulic Excavator GALEO PC160LC-7 Operation &amp; Maintenance Manual….3100
  COVER….3100
  FOREWORD….3101
    FOREWORD….3102
    SAFETY INFORMATION….3105
    INTRODUCTION….3107
      DIRECTIONS OF MACHINE….3107
      BREAKING-IN THE NEW MACHINE….3107
    PRODUCT INFORMATION….3108
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….3108
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….3108
      SERVICE METER LOCATION….3109
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….3109
  CONTENTS….3110
  SAFETY….3113
    SAFETY INFORMATION….3114
    SAFETY LABELS….3116
      LOCATION OF SAFETY LABELS….3116
      SAFETY LABELS….3117
    SAFETY INFORMATION….3122
      SAFETY RULES….3122
      IF PROBLEMS ARE FOUND….3122
      WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….3122
      FIRE EXTINGUISHER AND FIRST AID KIT….3122
      SAFETY EQUIPMENT….3122
      KEEP MACHINE CLEAN….3123
      KEEP OPERATOR&apos;S COMPARTMENT CLEAN….3123
      LEAVING OPERATOR&apos;S SEAT WITH LOCK….3123
      HANDRAILS AND STEPS….3124
      MOUNTING AND DISMOUNTING….3124
      NO PERSONS ON ATTACHMENTS….3124
      BURN PREVENTION….3125
      FIRE PREVENTION AND EXPLOSION PREVENTION….3126
      ACTION IF FIRE OCCURS….3127
      WINDSHIELD WASHER FLUID….3127
      FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….3127
      ATTACHMENT INSTALLATION….3127
      ATTACHMENT COMBINATIONS….3127
      CAB WINDOW GLASSES….3127
      UNAUTHORIZED MODIFICATIONS….3128
      SAFETY AT JOBSITE….3128
      WORKING ON LOOSE GROUND….3128
      DISTANCE TO HIGHT VOLTAGE CABLES….3129
      ENSURE GOOD VISIBILITY….3129
      VENTILATION FOR ENCLOSED AREA….3129
      SIGNALMAN&apos;S SIGNAL AND SIGNS….3130
      EMERGENCY EXIT FROM OPERATOR&apos;S CAB….3130
      ASBESTOS DUST HAZARD PREVENTION….3130
    SAFETY MACHINE OPERATION….3131
      STARTING ENGINE….3131
        CHECKS BEFORE STARTING ENGINE….3131
        SAFETY RULES FOR STARTING ENGINE….3132
        STARTING ENGINE IN COLD WEATHER….3132
      OPERATION….3133
        CHECKS BEFORE OPERATION….3133
        SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….3133
        SAFETY RULES FOR TRAVELING….3134
        TRAVELING ON SLOPES….3135
        OPERATIONS ON SLOPES….3136
        PROHIBITED OPERATIONS….3136
        OPERATIONS ON SNOW….3137
        PARKING MACHINE….3138
      TRANSPORTATION….3139
        SHIPPING THE MACHINE….3139
      BATTERY….3140
        BATTERY HAZARD PREVENTION….3140
        STARTING ENGINE WITH BOOSTER CABLES….3141
      TOWING….3142
        SAFETY RULES FOR TOWING….3142
      LIFTING OBJECTS WITH BUCKET….3143
        LIFTING WORK USING BUCKET WITH HOOK….3143
        SAFETY RULES FOR LIFTING OBJECTS….3143
    SAFETY MAINTENANCE INFORMATION….3144
      WARNING TAG….3144
      KEEP WORK PLACE CLEAN AND TIDY….3144
      APPOINT LEADER WHEN WORKING WITH OTHERS….3144
      STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….3145
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….3146
      PROPER TOOLS….3146
      ACCUMULATOR….3147
      PERSONNEL….3147
      ATTACHMENTS….3147
      WORK UNDER THE MACHINE….3147
      NOISE….3147
      WHEN USING HAMMER….3148
      WELDING WORKS….3148
      REMOVING BATTERY TERMINALS….3148
      SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….3148
      DO NOT DISASSEMBLE RECOIL SPRINGS….3148
      SAFETY RULES FOR HIGH-PRESSURE OIL….3149
      SAFETY HANDLING HIGH-PRESSURE HOSES….3149
      WASTE MATERIALS….3149
      AIR CONDITIONER MAINTENANCE….3149
      COMPRESSED AIR….3150
      PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….3150
  OPERATION….3151
    MACHINE VIEW ILLUSTRATIONS….3152
      OVERALL MACHINE VIEW….3152
      CONTROLS AND GAUGES….3153
    DETAILED CONTROLS AND GAUGES….3154
      MONITORING SYSTEM….3154
      SWITCHES….3178
      CONTROL LEVERS AND PEDALS….3183
      SUN ROOF….3186
      WINDSHIELD….3186
      EMERGENCY EXIT FROM OPERATOR&apos;S CAB….3191
      DOOR LOCK….3191
      CAP WITH LOCK….3192
      HOT AND COOL BOX….3193
      MAGAZINE BOX….3193
      ASHTRAY….3193
      AIR CONDITIONER CONTROLS….3194
      RADIO….3209
      AUXILIARY ELECTRIC POWER….3214
      FUSE….3215
      FUSIBLE LINK….3216
      CONTROLLERS….3216
      TOOL BOX….3216
      GREASE GUN HOLDER….3216
      ACCUMULATOR….3217
    MACHINE OPERATIONS AND CONTROLS….3219
      BEFORE STARTING ENGINE….3219
      STARTING ENGINE….3234
      AFTER STARTING ENGINE….3238
      STOPPING THE ENGINE….3247
      MACHINE OPERATION….3248
      STEERING THE MACHINE….3252
      SWINGING….3254
      WORK EQUIPMENT CONTROLS AND OPERATIONS….3255
      WORKING MODE….3257
      PROHIBITED OPERATIONS….3258
      GENERAL OPERATION INFORMATION….3260
      TRAVELING ON SLOPES….3261
      ESCAPE FROM MUD….3263
      RECOMMENDED APPLICATIONS….3264
      BUCKET REPLACEMENT AND INVERSION….3266
      PARKING MACHINE….3269
      CHECK AFTER SHUT OFF ENGINE….3270
      MACHINE INSPECTION AFTER DAILY WORK….3270
      LOCKING….3271
    TRANSPORTATION….3272
      TRANSPORTATION PROCEDURE….3272
      LOADING AND UNLOADING WITH TRAILER….3272
      LIFTING MACHINE….3279
    COLD WEATHER OPERATION….3281
      COLD WEATHER OPERATION INFORMATION….3281
      AFTER DAILY WORK COMPLETION….3284
      AFTER COLD WEATHER SEASON….3284
    LONG TERM STORAGE….3285
      BEFORE STORAGE….3285
      DURING STORAGE….3285
      AFTER STORAGE….3285
      STARTING MACHINE AFTER LONG-TERM STORAGE….3286
    TROUBLES AND ACTIONS….3287
      RUNNING OUT OF FUEL….3287
      PHENOMENA THAT ARE NOT FAILURES….3287
      TOWING THE MACHINE….3288
      LIGHTWEIGHT TOWING HOLE….3289
      SEVERE JOB CONDITION….3289
      DISCHARGED BATTERY….3290
      OTHER TROUBLE….3294
  MAINTENANCE….3299
    MAINTENANCE INFORMATION….3300
    OUTLINE OF SERVICE….3302
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….3302
      ELECTRIC SYSTEM MAINTENANCE….3305
    WEAR PARTS….3306
      WEAR PARTS LIST….3306
    LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….3307
    TIGHTENING TORQUE SPECIFICATIONS….3311
      TIGHTENING TORQUE LIST….3311
    SAFETY CRITICAL PARTS….3312
      SAFETY CRITICAL PARTS LIST….3312
    MAINTENANCE SCHEDULE….3313
      MAINTENANCE SCHEDULE CHART….3313
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….3315
    MAINTENANCE PROCEDURE….3316
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….3316
      INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)….3316
      WHEN REQUIRED….3317
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….3317
        CLEAN INSIDE OF COOLING SYSTEM….3322
        CHECK AND TIGHTEN TRACK SHOE BOLTS….3325
        CHECK AND ADJUST TRACK TENSION….3326
        CHECK ELECTRICAL INTAKE AIR HEATER….3327
        REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….3328
        REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….3331
        ADJUST BUCKET CLEARANCE….3332
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….3333
        CHECK AND MAINTENANCE AIR CONDITIONER….3334
        WASH WASHABLE FLOOR….3335
        BLEEDING AIR FROM HYDRAULIC SYSTEM….3338
        METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT….3340
        CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)….3341
      CHECK BEFORE STARTING….3342
      EVERY 100 HOURS MAINTENANCE….3343
        LUBRICATING….3343
      EVERY 250 HOURS MAINTENANCE….3344
        CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL….3344
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….3345
        CHECK LEVEL OF BATTERY ELECTROLYTE….3346
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST….3349
      EVERY 500 HOURS MAINTENANCE….3350
        LUBRICATING….3350
        LUBRICATE SWING CIRCLE….3351
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….3352
        REPLACE FUEL FILTER CARTRIDGE….3354
        CHECK SWING PINION GREASE LEVEL, ADD GREASE….3355
        CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS ….3356
        CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….3357
        REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….3359
      EVERY 1000 HOURS MAINTENANCE….3360
        REPLACE HYDRAULIC OIL FILTER ELEMENT….3360
        CHANGE OIL IN SWING MACHINERY CASE….3361
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL….3362
        CHECK FAN BELT TENSION AND REPLACE FAN BELT….3362
      EVERY 2000 HOURS MAINTENANCE….3363
        CHANGE OIL IN FINAL DRIVE CASE….3363
        CLEAN HYDRAULIC TANK STRAINER….3364
        CHECK ALTERNATOR, STARTING MOTOR….3364
        CHECK ENGINE VALVE CLEARANCE, ADJUST….3364
      EVERY 4000 HOURS MAINTENANCE….3365
        CHECK WATER PUMP….3365
      EVERY 5000 HOURS MAINTENANCE….3366
        CHANGE OIL IN HYDRAULIC TANK….3366
  SPECIFICATIONS….3367
    SPECIFICATIONS….3368
  ATTACHMENTS, OPTIONS….3370
    GENERAL PRECAUTIONS FOR SAFETY….3371
      PRECAUTIONS WHEN SELECTING….3371
      READ THE INSTRUCTION MANUAL THOROUGHLY….3371
      PRECAUTIONS WHEN REMOVING OR INSTALLING….3371
      PRECAUTIONS WHEN USING….3371
    BUCKET WITH HOOK….3372
      HOOK CONDITION….3372
      PROHIBITED OPERATIONS….3372
    MACHINE READY FOR ATTACHMENT….3373
      LOCATIONS….3373
      HYDRAULIC CIRCUIT….3376
      ATTACHMENT REMOVAL AND INSTALLATION….3380
      ATTACHMENT OPERATIONS….3382
      LONG TERM STORAGE….3384
      SPECIFICATIONS….3384
    ATTACHMENT GUIDE….3385
      OTHER ATTACHMENTS….3385
      ATTACHMENT COMBINATIONS….3387
      TRACK SHOES SELECTION….3388
      BUCKET TEETH SELECTION….3389
    RECOMMENDED ATTACHMENT OPERATIONS….3390
      HYDRAULIC BREAKER….3390
  INDEX….3395
TEN00308-00TH – Hydraulic Excavator PC160LC-8 Operation &amp; Maintenance Manual….3398
TEN00308-03 – Hydraulic Excavator PC160LC-8 Operation &amp; Maintenance Manual….3777
  COVER….3777
  FOREWORD….3778
    BEFORE READING THIS MANUAL….3779
    SAFETY INFORMATION….3780
    INTRODUCTION….3781
      USE OF MACHINE….3781
      DIRECTIONS OF MACHINE….3781
      VISIBILITY FROM OPERATOR&apos;S SEAT….3781
    PRODUCT INFORMATION….3782
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….3782
      EPA REGULATIONS, ENGINE NUMBER PLATE….3782
      SERVICE METER LOCATION….3783
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….3783
    CONTENTS….3784
  SAFETY….3788
    SAFETY….3789
    SAFETY LABELS….3792
      LOCATION OF SAFETY LABELS….3793
      SAFETY LABELS….3794
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….3801
      PRECAUTIONS BEFORE STARTING OPERATION….3801
      PREPARATIONS FOR SAFE OPERATION….3801
      FIRE PREVENTION….3803
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….3804
      DO NOT GET CAUGHT IN WORK EQUIPMENT….3806
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….3806
      PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….3806
      UNAUTHORIZED MODIFICATION….3807
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….3807
      PRECAUTIONS RELATED TO CAB GLASS….3807
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….3807
    PRECAUTIONS FOR OPERATION….3808
      PRECAUTIONS FOR JOBSITE….3808
      STARTING ENGINE….3810
      OPERATION….3812
      TRANSPORTATION….3820
      TOWING….3821
      LIFTING OBJECTS WITH BUCKET….3821
    PRECAUTIONS FOR MAINTENANCE….3822
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….3822
      PRECAUTIONS FOR INSPECTION AND MAINTENANCE….3826
  OPERATION….3832
    MACHINE VIEW ILLUSTRATIONS….3833
      OVERALL MACHINE VIEW….3833
      CONTROLS AND GAUGES….3834
    DETAILED CONTROLS AND GAUGES….3836
      MONITORING SYSTEM….3836
      SWITCHES….3902
      CONTROL LEVERS AND PEDALS….3906
      SUN ROOF….3909
      WINDSHIELD….3909
      EMERGENCY ESCAPE HAMMER….3915
      DOOR LOCK….3915
      CAP WITH LOCK….3916
      DRINK BOX….3918
      MAGAZINE BOX….3918
      ASHTRAY….3918
      AIR CONDITIONER CONTROLS….3919
      RADIO….3932
      AUXILIARY ELECTRIC POWER….3937
      FUSE….3938
      FUSIBLE LINK….3939
      CONTROLLER….3939
      TOOL BOX….3939
      GREASE GUN HOLDER….3940
      FIRE EXTINGUISHER….3940
    MACHINE OPERATIONS AND CONTROLS….3941
      BEFORE STARTING ENGINE….3941
      STARTING ENGINE….3963
      AFTER STARTING ENGINE….3966
      STOPPING THE ENGINE….3977
      MACHINE OPERATION….3978
      STEERING THE MACHINE….3982
      SWINGING….3984
      WORK EQUIPMENT CONTROLS AND OPERATIONS….3985
      WORKING MODE….3987
      PROHIBITED OPERATIONS….3989
      GENERAL OPERATION INFORMATION….3992
      TRAVELING ON SLOPES….3994
      ESCAPE FROM MUD….3996
      RECOMMENDED APPLICATIONS….3997
      BUCKET REPLACEMENT AND INVERSION….3999
      PARKING MACHINE….4003
      MACHINE INSPECTION AFTER DAILY WORK….4004
      LOCKING….4005
    TRANSPORTATION….4006
      TRANSPORTATION PROCEDURE….4006
      LOADING AND UNLOADING WITH TRAILER….4007
      LIFTING MACHINE….4017
    COLD WEATHER OPERATION….4019
      COLD WEATHER OPERATION INFORMATION….4019
      AFTER DAILY WORK COMPLETION….4021
      AFTER COLD WEATHER SEASON….4021
    LONG TERM STORAGE….4022
      BEFORE STORAGE….4022
      DURING STORAGE….4022
      AFTER STORAGE….4023
      STARTING MACHINE AFTER LONG-TERM STORAGE….4023
    TROUBLES AND ACTIONS….4024
      RUNNING OUT OF FUEL….4024
      PHENOMENA THAT ARE NOT FAILURES….4024
      TOWING THE MACHINE….4025
      LIGHTWEIGHT TOWING HOLE….4026
      SEVERE JOB CONDITION….4026
      DISCHARGED BATTERY….4027
      OTHER TROUBLE….4031
  MAINTENANCE….4038
    MAINTENANCE INFORMATION….4039
    OUTLINE OF SERVICE….4041
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4041
      ELECTRIC SYSTEM MAINTENANCE….4044
    WEAR PARTS….4045
      WEAR PARTS LIST….4045
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT….4046
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….4048
    TIGHTENING TORQUE SPECIFICATIONS….4049
      TIGHTENING TORQUE LIST….4049
    SAFETY CRITICAL PARTS….4050
      SAFETY CRITICAL PARTS LIST….4051
    MAINTENANCE SCHEDULE….4052
      MAINTENANCE SCHEDULE CHART….4052
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….4054
    MAINTENANCE PROCEDURE….4055
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….4055
      INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)….4055
      WHEN REQUIRED….4056
      CHECK BEFORE STARTING….4083
      EVERY 100 HOURS MAINTENANCE….4084
      EVERY 250 HOURS MAINTENANCE….4085
      EVERY 500 HOURS MAINTENANCE….4089
      EVERY 1000 HOURS MAINTENANCE….4102
      EVERY 2000 HOURS MAINTENANCE….4109
      EVERY 4000 HOURS MAINTENANCE….4116
      EVERY 5000 HOURS MAINTENANCE….4120
      EVERY 8000 HOURS MAINTENANCE….4121
  SPECIFICATIONS….4122
    SPECIFICATIONS….4123
  ATTACHMENTS, OPTIONS….4126
    GENERAL PRECAUTIONS FOR SAFETY….4127
      PRECAUTIONS WHEN SELECTING….4127
      READ THE INSTRUCTION MANUAL THOROUGHLY….4127
      PRECAUTIONS WHEN REMOVING OR INSTALLING….4127
      PRECAUTIONS WHEN USING….4127
    BUCKET WITH HOOK….4128
      HOOK CONDITION….4128
      PROHIBITED OPERATIONS….4128
    MACHINE READY FOR ATTACHMENT….4129
      LOCATIONS….4129
      HYDRAULIC CIRCUIT….4133
      ATTACHMENT REMOVAL AND INSTALLATION….4138
      ATTACHMENT OPERATIONS….4142
      LONG TERM STORAGE….4146
      SPECIFICATIONS….4146
    ATTACHMENT GUIDE….4147
      ATTACHMENT COMBINATIONS….4148
      TRACK SHOES SELECTION….4149
      BUCKET TEETH SELECTION….4150
    RECOMMENDED ATTACHMENT OPERATIONS….4151
      HYDRAULIC BREAKER….4151
    HANDLING MACHINES EQUIPPED WITH KOMTRAX….4156
      BASIC PRECAUTIONS….4156
  INDEX….4158
TEN00473-02 – Hydraulic Excavator PC160LC-8 Operation &amp; Maintenance Manual….4162
  COVER….4162
  FOREWORD….4163
    BEFORE READING THIS MANUAL….4164
    SAFETY INFORMATION….4165
    INTRODUCTION….4166
      USE OF MACHINE….4166
      DIRECTIONS OF MACHINE….4166
      VISIBILITY FROM OPERATOR&apos;S SEAT….4166
      PROTECTIVE STRUCTURE….4166
    PRODUCT INFORMATION….4167
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….4167
      EPA REGULATIONS, ENGINE NUMBER PLATE….4167
      SERVICE METER LOCATION….4168
      YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….4168
    CONTENTS….4169
  SAFETY….4173
    SAFETY….4174
    SAFETY LABELS….4177
      LOCATION OF SAFETY LABELS….4178
      SAFETY LABELS….4179
    GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….4187
      PRECAUTIONS BEFORE STARTING OPERATION….4187
      PREPARATIONS FOR SAFE OPERATION….4187
      FIRE PREVENTION….4189
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….4190
      DO NOT GET CAUGHT IN WORK EQUIPMENT….4192
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….4192
      PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….4193
      UNAUTHORIZED MODIFICATION….4194
      PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….4194
      PRECAUTIONS RELATED TO CAB GLASS….4194
      PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….4194
    PRECAUTIONS FOR OPERATION….4195
      PRECAUTIONS FOR JOBSITE….4195
      STARTING ENGINE….4197
      OPERATION….4199
      TRANSPORTATION….4207
      TOWING….4208
      LIFTING OBJECTS WITH BUCKET….4208
    PRECAUTIONS FOR MAINTENANCE….4209
      PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….4209
  OPERATION….4219
    MACHINE VIEW ILLUSTRATIONS….4220
      OVERALL MACHINE VIEW….4220
      CONTROLS AND GAUGES….4221
    DETAILED CONTROLS AND GAUGES….4223
      MONITORING SYSTEM….4223
      SWITCHES….4289
      CONTROL LEVERS AND PEDALS….4293
      SUN ROOF….4296
      WINDSHIELD….4296
      EMERGENCY ESCAPE HAMMER….4302
      DOOR LOCK….4302
      CAP WITH LOCK….4303
      DRINK BOX….4305
      MAGAZINE BOX….4305
      ASHTRAY….4305
      AIR CONDITIONER CONTROLS….4306
      RADIO….4319
      AUXILIARY ELECTRIC POWER….4324
      FUSE….4325
      FUSIBLE LINK….4326
      CONTROLLER….4326
      TOOL BOX….4326
      GREASE GUN HOLDER….4327
      FIRE EXTINGUISHER….4327
    MACHINE OPERATIONS AND CONTROLS….4328
      BEFORE STARTING ENGINE….4328
      STARTING ENGINE….4350
      AFTER STARTING ENGINE….4353
      STOPPING THE ENGINE….4364
      MACHINE OPERATION….4365
      STEERING THE MACHINE….4369
      SWINGING….4371
      WORK EQUIPMENT CONTROLS AND OPERATIONS….4372
      WORKING MODE….4374
      PROHIBITED OPERATIONS….4376
      GENERAL OPERATION INFORMATION….4379
      TRAVELING ON SLOPES….4381
      ESCAPE FROM MUD….4383
      RECOMMENDED APPLICATIONS….4384
      BUCKET REPLACEMENT AND INVERSION….4386
      PARKING MACHINE….4390
      MACHINE INSPECTION AFTER DAILY WORK….4391
      LOCKING….4392
    TRANSPORTATION….4393
      TRANSPORTATION PROCEDURE….4393
      LOADING AND UNLOADING WITH TRAILER….4394
      LIFTING MACHINE….4404
    COLD WEATHER OPERATION….4406
      COLD WEATHER OPERATION INFORMATION….4406
      AFTER DAILY WORK COMPLETION….4408
      AFTER COLD WEATHER SEASON….4408
    LONG TERM STORAGE….4409
      BEFORE STORAGE….4409
      DURING STORAGE….4409
      AFTER STORAGE….4410
      STARTING MACHINE AFTER LONG-TERM STORAGE….4410
    TROUBLES AND ACTIONS….4411
      RUNNING OUT OF FUEL….4411
      PHENOMENA THAT ARE NOT FAILURES….4411
      TOWING THE MACHINE….4412
      LIGHTWEIGHT TOWING HOLE….4413
      SEVERE JOB CONDITION….4413
      DISCHARGED BATTERY….4414
      OTHER TROUBLE….4418
  MAINTENANCE….4425
    MAINTENANCE INFORMATION….4426
    OUTLINE OF SERVICE….4428
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4428
      ELECTRIC SYSTEM MAINTENANCE….4431
    WEAR PARTS….4432
      WEAR PARTS LIST….4432
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT….4433
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….4435
    TIGHTENING TORQUE SPECIFICATIONS….4436
      TIGHTENING TORQUE LIST….4436
    SAFETY CRITICAL PARTS….4437
      SAFETY CRITICAL PARTS LIST….4438
    MAINTENANCE SCHEDULE….4439
      MAINTENANCE SCHEDULE CHART….4439
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….4441
    MAINTENANCE PROCEDURE….4442
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….4442
      INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)….4442
      WHEN REQUIRED….4443
      CHECK BEFORE STARTING….4470
      EVERY 100 HOURS MAINTENANCE….4471
      EVERY 250 HOURS MAINTENANCE….4472
      EVERY 500 HOURS MAINTENANCE….4476
      EVERY 1000 HOURS MAINTENANCE….4489
      EVERY 2000 HOURS MAINTENANCE….4496
      EVERY 4000 HOURS MAINTENANCE….4503
      EVERY 5000 HOURS MAINTENANCE….4507
      EVERY 8000 HOURS MAINTENANCE….4508
  SPECIFICATIONS….4509
    SPECIFICATIONS….4510
  ATTACHMENTS AND OPTIONS….4513
    GENERAL PRECAUTIONS FOR SAFETY….4514
      PRECAUTIONS WHEN SELECTING….4514
      READ THE INSTRUCTION MANUAL THOROUGHLY….4514
      PRECAUTIONS WHEN REMOVING OR INSTALLING….4514
      PRECAUTIONS WHEN USING….4514
    BUCKET WITH HOOK….4515
      HOOK CONDITION….4515
      PROHIBITED OPERATIONS….4515
    MACHINE READY FOR ATTACHMENT….4516
      LOCATIONS….4516
      HYDRAULIC CIRCUIT….4520
      ATTACHMENT REMOVAL AND INSTALLATION….4525
      ATTACHMENT OPERATIONS….4529
      LONG TERM STORAGE….4533
      SPECIFICATIONS….4533
    ATTACHMENT GUIDE….4534
      ATTACHMENT COMBINATIONS….4535
      TRACK SHOES SELECTION….4536
      BUCKET TEETH SELECTION….4537
    RECOMMENDED ATTACHMENT OPERATIONS….4538
      HYDRAULIC BREAKER….4538
    HANDLING MACHINES EQUIPPED WITH KOMTRAX….4543
      BASIC PRECAUTIONS….4543
  INDEX….4545

Komatsu Hydraulic Excavators PC160LC Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

UEBD000601 – Hydraulic Excavator PC160-6K, PC180LC, 180NLC-6K Shop Manual.pdf
EEBM001101 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Shop Manual.pdf
EEAM008501 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K, PC200EN-6K, PC200EL-6K Operation & Maintenance Manual.pdf
PEPBK21P0301 – Hydraulic Excavator PC180LC-3K, PC180LLC-3K, PC180NLC-3K Parts Book.pdf
UEAM000303 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Operation & Maintenance Manual.pdf
UEAM002401 – Hydraulic Excavator PC160LC-7KA Operation & Maintenance Manual.pdf

Total Pages: 2,533 pages
File Format: PDF
Language: English

EEAM008501 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K, PC200EN-6K, PC200EL-6K Operation & Maintenance Manual…2
EEBM001101 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Shop Manual…268
PEPBK21P0301 – Hydraulic Excavator PC180LC-3K, PC180LLC-3K, PC180NLC-3K Parts Book…937
UEAM000303 – Hydraulic Excavator PC160-6K, PC180LC-6K, PC180NLC-6K Operation & Maintenance Manual…1289
FOREWORD…1291
SAFETY INFORMATION…1292
SAFETY MESSAGES…1292
NOISE…1293
VIBRATION…1294
INTRODUCTION…1295
INTENDED USE…1295
FEATURES…1295
BREAKING IN YOUR NEW MACHINE…1296
LOCATION OF PLATES, TABLES TO ENTER SERIAL NO. AND DISTRIBUTOR…1297
MACHINE SERIAL NO. PLATE POSITION…1297
ENGINE SERIAL NO. PLATE POSITION…1297
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1297
MACHINE SERIAL PLATE…1298
SAFETY…1303
GENERAL PRECAUTIONS…1304
PRECAUTIONS DURING OPERATION…1312
BEFORE STARTING ENGINE…1312
OPERATING MACHINE…1314
TRANSPORTATION…1321
BATTERY…1322
TOWING…1323
BUCKET WITH HOOK…1324
GENERAL PRECAUTIONS…1324
PRECAUTIONS FOR LIFTING OPERATION…1325
PRECAUTIONS FOR MAINTENANCE…1327
BEFORE CARRYING OUT MAINTENANCE…1327
DURING MAINTENANCE…1330
POSITION FOR ATTACHING SAFETY LABELS…1335
POSITION FOR ATTACHING SAFETY LABELS…1335
OPERATION…1341
GENERAL VIEW…1342
GENERAL VIEW OF MACHINE…1342
GENERAL VIEW OF CONTROLS AND GAUGES…1343
EXPLANATION OF COMPONENTS…1345
MACHINE MONITOR…1345
A: BASIC CHECK ITEMS…1347
B: CAUTION ITEMS…1348
C: EMERGENCY STOP ITEMS…1349
D: METER DISPLAY PORTION…1350
METERS…1351
E: SWITCHES…1353
SWITCHES…1356
CONTROL LEVERS, PEDALS…1362
CEILING WINDOW…1366
CLEAR RAIN VISOR…1366
PULL DOWN SUN VISOR…1366
CUP HOLDER…1367
FRONT WINDOW…1368
DOOR LOCK…1370
CAP, COVER WITH LOCK…1370
LUGGAGE TRAY…1371
ASHTRAY…1372
HEATER…1373
VIEW OF CONTROL PANEL…1373
AIR CONDITIONER (option)…1375
GENERAL LOCATIONS ON CONTROL PANEL…1375
AIR CONDITIONER SWITCH…1377
OFF SWITCH…1377
DEFROSTER SELECTOR LEVER…1377
PRECAUTIONS WHEN USING AIR CONDITIONER…1377
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…1378
CAB RADIO (option)…1378
FUSE…1379
Fuse capacity and name of circuit…1379
FUSIBLE LINK…1380
CONTROLLERS…1380
TOOL BOX…1380
REFUELLING PUMP…1381
HANDLING THE ACCUMULATOR…1382
METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR…1382
OPERATION…1383
CHECK BEFORE STARTING ENGINE…1383
WALK-AROUND CHECK…1383
CHECK BEFORE STARTING…1384
CHECK FUEL LEVEL, ADD FUEL…1386
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…1387
CHECK AIR CLEANER FOR CLOGGING…1388
CHECK ELECTRIC WIRINGS…1388
CHECK FUNCTION OF HORN…1388
CHECK FOR WATER IN FUEL SEDIMENTOR…1389
CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER…1389
ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT…1390
USING THE SEAT BELT…1392
OPERATIONS AND CHECKS BEFORE STARTING ENGINE…1393
STARTING ENGINE…1395
NORMAL STARTING…1395
STARTING IN COLD WEATHER…1396
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1397
WHEN NORMAL…1397
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)…1399
MOVING MACHINE OFF…1403
MOVING MACHINE FORWARD…1403
MOVING MACHINE BACKWARD…1404
STEERING MACHINE…1406
STEERING (changing direction)…1406
STOPPING MACHINE…1408
SWINGING…1409
OPERATION OF WORK EQUIPMENT…1410
HANDLING ACTIVE MODE…1411
WORKING MODE SELECTION…1412
PROHIBITIONS FOR OPERATION…1414
PRECAUTIONS FOR OPERATION…1416
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS…1417
HOW TO ESCAPE FROM MUD…1418
WHEN ONE SIDE IS STUCK…1418
WHEN BOTH SIDES ARE STUCK…1418
WORK POSSIBLE USING HYDRAULIC EXCAVATOR…1419
BACKHOE WORK…1419
SHOVEL WORK…1419
DITCHING WORK…1419
LOADING WORK…1420
REPLACEMENT AND INVERSION OF BUCKET…1420
REPLACEMENT…1420
INVERSION…1421
PARKING THE MACHINE…1422
CHECK AFTER FINISHING WORK…1423
STOPPING ENGINE…1423
CHECK AFTER STOPPING ENGINE…1424
LOCKING…1425
OVERLOAD WARNING DEVICE…1425
TRANSPORTATION…1426
LOADING, UNLOADING WORK…1426
PRECAUTIONS FOR LOADING…1428
PRECAUTIONS FOR TRANSPORTATION…1428
METHOD OF LIFTING MACHINE…1429
COLD WEATHER OPERATION…1431
PRECAUTIONS FOR LOW TEMPERATURE…1431
FUEL AND LUBRICANTS…1431
COOLANT…1431
BATTERY…1432
PRECAUTIONS AFTER COMPLETION OF WORK…1432
AFTER COLD WEATHER…1433
LONG-TERM STORAGE…1434
BEFORE STORAGE…1434
DURING STORAGE…1434
AFTER STORAGE…1435
STARTING MACHINE AFTER LONG-TERM STORAGE…1435
TROUBLESHOOTING…1436
PHENOMENA THAT ARE NOT FAILURES…1436
METHOD OF TOWING MACHINE…1436
USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…1437
PRECAUTIONS ON PARTICULAR JOBSITES…1437
IF BATTERY IS DISCHARGED…1438
STARTING ENGINE WITH BOOSTER CABLE…1439
OTHER TROUBLE…1441
ELECTRICAL SYSTEM…1441
CHASSIS…1442
ENGINE…1443
ENGINE (cont’d)…1444
ELECTRONIC CONTROL SYSTEM…1445
MAINTENANCE…1447
GUIDES TO MAINTENANCE…1448
OUTLINES OF SERVICE…1451
OUTLINE OF OIL, FUEL, COOLANT…1451
OIL…1451
FUEL…1452
COOLANT…1452
GREASE…1453
STORING OIL AND FUEL…1453
FILTERS…1453
EXPLANATION OF LUBRICATION CHART DECAL…1454
OUTLINE OF ELECTRICAL SYSTEM…1456
OUTLINE OF HYDRAULIC SYSTEM…1456
WEAR PARTS LIST…1458
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1459
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…1459
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1463
LIST OF NECESSARY TOOLS…1463
TORQUE LIST…1464
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1465
MAINTENANCE SCHEDULE CHART…1468
MAINTENANCE SCHEDULE CHART…1468
MAINTENANCE WHEN USING HYDRAULIC BREAKER…1471
SERVICE PROCEDURE…1472
INITIAL 250 HOURS SERVICE…1472
WHEN REQUIRED…1472
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1472
CLEAN INSIDE OF COOLING SYSTEM…1474
CHECKING COOLANT LEVEL…1476
DRAINING THE SYSTEM…1476
CLEANING THE SYSTEM…1477
FILLING THE SYSTEM…1477
REFILLING AN OVERHEATED SYSTEM…1478
CLEANING THE RADIATOR…1478
CLEANING THE RADIATOR PRE SCREEN…1478
THERMOSTATS…1479
CHECK AND TIGHTEN TRACK SHOE BOLTS…1479
CHECK and adjust TRACK TENSION…1480
CHECK ELECTRICAL INTAKE AIR HEATER…1482
REPLACE BUCKET SIDE CUTTERS…1482
CHECK ALTERNATOR…1482
CHECK START MOTOR…1483
REPLACE BUCKET TEETH…1484
ADJUST BUCKET CLEARANCE…1484
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1485
CHECK, MAINTAIN AIR CONDITIONER…1486
CHECK BEFORE STARTING…1487
CHECK COOLANT LEVEL, ADD COOLANT…1487
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…1487
CHECK FUEL LEVEL, ADD FUEL…1488
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…1488
CHECK AIR CLEANER FOR CLOGGING…1489
CHECK ELECTRIC WIRINGS…1490
CHECK FUNCTION OF HORN…1490
CHECK FOR WATER IN FUEL SEDIMENTOR…1490
CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER…1491
EVERY 100 HOURS SERVICE…1491
LUBRICATING…1491
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…1493
DRAIN WATER AND SEDIMENT FROM FUEL TANK…1494
CLEAN FRESH AIR INTAKE FILTER…1494
EVERY 250 HOURS SERVICE…1495
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1495
CHECK LEVEL OF BATTERY ELECTROLYTE…1496
LUBRICATE SWING CIRCLE (2 POINTS)…1496
BELTS, GENERAL…1496
CHECK ALTERNATOR AND WATER PUMP BELT TENSION, ADJUST CHECKING TENSION…1497
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…1498
EVERY 500 HOURS SERVICE…1499
REPLACE FUEL FILTER CARTRIDGE…1499
CHECK SWING PINION GREASE LEVEL, ADD GREASE…1501
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…1502
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED W….1503
REPLACE HYDRAULIC FILTER ELEMENT…1504
EVERY 1000 HOURS SERVICE…1505
CHANGE OIL IN SWING MACHINERY CASE…1505
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…1505
CHECK PLAY OF TURBOCHARGER ROTOR…1505
CHECK AND ADJUST VALVE CLEARANCE…1506
CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB…1506
CHECK FAN BELT TENSION…1506
EVERY 2000 HOURS SERVICE…1507
CHANGE OIL IN FINAL DRIVE CASE…1507
CLEAN HYDRAULIC TANK STRAINER…1508
CLEAN, CHECK TURBOCHARGER…1508
CHECK ALTERNATOR, STARTING MOTOR…1508
CHECK ENGINE VALVE CLEARANCE, ADJUST…1508
CHECK VIBRATION DAMPER…1508
CHANGE ANTI FREEZE…1508
CHECK AND ADJUST VALVE CLEARANCE…1509
EVERY 4000 HOURS SERVICE…1509
CHECK WATER PUMP…1509
EVERY 5000 HOURS SERVICE…1509
CHANGE OIL IN HYDRAULIC TANK…1509
SPECIFICATIONS…1515
SPECIFICATIONS…1516
PC160-6K, PC180LC-6K, PC180NLC-6K…1516
explanation of LIFTING CAPACITY CHART…1522
OPTIONS, ATTACHMENTS…1529
PRECAUTIONS RELATED TO SAFETY…1530
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…1531
HANDLING BUCKET WITH HOOK…1532
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…1532
PROHIBITED OPERATIONS…1532
PRECAUTIONS DURING OPERATIONS…1532
MACHINES READY FOR ATTACHMENTS…1533
1. STOP VALVE…1533
3. CONTROL PEDAL FOR ATTACHMENT…1533
4. ACCUMULATOR…1534
5. HYDRAULIC CIRCUIT…1534
Change-over hydraulic circuit…1534
CONNECTING HYDRAULIC CIRCUIT…1535
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…1536
OPERATION…1537
LONG TERM STORAGE…1538
SPECIFICATIONS…1539
INTRODUCTION OF ATTACHMENTS…1540
SPECIFICATION, USE…1540
ATTACHMENT INSTALLATION COMBINATION TABLE…1542
SELECTION OF TRACK SHOES…1543
SELECTION OF BUCKET TEETH…1545
HANDLING TRAPEZOIDAL BUCKET…1545
HANDLING THE CLAMSHELL BUCKET…1547
EXTENDING MACHINE SERVICE LIFE…1548
HYDRAULIC BREAKER…1548
POWER RIPPER…1551
MAIN FIELDS OF APPLICATIONS…1551
FORK GRAB…1553
GRAPPLE BUCKET…1554
SCRAP GRAPPLE…1555
CRUSHER & SMASHER…1556
HYDRAULIC PILE DRIVER…1558
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE…1559
2-PC BOOM…1561
FEATURES OF 2-PIECE BOOM & ARM…1561
OPERATION…1561
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE…1563
TESTING AND ADJUSTING…1563
PERODIC MAINTENANCE…1564
TRANSPORTATION…1565
UEAM002401 – Hydraulic Excavator PC160LC-7KA Operation & Maintenance Manual…1566
FOREWORD…1568
FOREWORD…1569
SAFETY INFORMATION…1571
INTRODUCTION…1573
DIRECTIONS OF MACHINE…1573
PRODUCT INFORMATION…1574
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…1574
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…1574
SERVICE METER LOCATION…1575
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1575
MACHINE SERIAL PLATE…1576
FOREWORD…1577
SAFETY…1577
OPERATION…1578
MAINTENANCE…1580
SPECIFICATIONS…1582
ATTACHMENTS AND OPTIONS…1582
SAFETY…1584
SAFETY INFORMATION…1585
SAFETY LABELS…1587
LOCATION OF SAFETY LABELS…1587
SAFETY LABELS…1588
SAFETY INFORMATION…1593
SAFETY MACHINE OPERATION…1601
STARTING ENGINE…1601
OPERATION…1602
TRANSPORTATION…1608
BATTERY…1609
TOWING…1611
LIFTING OBJECTS WITH BUCKET…1612
SAFETY MAINTENANCE INFORMATION…1613
OPERATION…1620
MACHINE VIEW ILLUSTRATIONS…1621
OVERALL MACHINE VIEW…1621
CONTROLS AND GAUGES…1622
DETAILED CONTROLS AND GAUGES…1623
MONITORING SYSTEM…1623
Basic Operation Of Machine Monitor…1624
Basic Check Monitors…1626
Caution Monitors…1628
Emergency Monitors…1630
Meter Display Portion…1632
Monitor Switches Portion…1636
SWITCHES…1646
CONTROL LEVERS AND PEDALS…1650
SUN ROOF…1653
WINDSHIELD…1653
EMERGENCY EXIT FROM OPERATOR'S CAB…1658
DOOR LOCK…1658
CAP WITH LOCK…1659
HOT AND COOL BOX…1660
MAGAZINE BOX…1660
ASHTRAY…1660
AIR CONDITIONER CONTROLS…1661
Air Conditioner Control Panel…1661
Method Of Operation…1666
Use Air Conditioner With Care…1671
Air Conditioner Maintenance…1671
Other Functions…1672
RADIO…1674
Control Panel…1674
Controls Of Radio…1677
Use Radio With Care…1678
AUXILIARY ELECTRIC POWER…1679
12 V power source…1679
FUSE…1679
FUSIBLELINK…1680
CONTROLLERS…1681
TOOL BOX…1681
GREASE GUN HOLDER…1681
ACCUMULATOR…1682
Releasing Hydraulic Pressure With Accumulator…1682
MACHINE OPERATIONS AND CONTROLS…1683
BEFORE STARTING ENGINE…1683
Walk-Around Checks…1683
Checks Before Starting…1684
Adjustment…1690
Seat Belt…1692
Operations Before Starting Engine…1693
STARTING ENGINE…1696
Normal Starting…1696
Starting Engine In Cold Weather…1697
AFTER STARTING ENGINE…1700
Breaking-In The New Machine…1700
Warming-Up Operation…1700
In Cold Weather Areas…1703
STOPPING THE ENGINE…1707
CHECK AFTER SHUT OFF ENGINE…1707
MACHINE OPERATION…1708
Preparations For Moving The Machine Off…1708
Moving Machine Forward…1709
Moving Machine Backward…1710
Stopping Machine…1711
STEERING THE MACHINE…1712
Steering…1712
SWINGING…1714
WORK EQUIPMENT CONTROLS AND OPERATIONS…1715
WORKING MODE…1716
PROHIBITED OPERATIONS…1717
GENERAL OPERATION INFORMATION…1719
TRAVELING ON SLOPES…1720
ESCAPE FROM MUD…1722
Stuck One Side Of Track…1722
Stuck Both Sides Of Tracks…1722
RECOMMENDED APPLICATIONS…1723
Backhoe Work…1723
Shovel Work…1723
Ditching Work…1723
Loading Work…1724
BUCKET REPLACEMENT AND INVERSION…1724
Replacement…1724
Inversion…1725
PARKING MACHINE…1726
MACHINE INSPECTION AFTER DAILY WORK…1728
LOCKING…1728
TRANSPORTATION…1729
TRANSPORTATION PROCEDURE…1729
LOADING AND UNLOADING WITH TRAILER…1729
Loading…1730
Securing Machine…1732
Unloading…1733
LIFTING MACHINE…1736
COLD WEATHER OPERATION…1737
COLD WEATHER OPERATION INFORMATION…1737
Fuel And Lubricants…1737
Cooling System Coolant…1737
Battery…1738
AFTER DAILY WORK COMPLETION…1739
AFTER COLD WEATHER SEASON…1739
LONG TERM STORAGE…1740
BEFORE STORAGE…1740
DURING STORAGE…1740
AFTER STORAGE…1740
STARTING MACHINE AFTER LONG-TERM STORAGE…1740
TROUBLES AND ACTIONS…1741
RUNNING OUT OF FUEL…1741
PHENOMENA THAT ARE NOT FAILURES…1741
TOWING THE MACHINE…1742
LIGHTWEIGHT TOWING HOLE…1742
SEVERE JOB CONDITION…1742
DISCHARGED BATTERY…1743
Battery Removal And Installation…1743
Battery Charges…1744
Starting Engine With Booster Cables…1744
OTHER TROUBLE…1746
Electrical System…1746
Chassis…1747
Engine…1748
Electronic Control System…1750
Point Of Contact To Telephone When Error Occurs…1751
MAINTENANCE…1752
MAINTENANCE INFORMATION…1753
LUBRICANTS, COOLANT AND FILTERS…1755
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1755
Oil…1755
Fuel…1755
Cooling System Coolant…1755
Grease…1756
Carrying out KOWA (Komatsu Oil Wear Analysis)…1756
Oil And Fuel Storage…1757
Filters…1757
ELECTRIC SYSTEM MAINTENANCE…1757
WEAR PARTS…1758
WEAR PARTS LIST…1758
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…1759
PROPER SELECTION…1759
TIGHTENING TORQUE SPECIFICATIONS…1763
TIGHTENING TORQUE LIST…1763
SAFETY CRITICAL PARTS…1765
SAFETY CRITICAL PARTS LIST…1766
MAINTENANCE SCHEDULE…1767
MAINTENANCE SCHEDULE CHART…1767
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…1768
USE OF BIO-DEGRADEABLE OIL…1768
Filter changes…1768
Oil changes…1768
.MAINTENANCE PROCEDURE…1769
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…1769
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…1769
WHEN REQUIRED…1770
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1770
CLEAN INSIDE OF COOLING SYSTEM…1774
CHECK AND TIGHTEN TRACK SHOE BOLTS…1776
CHECK AND ADJUST TRACK TENSION…1776
CHECK ELECTRICAL INTAKE AIR HEATER…1778
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…1778
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…1780
ADJUST BUCKET CLEARANCE…1781
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1782
CHECK AND ADJUST AIR CONDITIONER…1783
WASH WASHABLE FLOOR…1784
BLEEDING AIR FROM HYDRAULIC SYSTEM…1787
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…1789
CHECK BEFORE STARTING…1790
EVERY 250 HOURS MAINTENANCE…1791
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…1791
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1791
CHECK LEVEL OF BATTERY ELECTROLYTE…1792
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…1793
EVERY 500 HOURS MAINTENANCE…1795
LUBRICATING…1795
LUBRICATE SWING CIRCLE…1796
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…1797
REPLACE FUEL FILTER CARTRIDGE…1798
CHECK SWING PINION GREASE LEVEL, ADD GREASE…1799
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS…1799
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER…1800
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…1801
EVERY 1000 HOURS MAINTENANCE…1802
REPLACE HYDRAULIC OIL FILTER ELEMENT…1802
CHANGE OIL IN SWING MACHINERY CASE…1803
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…1804
CHECK FAN BELT TENSION AND REPLACE FAN BELT…1804
EVERY 2000 HOURS MAINTENANCE…1805
CHANGE OIL IN FINAL DRIVE CASE…1805
CLEAN HYDRAULIC TANK STRAINER…1805
CHECK ALTERNATOR, STARTING MOTOR…1806
CHECK ENGINE VALVE CLEARANCE, ADJUST…1806
EVERY 4000 HOURS MAINTENANCE…1806
CHECK WATER PUMP…1806
EVERY 5000 HOURS MAINTENANCE…1807
CHANGE OIL IN HYDRAULIC TANK…1807
SPECIFICATIONS…1808
SPECIFICATIONS…1809
ATTACHMENTS AND OPTIONS…1812
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…1813
SAFETY FIRST…1813
ATTACHMENT INSTALLATION…1814
BUCKET WITH HOOK…1815
HOOK CONDITION…1815
PROHIBITED OPERATIONS…1815
MACHINE READY FOR ATTACHMENT (DELUXE HCU SYSTEM)…1816
LOCATIONS…1816
HYDRAULIC CIRCUIT…1819
Switching Hydraulic Circuit…1819
Adjusting Oil Flow…1819
Switching Between Breaker and General Attachment…1819
Hydraulic Circuit Connection…1820
Oil Flow Path…1820
Replace Additional Breaker Filter Element…1821
MACHINE READY FOR ATTACHMENTS (SIMPLE HCU SYSTEM)…1822
EXPLANATION OF COMPONENTS…1822
(1) STOP VALVE…1822
(2) SELECTOR VALVE…1823
(3) ATTACHMENT CONTROL PEDAL…1823
(4) LOCK PIN…1823
HYDRAULIC CIRCUIT…1823
SWITCHING HYDRAULIC CIRCUIT…1824
ADJUSTING OIL FLOW…1824
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT…1825
HYDRAULIC CIRCUIT CONNECTION…1826
PATH OF OIL…1826
ATTACHMENT REMOVAL AND INSTALLATION…1827
Attachment Removal…1827
Attachment Installation…1828
ATTACHMENT OPERATIONS…1829
When Using Breaker…1829
When Using General Attachment Such As Crusher…1830
LONG TERM STORAGE…1830
SPECIFICATIONS…1830
ATTACHMENT GUIDE…1831
OTHER ATTACHMENTS…1831
ATTACHMENT COMBINATIONS…1833
TRACK SHOES SELECTION…1834
BUCKET TEETH SELECTION…1835
Teeth Selection…1835
Selection Guide For Horizontal Or Vertical Pin Type Tooth…1835
RECOMMENDED ATTACHMENT OPERATIONS…1836
HYDRAULIC BREAKER…1836
<A>…1840
<B>…1840
<C>…1840
<D>…1840
<E>…1840
<F>…1840
<G>…1840
<H>…1840
<I>…1840
<L>…1840
<M>…1840
<O>…1841
<P>…1841
<R>…1841
<S>…1841
<T>…1841
<W>…1841
<Y>…1841
UEBD000601 – Hydraulic Excavator PC160-6K, PC180LC, 180NLC-6K Shop Manual…1842
COVER…1842
CONTENTS…1842
SAFETY…1842
SAFETY NOTICE…1847
FOREWARD…1849
GENERAL…1849
HOW TO READ THE SHOP MANUAL…1850
HOISTING INSTRUCTIONS…1851
COATING MATERIALS…1852
STANDARD TIGHTENING TORQUE…1853
ELECTRIC WIRE CODE…1855
CONVERSION TABLE…1856
01 GENERAL…1863
SPECIFICATIONS…1864
SPECIFICATION DRAWINGS…1866
WEIGHT TABLE…1870
FUEL, COOLANT AND LUBRICANTS…1874
10 STRUCTURE AND FUNCTION…1876
ENGINE RELATED PARTS…1877
RADIATOR * OIL COOLER…1878
POWER TRAIN…1879
FINAL DRIVE…1880
SWING CIRCLE…1881
SWING MACHINERY…1882
TRACK FRAME, RECOIL SPRING…1884
TRACK SHOE…1885
HYDRAULIC CIRCUIT DIAGRAM…1888
FUEL & HYDRAULIC TANK…1889
HYDRAULIC PUMP…1892
CONTROL VALVE…1899
CLSS…1905
SWING MOTOR…1942
CENTER SWIVEL JOINT…1944
TRAVEL MOTOR…1945
VALVE CONTROL…1953
WORK EQUIPMENT – SWING PPC VALVE…1954
TRAVEL PPC PEDAL…1958
SAFETY LOCK VALVE…1965
PPC ACCUMULATOR…1965
PPC SHUTTLE * TRAVEL JUNCTION VALVE…1966
EPC * SOLENOID VALVE…1973
HYDRAULIC CYLINDER…1978
ADDITIONAL FILTER FOR BREAKING…1980
OVERLOAD WARNING DEVICE…1981
HOSE BURST PROTECTION VALVE (BOOM)…1985
WORK EQUIPMENT…1988
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE…1991
ENGINE CONTROL SYSTEM…1992
ELECTRONIC CONTROL SYSTEM…1998
MACHINE MONITOR SYSTEM…2022
20 TESTING AND ADJUSTING…2034
TABLE OF JUDGEMENT STANDARD VALUE…2035
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…2045
CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…2053
ADJUSTING ENGINE SPEED SENSOR…2054
TESTING AND ADJUSTING GOVERNOR MOTOR LEVEL STROKE…2055
TESTING CLEARANCE OF SWING CIRCLE BEARING…2057
TESTING AND ADJUSTING TRACK SHOE TENSION…2058
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…2059
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)…2067
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…2069
TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE…2072
TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE…2074
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE…2076
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…2078
TESTING TRAVEL DEVIATION…2079
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…2080
MEASURING OIL LEAKAGE…2082
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…2084
BLEEDING AIR…2085
TROUBLESHOOTING…2088
POINTS TO REMEMBER WHEN TROUBLSHOOTING…2089
SEQUENCE OF EVENTS IN TROUBLSHOOTING…2090
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…2091
CHECKS BEFORE TROUBLESHOOTING…2098
CONNECTOR TYPES AND MOUNTING LOCATIONS…2099
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2104
EXPLANATION OF CONTROL MACHANISM FOR ELECTRICAL SYSTEM…2117
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL…2118
METHOD OF USING JUDGEMENT TABLE…2126
METHOD OF USING TROUBLESHOOTING CHARTS…2128
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…2130
SERVICE CODE TABLE…2135
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)…2136
N-1 [E218] COMMUNICATION ABNORMALITY…2137
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)…2139
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM…2140
ACTION BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2141
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS…2145
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE…2147
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)…2149
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…2150
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED…2151
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED…2152
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…2153
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…2154
E-7 [E316] ABNORMALITY (STEP OUT) IN MOTOR IS DISPLAYED…2155
E-8 ENGINE DOES NOT START…2157
E-9 ENGINE SPEED IS IRREGULAR…2159
a) IDLING SPEED IS IRREGULAR…2159
b) THERE IS HUNTING…2161
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)…2163
E-11 ENGINE DOES NOT STOP…2165
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)…2167
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…2170
METHOD OF USING TROUBLESHOOTING CHARTS…2171
S-1 STARTING PERFORMARMANCE IS POOR (STARTING ALWAYS TAKES TIME)…2175
S-2 ENGINE DOES NOT START…2176
1) ENGINE DOES NOT TURN…2176
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEEN INJECTED)…2177
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FEUL IS BEING INJECTED)…2178
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)…2179
S-4 ENGINE STOPS DURING OPERATIONS…2180
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…2181
S-6 ENGINE LACKS OUTPUT (NO POWER)…2182
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…2183
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…2184
S-9 OIL BECOMES CONTAMINATED QUICKLY…2185
S-10 FUEL CONSUMPTION IS EXCESSIVE…2186
S-11 OIL LEVEL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…2187
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…2188
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…2189
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…2190
S-15 ABNORMAL NOISE IS MADE…2191
S-16 VIBRATION IS EXCESSIVE…2192
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)…2193
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…2194
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2195
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS…2201
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE …2203
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)…2205
C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED…2206
C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED…2208
C-6 [E201] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED…2210
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…2212
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…2214
C-10 [E205] SHORT CIRCUIT IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…2216
C-11 [E215] DISCONNECTION IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…2217
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED…2218
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED…2219
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED…2220
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…2222
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS…2223
C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…2224
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED…2225
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…2226
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)…2228
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE…2229
F-1 BIT PATTERN 20- (1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP…2231
F-2 BIT PATTERN 20- (2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…2232
F-3 BIT PATTERN 20- (3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP…2233
F-4 BIT PATTERN 20- (4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP…2234
F-5 BIT PATTERN 20- (5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP…2235
F-6 BIT PATTERN 20- (6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP…2236
F-7 BIT PATTERN 21- (1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP…2237
F-8 BIT PATTERN 21- (2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP…2238
F-9 BIT PATTERN 21- (3) SWING LOCK SWITCH DOES NOT LIGHT UP…2239
F-10 BIT PATTERN 22- (5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP…2240
F-11 BIT PATTERN 22- (6) L.H. KNOB SWITCH DOES NOT LIGHT UP…2241
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…2242
TABLE OF FAILURE MODES AND CAUSES…2243
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…2247
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…2249
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…2250
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…2250
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)…2251
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…2251
H-7 BOOM IS SLOW OR LACKS POWER…2253
H-8 ARM IS SLOW OR LACKS POWER…2255
H-9 BUCKET IS SLOW OR LACKS POWER…2257
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…2258
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…2258
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…2259
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…2259
H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED…2260
H-15 LACK OF POWER WHEN PRESSURE RISES…2260
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…2260
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…2261
H-20 TRAVEL DEVIATION…2262
H-21 TRAVEL SPEED IS SLOW…2263
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER…2265
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…2267
H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…2267
H-25 DOES NOT SWING…2268
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW…2269
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING…2271
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…2272
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…2272
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING…2273
H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED…2274
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…2276
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2277
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE…2279
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED; [E102] ERROR IN CLOCK DATA IS DISPLAYED…2281
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED…2282
M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED…2283
M-4 [E106] DROP IN ENGINE OIL PRESSURE DETECTED IS DISPLAYED…2283
M-5 [E108] ENGINE WATER TEMPERATURE 105 c DETECTED IS DISPLAYED…2284
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL LIGHT UP FOR 3 SECONDS…2285
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT…2287
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)…2287
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES…2288
M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP…2290
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH…2291
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)…2293
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)…2295
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND…2298
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS…2298
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…2299
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE…2300
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)…2300
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…2301
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…2301
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP…2302
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH…2302
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING…2303
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED…2303
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM…2304
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM…2305
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM…2306
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…2307
M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…2308
30 DISASSEMBLY AND ASSEMBLY…2314
METHOD OF USING MANUAL…2316
PRECAUTIONS WHEN CARRYING OUT OPERATION…2318
SPECIAL TOOL LIST…2320
GOVERNOR MOTOR ASSEMBLY…2323
REMOVAL AND INSTALLATION…2323
HYDRAULIC OIL COOLER ASSEMBLY…2324
REMOVAL AND INSTALLATION…2324
RADIATOR * HYDRAULIC OIL COOLER ASSEMBLY…2325
REMOVAL…2325
INSTALLATION…2326
ENGINE * HYDRAULIC PUMP ASSEMBLY…2327
REMOVAL…2327
INSTALLATION…2330
DAMPER ASSEMBLY…2331
REMOVAL AND INSTALLATION…2331
FUEL/HYDRAULIC TANK ASSEMBLY…2332
REMOVAL…2332
INSTALLATION…2333
CENTER SWIVEL JOINT ASSEMBLY…2334
DISASSEMBLY AND ASSEMBLY…2334
TRAVEL MOTOR ASSEMBLY…2335
REMOVAL AND INSTALLATION…2335
FINAL DRIVE ASSEMBLY…2336
REMOVAL AND INSTALLATION…2336
SPROCKET…2338
REMOVAL AND INSTALLATION…2338
SWING MOTOR ASSEMBLY…2339
REMOVAL AND INSTALLATION…2339
SWING MACHINERY ASSEMBLY…2340
REMOVAL AND INSTALLATION…2340
SWING MOTOR…2342
DISASSEMBLY AND ASSEMBLY…2342
REVOLVIING FRAME ASSEMBLY…2349
REMOVAL…2349
INSTALLATION…2350
SWING CIRCLE ASSEMBLY…2351
REMOVAL…2351
INSTALLATION…2352
IDLER * RECOIL SPRING ASSEMBLY…2353
REMOVAL AND INSTALLATION…2353
RECOIL SPRING ASSEMBLY…2354
DISASSEMBLY…2354
ASSEMBLY…2355
IDLER ASSEMBLY…2356
DISASSEMBLY…2356
ASSEMBLY…2357
TRACK ROLLER…2359
REMOVAL AND INSTALLATION…2359
DISASSEMBLY…2360
ASSEMBLY…2361
CARRIER ROLLER ASSEMBLY…2363
REMOVAL AND INSTALLATION…2363
DISASSEMBLY…2364
ASSEMBLY…2365
TRACK SHOE ASSEMBLY…2367
REMOVAL AND INSTALLATION…2367
MAIN PUMP ASSEMBLY…2370
REMOVAL…2370
INSTALLATION…2371
CONTROL VALVE ASSEMBLY…2372
REMOVAL…2372
INSTALLATION …2373
DISASSEMBLY…2374
ASSEMBLY…2376
LS SELECT VALVE ASSEMBLY…2378
DISASSEMBLY AND ASSEMBLY…2378
LS SHUTTLE VALVE…2379
DISASSEMBLY AND ASSEMBLY…2379
PRESSURE COMPENSATION VALVE ASSEMBLY…2380
DISASSEMBLY…2380
ASSEMBLY…2381
MAIN RELIEF VALVE ASSEMBLY…2382
DISASSEMBLY…2382
ASSEMBLY…2383
LS CONTROL EPC VALVE ASSEMBLY…2384
REMOVAL AND INSTALLATION…2384
SOLENOID VALVE ASSEMBLY…2385
REMOVAL AND INSTALLATION…2385
PPC SHUTTLE VALVE ASSEMBLY…2386
REMOVAL…2386
INSTALLATION…2387
DISASSEMBLY…2388
ASSEMBLY…2389
WORK EQUIPMENT SWING PPC VALVE ASSEMBLY…2390
REMOVAL AND INSTALLATION…2390
TRAVEL PPC VALVE ASSEMBLY…2391
REMOVAL AND INSTALLATION…2391
DISASSEMBLY AND ASSEMBLY…2392
BOOM CYLINDER ASSEMBLY…2394
REMOVAL…2394
INSTALLATION…2395
ARM CYLINDER ASSEMBLY…2396
REMOVAL…2396
INSTALLATION…2397
BUCKET CYLINDER ASSEMBLY…2398
REMOVAL…2398
INSTALLATION…2399
HYDRAULIC CYLINDER ASSEMBLY…2400
DISASSEMBLY…2400
ASSEMBLY…2402
WORK EQUIPMENT ASSEMBLY…2405
REMOVAL…2405
INSTALLATION…2406
BUCKET ASSEMBLY…2407
REMOVAL AND INSTALLATION…2407
ARM ASSEMBLY…2407
REMOVAL AND INSTALLATION…2407
ARM, BUCKET ASSEMBLY…2409
REMOVAL AND INSTALLATION…2409
BOOM ASSEMBLY…2411
REMOVAL…2411
INSTALLATION …2412
OPERATOR'S CAB ASSEMBLY…2413
REMOVAL…2413
INSTALLATION…2415
COUNTERWEIGHT ASSEMBLY…2416
REMOVAL AND INSTALLATION…2416
GOVERNOR, PUMP CONTROLLER ASSEMBLY…2417
REMOVAL AND INSTALLATION…2417
MONITOR PANEL ASSEMBLY…2418
REMOVAL AND INSTALLATION…2418
FINAL DRIVE ASSEMBLY…2424
DISASSEMBLY…2424
ASSEMBLY…2435
(SPECIAL TOOLS)…2447
SWING MACHINERY ASSEMBLY…2454
DISASSEMBLY…2454
ASSEMBLY…2470
(SPECIAL TOOLS)…2490
40 MAINTENANCE STANDARD…2494
ENGINE MOUNT…2495
SWING MACHINERY…2496
SWING CIRCLE…2498
FINAL DRIVE…2499
TRACK FRAME, RECOIL SPRING…2501
IDLER…2502
CARRIER ROLLER…2504
TRACK ROLLER…2505
TRACK SHOE…2506
CONTROL VALVE…2508
SUCTION-SAFETY VALVE…2516
SWING MOTOR…2517
WORK EQUIPMENT, SWING PPC VALVE…2518
TRAVEL PPC VALVE…2519
SERVICE PPC VALVE…2520
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE…2521
EPC SOLENOID VALVE…2522
CENTER SWIVEL JOINT…2523
ARM, BOOM SAFETY VALVE…2524
HYDRAULIC CYLINDER…2525
WORK EQUIPMENT…2526

Komatsu Hydraulic Excavator PC160K, PC180LC-K, PC180NLC-K Repair Service Manuals

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