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
File Format: PDF
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 "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" 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 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….553
E-23 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….554
E-24 "ARM IN" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….555
E-25 "ARM OUT" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….556
E-26 "BUCKET CURL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….557
E-27 "BUCKET DUMP" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….558
E-28 "SWING" IS NOT CORRECTLY DISPLAYED IS MONITOR FUNCTION….559
E-29 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION ….561
E-30 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION….563
E-31 "SERVICE" 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'S CAB ….738
REMOVAL….738
INSTALLATION ….740
OPERATOR'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 & 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'S COMPARTMENT CLEAN….2826
LEAVING OPERATOR'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'S SIGNAL AND SIGNS….2832
EMERGENCY EXIT FROM OPERATOR'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'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 & 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'S COMPARTMENT CLEAN….3123
LEAVING OPERATOR'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'S SIGNAL AND SIGNS….3130
EMERGENCY EXIT FROM OPERATOR'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'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 & Maintenance Manual….3398
TEN00308-03 – Hydraulic Excavator PC160LC-8 Operation & 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'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 & 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'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
