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