Komatsu Pc160lc 7

SEBM028606
MACHINE MODEL SERIAL NUMBER
PC160LC-7 10001 and up
• This shop manual may contain attachiments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
• PC160LC-7 mount the SAA4D102E-2 engine.

• For details of the engine, see the 102 Series Engine Shop Manual.
© 2007
All Rights Reserved 00-1
Printed in Japan 09-07 (02) (6)
CONTENTS
No. of page
01 GENERAL .................................................................................................................01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD......................................................................10-1
20 TESTING AND ADJUSTING .......................................................................20-1
30 DISASSEMBLY AND ASSEMBLY ..........................................................30-1
90 OTHERS ....................................................................................................................90-1
00-2 PC160LC-7
(2)
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
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00-2-4 PC160LC-7
(5)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
k Slinging with one rope may cause turning

wound onto the load.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
! The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
! The adapter can be pushed in about 3.5
mm.
! Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
! Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
! Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
! When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
! The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
! For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
! In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

! In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

! In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

! Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

! Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
! Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
! Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
Specification dimension drawings ....................... 01-2

Specifications ...................................................... 01-4
Weight table ........................................................ 01-6
Fuel, coolant, and lubricants ............................... 01-8
PC160LC-7 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
SPECIFICATION DIMENSION DRAWINGS

DIMENSIONS
WORKING RANGES
01-2 PC160LC-7
GENERAL SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
Item Unit PC160LC-7
A Overall length mm 8,525
B Overall height mm 3,000
C Overall width mm 2,590
D Track shoe width mm 600
E Height of cab mm 2,970
F Tail swing radius mm 2,435
G Track overall length mm 3,965
H Length of track on ground mm 3,170
Min. ground clearance mm 440
WORKING RANGES
Item Unit PC160LC-7
A Max. digging reach mm 8,960
B Max. digging depth mm 5,960
C Max. digging height mm 8,980
D Max. vertical wall depth mm 5,040
E Max. dumping height mm 6,370
F Min. dumping height mm 2,400
G Max. reach at ground level mm 8,800
PC160LC-7 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model PC160LC-7
Serial Number 10001 and up
Bucket capacity m3 0.6
Operating weight kg 16,620
Max. digging depth mm 5,960
Max. vertical wall depth mm 5,040

Working ranges
Max. digging reach mm 8,960
Max. reach at ground level mm 8,800
Max. digging height mm 8,980

Performance
Max. dumping height mm 6,370
Max. digging force 112.8 {11,500}

kN {kg}
(using power max. function) (122.6 {12,500})
Swing speed rpm 12
Swing max. slope angle deg. 20
Travel speed km/h Lo: 3.4 Hi: 5.5
Gradeability deg. 35
Ground pressure kPa {kg/cm2} 46.1 {0.47}

(standard shoe width) (mm) (600)
Overall length (for transport) mm 8,565
Overall width mm 2,490
Overall width of track mm 2,590
Overall height (for transport) mm 3,025
Overall height to chassis mm 2,970
Ground clearance to bottom of upper structure mm 1,034

Dimensions
Min. ground clearance mm 440
Tail swing radius mm 2,435
Min. swing radius of work equipment mm 2,990
Height of work equipment at min. swing radius mm 7,185
Length of track on ground mm 3,170
Track gauge mm 1,990
Height of machine cab mm 2,305
Model SAA4D102E-2
4-cycle, water-cooled, in-line, vertical, direct

Engine
Type
injection, with turbocharger and aftercooler
No. of cylinders - bore x stroke mm 4 – 102 x 120
Piston displacement {cc} 3.92 {3,920}
01-4 PC160LC-7
GENERAL SPECIFICATIONS

kW/rpm 83/2,200
Flywheel horsepower
{HP/rpm} {110/2,200}
Nm/rpm 451/1,500
Performance
Max. torque
{kgm/rpm} {46/1,500}
Max. speed at no load rpm 2,450
Min. speed at no load rpm 1,050

Engine
Min. fuel consumption g/kWh {g/HPh} 226 {168}
Starting motor 24V, 4.5 kW
Alternator 24V, 35 A
Battery 12V, 80 Ah x 2
Radiator core type Corrugated aluminum
Carrier roller 2 on each side

Under-carriage
Track roller 7 on each side
Track shoe Assembly-type triple grouser, 44 on each side
Type x No. HPD71, variable capacity piston type

Hydraulic
pump
Delivery {cc} Piston type: 156 x 2
Set pressure MPa (kg/cm2) 31.4 {320}

Control
Type x No. 6-spool type x 1

valve
Control method Hydraulic type
Travel motor HMV110ADT-2, Variable capacity piston type

Hydraulic
(with brake valve, parking brake x 2)

motor
Swing motor MSG-85P-17TR fixed capacity, Piston type

(with safety valve, holding brake x 2)
Hydraulic system
Type Boom ( 1) Arm ( 1, 2) Bucket
Double acting Double acting Double acting

piston piston piston
Hydraulic culinder
Inside diameter of cylinder mm 110 120 105
Diameter of piston rod mm 75 85 70
Stroke mm 1,175 1,342 1,027
Max. distance between pins mm 2,810 3,246 2,528
Min. distance between pins mm 1,635 1,904 1,501
Hrdraulic tank Closed box type
Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
1. With cushion on head side 2. With cushion on bottom side
PC160LC-7 01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is for use when handling components or when transporting the machine.
Unit: kg
Engine assembly 572
• Engine 445
• Damper 6
• Hydraulic pump 121
Radiator, oil cooler assembly 112
Hydraulic tank, filter assembly (excluding hydraulic oil) 116
Fuel tank (excluding fuel) 117
Revolving frame 1,490
Operator's cab 278
Operator's seat 35
Counterweight 2,850
Swing machinery (including swing motor) 176
Main control valve 125
Travel motor 98 x 2
Center swivel joint 36
Track frame assembly 3,868
• Track frame 1,934
• Swing circle 222
• Idler 99 x 2
• Idler cushion 130 x 2
• Carrier roller 16 x 4
• Track roller 36 x 14
• Final drive (including travel motor) 343 x 2
01-6 PC160LC-7
GENERAL WEIGHT TABLE
Unit: kg
Track shoe assembly
• Standard triple grouser shoe (600 mm) 1,190 x 2
• Standard triple grouser shoe (700 mm) 1,300 x 2
• Wide triple grouser shoe (800 mm) 1,410 x 2
Boom assembly 1,085
Arm assembly 508
Bucket assembly 500
Boom cylinder assembly 138
Arm cylinder assembly 178
Bucket cylinder assembly 93
Front link assembly 25 x 2
List link assembly 15 x 2
Boom pin 29 + 6 x 2 + 21 + 10 + 19
Arm pin 11 + 7
Bucket pin 15 x 2
Link pin 15 x 2
PC160LC-7 01-7
GENERAL FUEL, COOLANT, AND LUBRICANTS
FUEL, COOLANT, AND LUBRICANTS
KIND AMBIENT TEMPERATURE CAPACITY ( )

RESERVOIR OF
-22 -4 14 32 50 68 86 104°F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 14.3 14.0
SAE 10W-30
SAE 15W-40
Damper case 0.75 —
Swing machinery case 4.5 4.5

Engine
Final drive case (each)
oil
4.7 4.5
SAE 30
Idler (1 each) 0.07 – 0.08 0.07 – 0.08
Track roller (1 each) 0.19 – 0.20 0.19 – 0.20
Carrier roller (1 each) 0.075 – 0.085 0.075 – 0.085
SAE 10W
SAE 10W-30
Hydraulic system 190 121
SAE 15W-40
Hydrau-
lic oil HO46-HM (★)
Diesel ASTM D975 No. 2

Fuel tank
fuel
280 —
ASTM D975 No. 1
Cooling system Coolant Add antifreeze 18.6 18.6
★ For the HO46-HM, use the oil recommended by Komatsu.
01-8 PC160LC-7
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Engine related parts..............................................10- 2

Radiator • oil cooler • aftercooler ..........................10- 3
Power train............................................................10- 4
Swing machinery ..................................................10- 5
Swing circle...........................................................10- 6
Final drive .............................................................10- 8
Track frame • recoil spring ....................................10-10
Idler.......................................................................10-12
Carrier roller..........................................................10-14
Track roller ............................................................10-15
Track shoe ............................................................10-16
Hydraulic equipment layout drawing.....................10-20
Valve control .........................................................10-22
Hydraulic tank .......................................................10-23
Hydraulic pump.....................................................10-24
PC-EPC valve.......................................................10-42
Control valve.........................................................10-48
CLSS ....................................................................10-62
Travel junction valve .............................................10-93
Self-reducing pressure valve ................................10-94
Center swivel joint.................................................10-95
Swing motor..........................................................10-96
Travel motor..........................................................10-97
Work equipment • swing PPC valve ...................10-106
Travel PPC valve ................................................ 10-110
Service PPC valve .............................................. 10-119
Solenoid valve ....................................................10-122
Accumulator........................................................10-124
Return oil filter.....................................................10-125
Attachment circuit selector valve ........................10-126
Hydraulic cylinder ...............................................10-128
Work equipment..................................................10-130
Air conditioner.....................................................10-136
Engine control.....................................................10-137
Electronic control system....................................10-145
Multi monitor system...........................................10-170
7-Segment monitor system.................................10-191
Sensor ................................................................10-198
PC160LC-7 10-1
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE RELATED PARTS
ENGINE RELATED PARTS
1. Drive plate 5. Damper assembly OUTLINE

2. Torsion spring 6. Muffler • The damper assembly is a wet type.
3. Stopper pin 7. Rear engine mount Oil capacity: 0.75
4. Friction plate 8. Front engine mount
10-2 PC160LC-7
RADIATOR • OIL COOLER •
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AFTERCOOLER
RADIATOR • OIL COOLER • AFTERCOOLER
1. Radiator cap SPECIFICATIONS

2. Radiator inlet hose Radiator : Corrugated aluminum
3. Radiator Oil cooler : CF40-1
4. Aftercooler Aftercooler : Corrugated aluminum
5. Oil cooler
6. Net
7. Fan
8. Radiator outlet hose
9. Shroud
10. Reservoir tank
PC160LC-7 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Idler 7. Engine
2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing motor (MSG-85P-17TR)
5. Travel motor (HMV 110ADT-2) 11. Swing machinery
6. Hydraulic pump (HPD71) 12. Swing circle
10-4 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
SWING MACHINERY
1. Swing motor assembly 8. Collar

2. Oil level gauge 9. Swing pinion
3. No. 1 sun gear 10. Cover
4. No. 1 planetary gear 11. Case
5. No. 2 sun gear 12. No. 1 planetary carrier
6. No. 2 planetary gear 13. Ring gear
7. No. 2 planetary carrier
PC160LC-7 10-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 99) SPECIFICATIONS

2. Ball
Reduction ratio:  13  = 7.615
99
3. Swing circle outer race
a. Inner race soft zone S position Amount of grease: 10.5 (G2-LI)

b. Outer race soft zone S position
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

Axial clearance of bearing
4 Replace
(when mounted on chassis)
0.5 – 1.6 3.2
10-6 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
10-8 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
1. Level plug
2. Drain plug
3. No. 2 sun gear (No. of teeth: 21)
4. No. 1 sun gear (No. of teeth: 10)
6. Cover
8. Sprocket
9. Floating seal
10. Travel motor
11. Hub
12. No. 2 planetary gear (No. of teeth: 36)
13. Ring gear (No. of teeth: 95)
14. No. 1 planetary gear (No. of teeth: 42)
SPECIFICATIONS
Reduction ratio:
– 10+95  x 21+95 + 1 = – 57.00

 10   21 
Unit: mm

Backlash between No. 1 sun
15
gear and No. 1 planetary gear 0.14 – 0.46 1.00
Backlash between No. 2 plan-

16 0.17 – 0.57 1.10
etary gear and ring gear
Backlash between No. 1 plane-

17 0.38 – 0.66 —
tary carrier and No. 2 sun gear Replace
Backlash between No. 2 sun
18 0.15 – 0.49 1.00
gear and No. 2 planetary gear

19 0.17 – 0.57 1.10
etary gear and ring gear

20 0.06 – 0.25 1.00
etary carrier and mototr
Amount of wear on sprocket

21 Repair limit: 6
tooth
Rebuild or
Standard size Repair limit
replace
22 Width of sprocket tooth
71 68
PC160LC-7 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
TRACK FRAME • RECOIL SPRING
1. Idler • Number of track rollers

2. Track frame Q’ty
Model
3. Carrier roller (each side)
4. Final drive
PC160LC-7 7
5. Track roller
6. Track shoe
7. Center guard
8. Recoil spring
9. Front guard
10-10 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
Standard shoe
Model PC160LC-7
Item
Shoe width 600 mm
Link pitch 190 mm
No. on track (one side) 44 (pieces)
Unit: mm

Standard size Tolerance Repair limit
10 Vertical width of idler guide Track frame 107

Rebuild or
Idler support 105 replace
Track frame 250

11 Horizontal width of idler guide
Idler support 247.4
Free length Installation Installation Free length Installation

12 Recoil spring x O.D. length load load Replace
109.0 kN
558.5 X 237 437 — —
{11,110 kg}
PC160LC-7 10-11
(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
10-12 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
Unit: mm

1 Outside diameter of protruding
538 —
2 Outside diameter of tread 500 488

Rebuild or
3 Thickness of tread 26 20 replace
4 Total width 159 —
5 Width of tread 37.5 43.5
Tolerance Standard Clearance

Standard size
Clearance between shaft and Shaft Hole clearance limit
6
bushing
– 0.250 + 0.074
65 0.214 – 0.424 1.5
– 0.350 – 0.036
Replace
Tolerance bushing
Standard Interference
Standard size
Interference between idler and Shaft Hole interference limit
7
bushing
+ 0.089 – 0.006
72 0.065 – 0.161 —
+ 0.059 – 0.072
PC160LC-7 10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
145 —
3 Width of tread 43 —
4 Thickness of tread 36.5 29.5
5 Width of flange 14 —
Tolerance Replace
Standard Clearance
Standard size
6
bushing
– 0.179 + 0.284
40 0.339 – 0.474 —
– 0.190 + 0.169
Tolerance Standard Interference

Standard size
Interference between roller and Shaft Hole interference limit
7
bushing
– 0.061 0
47 0.036 – 0.101 —
– 0.036 – 0.040

8 Axial clearance of roller
0.44 – 0.76 —
10-14 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
188 —
3 Thickness of tread 44.5 38.5

Rebuild or
4 Overall width 225 — replace
5 Inside width 85 —
6 Width of tread 44.5 —
7 Width of flange 25.5 —
Tolerance Standard Clearance

Standard size
8
bushing
– 0.215 + 0.195
60 0.215 – 0.510 1.5
– 0.315 0
Replace
Tolerance bushing
Standard Interference
Standard size
Interference between roller and Shaft Hole interference limit
9
bushing
+ 0.153 + 0.030
67 0.023 – 0.153 —
+ 0.053 0
PC160LC-7 10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
★ P portion shows the link of bushing press fitting end.
10-16 PC160LC-7
Unit: mm

1 Link pitch
190.25 193.25
Reverse or
When turned replace
Standard size
2 Bushing outside diameter Normal load Impact load
59.3 — 54.3

3 Link height
105 97 Repair or
replace
Thickness of link metal
4 28.5 20.5
(bushing press-fitting portion)
5 160.4
6 Shoe bolt pitch 62
7 18
8 Inside width 84.8
9 Link Overall width 45.4
10 Tread width 39.6
Regular 2.5
Adjust or
11 Protrusion of pin
replace
Master 2.5
Regular 4.85
12 Protrusion of bushing
Master 0.0
Regular 212
13 Overall length of pin
Master 212
Regular 138.5
Overall length of
14
bushing
Master 128.7
Standard 10.4
Thickness of bushing Reverse or
15
metal When turned / Impact replace
5.4
Load
16 Thickness of spacer —
17 Bushing 88.2 – 245 kN {9 – 25 ton}

—
18 Press-fitting force Regular pin 127.4 – 274.4 kN {13 – 28 ton}
Master pin 78.4 – 147 kN {8 – 15 ton}

19
: Dry type track link
PC160LC-7 10-17
Unit: mm

Tightening torque Additional tightening
(Nm {kgm}) angle (deg.)
Regular link
490 ± 49
120 ± 10
{50 ± 5}
Shoe bolt Retighten
Tightening torque Additional tightening Lower limit torque
20
(Nm {kgm}) angle (deg.) (Nm {kgm})
Master link
— — —
No. of shoes (each side) 44 —
Tolerance Standard
Standard size
Shaft Hole interference
21 Interference between bushing and link
+ 0.434 + 0.074
59 0.320 – 0.434
+ 0.394 0
+ 0.222 + 0.138
22 Interference between regular pin and link 38 0.300 – 0.422
+ 0.162 – 0.200
Tolerance Standard
Standard size
Shaft Hole clearance
23 Clearance between regular pin and bushing
+ 0.222 + 0.902 Adjust or
38 0.180 – 0.740
+ 0.162 + 0.402 replace
Tolerance Standard
Standard size
Shaft Hole interference
Interference between master pin and link
24 + 0.062
+ 0.280
37.8 0.188 – 0.280
+ 0.250 0
Tolerance Standard
Standard size
Shaft Hole clearance
Clearance between master pin and bushing
25
– 0.150 + 0.902
38 0.552 – 1.252
– 0.350 + 0.402
Standard size Repair limit Lug weld-
— Height of grouser ing, rebuild
26 16 or replace
: Dry type track link
10-18 PC160LC-7
TRIPLE GROUSER SHOE
Unit: mm

1 Height
26 16
2 Thickness 8.5
3 26
Length of base
4 19
Rebuild or
replace
5 20
6 Length at tip 14
7 19

8 Thickness
34.5 24.5
PC160LC-7 10-19
HYDRAULIC EQUIPMENT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LAYOUT DRAWING
HYDRAULIC EQUIPMENT LAYOUT DRAWING

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. R.H. travel motor
7. Hydraulic pump
8. Control valve
9. Oil cooler
10. L.H. travel motor
11. Swing motor
12. L.H. PPC valve
13. Safety lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Accumulator
19. Solenoid valve assembly
19A PPC lock solenoid
19B Travel junction solenoid
19C Pump merge/divider solenoid
19D Travel speed solenoid
19E Swing holding brake solenoid
19F 2-stage relief solenoid
10-20 PC160LC-7
HYDRAULIC EQUIPMENT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LAYOUT DRAWING
PC160LC-7 10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
Lever positions
1. Travel PPC valve 8. Accumulator (1) Hold (9) Swing "RIGHT"
2. Service PPC valve 9. Hydraulic pump (2) Boom "RAISE" (10) Swing "LEFT"
3. Service pedal 10. Control valve (3) Boom "LOWER" (11) Neutral
4. L.H. travel lever 11. Solenoid block (4) Bucket "DUMP" (12) Travel "REVERSE"
5. R.H. travel lever 12. Junction box (5) Bucket "CURL" (13) Travel "FORWARD"
6. R.H. PPC valve 13. L.H. work equipment (6) Hold
7. R.H. work equipment control lever (7) Arm "IN"
control lever 14. L.H. PPC valve (8) Arm "OUT"
10-22 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Hydraulic tank SPECIFICATIONS

2. Oil filler cap Tank capacity: 167
3. Sight gauge Amount of oil inside tank: 121
4. Bypass valve Pressure valve
5. Strainer Relief cracking pressure:
6. Filter element 16.7 ± 6.9 kPa
7. Suction strainer {0.17 ± 0.07 kg/cm2}
Suction cracking pressure:
0 - 0.49 kPa
{0 - 0.005 kg/cm2}
Bypass Valve set pressure:
150 ± 30 kPa
{1.5 ± 0.3 kg/cm2}
PC160LC-7 10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
TEPE: HPD71
Outline
• This pump consists of variable capacity swash
plate piston pump, PC valve, LS valve, and EPC
valve.
IM: PC mode selector current PD1: Case drain port 1. Main pump
PB: Pump pressure input PEN: Pump control pressure pickup 2. LS valve
PM: PC mode selector pressure pickup port 3. PC valve
port PLS: Load pressure input 4. PC-EPC valve
PS: Suction port of pump PA1C: P1 pump discharge pressure 5. No. 1 check valve
PA1: Discharge port of pump pickup port 6. No. 2 check valve
PA2: Discharge port of pump PA2C: P2 pump discharge pressure 7. Shuttle valve
pickup port
PEPC: EPC base pressure input
PLSC: Load pressure pickup port
10-24 PC160LC-7
1. Shaft 6. Piston
2. Cradle 7. Cylinder block
3. Case 8. Valve plate
4. Rocker cam 9. End cap
5. Shoe 10. Servo piston
PC160LC-7 10-25
FUNCTION
• The rotation and torque transmitted to the pump • Rocker cam (4) has flat surface A, and shoe (5)
shaft are converted into hydraulic energy, and is always pressed against this surface while slid-
pressurized oil is discharged according to the ing in a circular movement.
load. • Rocker cam (4) brings high pressure oil at cylin-
• It is possible to change the discharge amount by der surface B with cradle (2), which is secured to
changing the swash plate angle. the case, and forms a static pressure bearing
when it slides.
STRUCTURE • Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
• Cylinder block (7) is supported to shaft (1) by a
cylinder block (7).
spline a, and shaft (1) is supported by the front
• The cylinder block seals the pressure oil to valve
and rear bearings.
plate (8) and carries out relative rotation. This
• The tip of piston (6) is a concave ball, and shoe
surface is designed so that the oil pressure bal-
(5) is caulked to it to form one unit. Piston (6) and
ance is maintained at a suitable level. The oil
shoe (5) form a spherical bearing.
inside each cylinder chamber of cylinder block
(7) is sucked in and discharged through valve
plate (8).
10-26 PC160LC-7
OPERATION
1. Operation of pump
• Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface A.
• When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α between
center line X of rocker cam (4) and the axial
direction of cylinder block (7) changes. (Angle α
is called the swash plate angle.)
• Center line X of rocker cam (4) maintains
swash plate angle α in relation to the axial
direction of cylinder block (7), and flat surface A
moves as a cam in relation to shoe (5).
• In this way, piston (6) slides on the inside of cyl-
inder block (7), so a difference between vol-
umes E and F is created inside cylinder block
(7). The suction and discharge is carried out by
this difference F - E.
• In other words, when cylinder block (7) rotates
and the volume of chamber E becomes smaller,
the oil is discharged during that stroke. On the
other hand, the volume of chamber F becomes
larger, and as the volume becomes bigger, the
oil is sucked in.
• If center line X of rocker cam (4) is in line with
the axial direction of cylinder block (7) (swash
plate angle = 0), the difference between vol-
u m e s E a n d F i n s i d e c y l i n d e r b l o c k ( 7)
becomes 0, so the pump does not carry out any
suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
• The number of holes on cylinder block (7) is
even and every second one of them is fitted to
2 grooves of valve plate (8). The quantity of the
oil equivalent to 1/2 of the all pistons is dis-
charged to each of discharge ports PA1 and
PA2.
PC160LC-7 10-27
2. Control of discharge amount

• If the swash plate angle α becomes larger, the
difference between volumes E and F becomes
larger and discharge amount Q increases.
• Swash plate angle α is changed by servo piston
(12).
• Servo piston (12) moves in a reciprocal move-
ment (↔) according to the signal pressure from
the PC and LS valves. This straight line move-
ment is transmitted through rod (13) to rocker
cam (4), and rocker cam (4), which is supported
by the cylindrical surface to cradle (2), slides in
a rotating movement in direction of arrow.
• With servo piston (12), the area receiving the
pressure is different on the left and the right, so
main pump discharge pressure (check valve
output pressure) PP is always brought to the
chamber receiving the pressure at the small
diameter piston end.
• Output pressure PEN of the LS valve is brought
to the chamber receiving the pressure at the
large diameter end. The relationship in the size
of pressure PP at the small diameter piston end
and pressure PEN at the large diameter end,
and the ratio between the area receiving the
pressure of the small diameter piston and the
large diameter piston controls the movement of
servo piston (12).
10-28 PC160LC-7
LS VALVE
1. Plug PA : Pump port

2. Locknut PP : Pump port
3. Sleeve PDP : Drain port
4. Spring PLP : LS control pressure output port
5. Seat PLS : LS pressure input port
6. Spool PPL : PC control pressure input port
7. Piston PSIG : Drain port
8. Sleeve
PC VALVE
1. Servo piston assembly PA : Pump port

2. Plug PA2 : Pump pressure pilot port
3. Pin PDP : Drain port
4. Spool PM : PC mode selector pressure pilot port
5. Retainer PPL : PC control pressure output port
6. Seat PPL2: LS control pressure output port
7. Cover
8. Wiring
PC160LC-7 10-29
FUNCTION
1. LS valve
• The LS valve detects the load and controls the
discharge amount.
• This valve controls main pump discharge
amount Q according to differential pressure
∆PLS (= PP – PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port pres-
sure PLS).
• Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control valve
output.
2. PC valve
• When the pump discharge pressure PP1
(check valve output pressure) and PP2 (shuttle
valve output pressure) are high, the PC valve
controls the pump so that no more oil than the
constant flow (in accordance with the discharge
pressure) flows even if the stroke of the control
valve becomes larger. In this way, it carries out
equal horsepower control so that the horse-
power absorbed by the pump does not exceed
the engine horsepower.
• In other words, If the load during the operation
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount
from the pump; and if the pump discharge pres-
sure drops, it increases the discharge amount
from the pump. The relationship between the
average of the front and rear pump discharge
pressures (average discharge amount of F, R
pumps (PP1 + PP2)/2) and pump discharge
amount Q is shown on the right, with the current
given to the PC-EPC valve solenoid shown as a
parameter. The controller senses the actual
speed of the engine, and if the speed drops
because of an increase in the load, it reduces
the pump discharge amount to allow the speed
to recover. In other words, when the load
increases and the engine speed drops below
the set value, the command current to the PC-
E P C v a l v e s o l e n o i d f r o m t h e c o n t r ol l e r
increases according to the drop in the engine
speed to reduce the pump swash plate angle.
10-30 PC160LC-7
OPERATION
1. LS valve
1) When control valve is at neutral position
• The LS valve is a three-way selector valve, with
pressure PLS (LS pressure) from the inlet port
of the control valve brought to spring chamber
B, and main pump discharge pressure PP
brought to port H of sleeve (8). The size of this
LS pressure PLS + force Z of spring (4) and the
main pump pressure (check valve output pres-
sure) PP determines the position of spool (6).
• Before the engine is started, servo piston (12)
is pushed to the right. (See the diagram on the
right)
• When the engine is started and the control
lever is at the neutral position, LS pressure PLS
is 0 MPa {0 kg/cm2}. (It is interconnected with
the drain circuit through the control valve
spool.)
At this point, spool (6) is pushed to the left,and

port C and port D are connected. Pump pres-
sure PP enters the large diameter end of the
piston from port K and the same pump pres-
sure PP also enters port J at the small diameter
end of the piston, so the swash plate is moved
to the minimum angle by the difference in the
area of the servo piston (12).
PC160LC-7 10-31
2) Operation in increase direction for pump • For this reason, the pressure at the large diam-
discharge amount eter end of servo piston (12) becomes drain
• When the difference between the main pump pressure PT, and pump pressure PP enters port
pressure PP and LS pressure PLS, in other J at the small diameter end, so servo piston
w o r d s , L S d i ff e r e n t i a l p r e s s u r e ∆ P L S , (12) is pushed to the right. Therefore, the
becomes smaller (for example, when the area swash plate moves in the direction to make the
of opening of the control valve becomes larger discharge amount larger.
and pump PP drops), spool (6) is pushed to the
right by the combined force of LS pressure PLS
and the force of spring (4).
• When spool (6) moves, port D and port E are
joined and connected to the PC valve. When
this happens, the PC valve is connected to the
drain port, so circuit D - K becomes drain pres-
sure PT. (The operation of the PC valve is
explained later).
10-32 PC160LC-7
3) Operation in decrease direction for pump

discharge amount
• The following explains the situation if the servo • Main pump pressure PP also enters port J at
piston (12) moves to the left (the discharge the small diameter end of the piston, but
amount becomes smaller). When LS differential because of the difference in area between the
pressure ∆ PLS becomes larger (for example, large diameter end and the small diameter end
when the area of opening of the control valve of servo piston (12), servo piston (12) is pushed
becomes smaller and pump pressure PP rises), to the left.
pump pressure PP pushes spool (6) to the left. • As a result, the swash plate moves in the direc-
• When spool (6) moves, main port pressure PP tion to make angle smaller.
flows from port C and port D and from port K, it
enters the large diameter end of the piston.
PC160LC-7 10-33
4) When servo piston is balanced

• Let us take the area receiving the pressure at • At this point, the relationship between the area
the large diameter end of the piston as A1, the receiving the pressure at both ends of piston
area receiving the pressure at the small diame- (12) is A0 : A1 = 1:2, so the pressure applied to
ter end as A0, and the pressure flowing into the both ends of the piston when it is balanced
large diameter end of the piston as PEN. If the becomes PP : PEN = 2:1.
main pump pressure PP of the LS valve and the • The position where spool (6) is balanced and
combined force of force Z of spring (4) and LS stopped is the standard center, and the force of
pressure PLS are balanced, and the relation- spring (4) is adjusted so that it is determined
ship is A0 x PP = A1 x PEN, servo piston (12) when PP - PLS = 2.2 MPa {22.3 kg/cm2}.
will stop in that position, and the swash plate
will be kept at an intermediate position. (It will
stop at a position where the opening of the
throttle from port D to port E and from port C to
port D of spool (6) is approximately the same.)
10-34 PC160LC-7
2. PC valve
1) When pump controller is normal
a. When the load on the actuator is small and
pump pressures PP1 and PP2 are low
i. Movement of PC-EPC solenoid (1)
• The command current from the pump controller • The size of command current X is determined
flows to PC-EPC solenoid (1). This command by the nature of the operation (lever operation),
current acts on the PC-EPC valve and outputs the selection of the working mode, and the set
the signal pressure. When this signal pressure value and actual value for the engine speed.
is received, the force pushing piston (2) is
changed.
• On the opposite side to the force pushing this
piston (2) is the spring set pressure of springs
(4) and (6) and pump pressure PP1 (check
valve output pressure) and PP2 (shuttle valve
output pressure) pushing spool (3). Piston (2)
stops at a position where the combined force
pushing spool (3) is balanced, and the pressure
(pressure of port C) output from the PC valve
changes according to this position.
PC160LC-7 10-35
ii. Action of spring

• The spring load of springs (4) and (6) in the PC • If the command circuit input to PC-EPC valve
valve is determined by the swash plate position. solenoid (1) changes further, the force pushing
• If piston (9) moves to the left, spring (6) is com- piston (2) changes, and the spring load of
pressed, and if it moves further to the left, springs (4) and (6) also changes according to
spring (6) contacts seat (5) and is fixed in posi- the valve of the PC-EPC valve solenoid com-
tion. In other words, the spring load is changed mand current.
by piston (9) extending or compressing springs
(4) and (6).
10-36 PC160LC-7
• Port C of the PC valve is connected to port E of

the LS valve (see 1. LS valve). Check valve
output pressure PP1 enters port B and the
small diameter end of servo piston (9), and
shuttle valve output pressure PP2 enters port
A.
• When pump pressures PP1 and PP2 are small,
spool (3) is on the left. At this point, port C and
D are connected, and the pressure entering the
LS valve becomes drain pressure PT. If port E
and port G of the LS valve are connected (see
1. LS valve), the pressure entering the large
diameter end of the piston from port J becomes
drain pressure PT, and servo piston (9) moves
to the right. In this way, the pump discharge
amount moves in the direction of increase.
• As servo piston (9) moves further, springs (4)
and (6) expand and the spring force becomes
weaker. When the spring force becomes
weaker, spool (3) moves to the right, so the
connection between port C and port D is cut,
and the pump discharge pressure ports B and
C are connected. As a result, the pressure at
port C rises, and the pressure at the large diam-
eter end of the piston also rises, so the move-
ment of piston (9) to the right is stopped.
• In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where the force of springs (4) and (6) and
the pushing force from the PC-EPC valve sole-
noid and the pushing force created by the pres-
sures PP1 and PP2 acting on the spool (3) are
in balance.
PC160LC-7 10-37
b. When load on actuator is large and pump dis-

charge pressure is high
• When the load is large and pump discharge • If main pump discharge pressure PP increases
pressures PP1 and PP2 are high, the force further and spool (3) moves further to the left,
pushing spool (3) to the left becomes larger and main pump pressure PP1 flows to port C and
spool (3) moves to the position in the diagram acts to make the discharge amount the mini-
above. When this happens, as shown in the mum. When piston (9) moves to the left,
diagram above, part of the pressurized oil from springs (4) and (6) are compressed and push
port A flows out through port C where the LS back spool (3). When spool (3) moves to the
valve is actuated to port D, and the pressurized left, the opening of port C and port D becomes
oil flowing from port C to the LS valve becomes larger. As a result, the pressure at port C (= J)
approximately half of main pump pressure PP. drops, and piston (9) stops moving to the left.
• When port E and port G of the LS valve are • The position in which piston (9) stops when this
connected, the pressure from port J enters the happens is further to the left than the position
large diameter end of servo piston (9), and when pump discharge pressures PP1 and PP2
servo piston (9) stops. are low.
10-38 PC160LC-7
• The relation of average pump discharge pres-

sure (PP1 + PP2)/2 and the position of servo
piston (9) forms a bent line because of the dou-
ble-spring effect of springs (4) and (6). The
relationship between average pump discharge
pressure (PP1 + PP2)/2 and pump discharge
amount Q is shown in the figure at the right.
• If command voltage X sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump discharge pressure
(PP1 + PP2)/2, and pump discharge amount Q
is proportional to the pushing force of the PC-
EPC valve solenoid and moves in parallel. In
other words, the pushing force of PC-EPC sole-
noid (1) is added to the force pushing to the left
because of the pump pressure applied to the
spool (3), so the relationship between the aver-
age pump discharge pressure (PP1 + PP2)/2
and Q moves from [1] to [2] in accordance with
the increase in X.
PC160LC-7 10-39
2) When pump controller is abnormal and PC

prolix switch is ON
a. When load on main pump is light
• If there is a failure in the pump controller, turn • At this point, port C is connected to the drain
PC prolix switch ON to switch to the resistor pressure of port D, and the large diameter end
side. In this case, the power source is taken of the piston of servo piston (9) also becomes
directly from the battery. But if the current is the drain pressure PT through the LS valve.
used as it is, it is too large, so use the resistor When this happens, the pressure at the small
to control the current flowing to PC-EPC valve diameter end of the piston is large, so servo
solenoid (1). piston (9) moves in the direction to make the
• When this is done, the current becomes con- discharge amount larger.
stant, so the force pushing piston (2) is also
constant.
• If the main pump discharge pressure PP1 and
PP2 are low, the combined force of the pump
discharge pressure and the force of PC-EPC
valve solenoid (1) is weaker than the spring set
force, so spool (3) is balanced at a position to
the left.
10-40 PC160LC-7
b. When main pump load is heavy

• In the same way as in the previous item, when the PC-EPC valve solenoid through the resis-
the PC prolix switch is ON, the command cur- tor.
r e nt se nt t o P C- E P C v al v e s ol en oi d ( 1 ) The curve when the PC prolix switch is ON is
becomes constant. For this reason, the force of curve [2], which is to the left of curve [1] for
piston (2) pushing spool (3) is constant. when the pump controller is normal.
• If main pump pressures PP1 and PP2 increase,
spool (3) moves further to the left than when the
main pump load is light, and is balanced at the
position in the diagram above.
• In this case, the pressure from port A flows to
port C, so servo piston (9) moves to the left (to
make the discharge amount smaller) and stops
at a position to the left of the position when the
load on the pump is light. In other words, even
when the emergency pump drive switch is ON,
the curve for the pump pressure PP and dis-
charge amount Q is determined as shown in
the diagram for the valve of the current sent to
PC160LC-7 10-41
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PC-EPC VALVE
PC-EPC VALVE
1. Body PM : To PC valve
2. Spool PT : To tank
3. Spring PEPC : From self-reducing pressure valve
4. Rod
5. Coil
6. Plunger
7. Connector
10-42 PC160LC-7
FUNCTION
• The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
• When it receives signal current i from the pump
controller, it generates the EPC output pressure
in proportion to the size of the signal, and out-
puts it to the PC valve.
OPERATION
1. When signal current is 0 (coil de-energized)
• When there is no signal current flowing from the
controller to coil (5), coil (5) is generalized.
• For this reason, spool (2) is pushed to the right in
the direction of the arrow by spring (3).
• As a result, port PEPC closes and the pressur-
ized oil from the main pump does not flow to the
PC valve.
At the same time, the pressurized oil from the PC
valve passes from port PM through port PT and
is drained to the tank.
PC160LC-7 10-43
2. When signal current is very small

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

(coil energized)
• When the signal current flows to coil (5), coil (5)
is energized.
• When this happens, the signal current is at its
maximum, so the propulsion force of plunger (6)
is also at its maximum.
• For this reason, spool (2) is pushed fully to the
left by push pin (4).
• As a result, the maximum flow of pressurized oil
from port PEPC flows to port PM, and the circuit
pressure between the EPC valve and PC valve
becomes the maximum.
At the same time, port PT closes and stops the
oil from flowing to the tank.
10-44 PC160LC-7
CHECK VALVE
FUNCTION
A set of 2 check valves is used to select and output
the higher discharge pressure of the 2 main pumps.
PA1: Discharge pressure of main pump 1. Poppet valve

PP1: Output pressure of check valve
OPERATION
1. When PA1 > PA2 2. When PA1 < PA2
• Discharge pressures PA1 and PA2 of the main • Reversely to 1., poppet valve (1) is kept closed
pumps are applied to poppet valves (1) and (2). and PA2 is output to PP1.
Since PA1 > PA2, however, poppet valve (2) is
kept closed and PA1 is output to PP1.
PC160LC-7 10-45
SHUTTLE VALVE
FUNCTION
The shuttle valve selects and outputs the lower dis-
charge pressure of the 2 main pumps.

PP2: Output pressure of shuttle valve 3. Pin
OPERATION
• The discharge pressures PA1 and PA2 of the 2
main pumps are applied to poppet valves (1) and
(2) respectively.
• Since poppet valves (1) and (2) push each other
through pin (3), either one of them receiving
higher pressure is closed and the other one
receiving lower pressure is opened.
• Accordingly, lower discharge pressure of the 2
main pumps is output.
10-46 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
OUTLINE
The following 4 types of control valve are set.
• 6-spool valve (Without service valve) • 7-spool valve (6-spool valve + Service valve)
• 6-spool valve (Without service valve, with alarm • 7-spool valve (6-spool valve + Service valve,
lock valve) with alarm lock valve)
The outside view and section of only 7-spool valve (6-spool valve + service valve) are shown here.
The specifications of only the arms of the valves having arm lock valves are added, however.
A1: To swing motor PB2: From left travel reverse PPC valve
A2: To left travel motor PB3: From right travel forward PPC valve
A3: To right travel motor PB4: From boom lower PPC valve
A4: To boom cylinder bottom PB5: From arm IN PPC valve
A5: To arm cylinder head PB6: From bucket CURL PPC valve
A6: To bucket cylinder head PB7: From service 1 PPC valve
A7: To attachment PP1: Pressure sensor port
B1: To swing motor (If equipped with pressure sensor)
B2: To left travel motor PP2: Pressure sensor port
B3: To right travel motor (If equipped with pressure sensor)
B4: To boom cylinder head PST: From travel junction solenoid valve
B5: To arm cylinder bottom SA5: From travel PPC valve
B6: To bucket cylinder bottom SA6: From travel PPC valve
B7: To attachment SB4: From travel PPC valve
LS: To pump LS valve SB5: From travel PPC valve
P1: From main pump TS1: To tank
P2: From main pump TS2: To tank
PP: To main pump
PR: To solenoid valve, PPC valve, and EPC valve 1. Swing bleed valve
PS: From merge-divider solenoid valve 2. LS check valve
PX: From 2-stage relief solenoid valve 3. Travel junction valve + LS check valve
TB: To tank 4. Arm regeneration valve
TC: To oil cooler 5. Boom hydraulic drift prevention valve
BP1: From boom raise PPC valve 6. Cover
BP2: From attachment circuit selector solenoid valve 7. Service valve
PA1: From swing left PPC valve 8. Butterfly valve
PA2: From left travel PPC valve 9. Arm valve
PA3: From right travel reverse PPC valve 10. Boom valve
PA4: From boom raise PPC valve 11. Right travel valve
PA5: From arm OUT PPC valve 12. Left travel valve
PA6: From bucket dump PPC valve 13. Swing valve
PA7: From service 1 PPC valve 14. Block
PB1: From swing right PPC valve 15. Pump merge-divider valve block
10-48 PC160LC-7
PC160LC-7 10-49
SPECIFICATION WITH ARM LOCK VALVE
16. Arm hydraulic drift prevention valve
10-50 PC160LC-7
1. Safety-suction valve (Service) 18. Spool (Service)

2. Suction valve (Bucket) 19. Spool (Bucket)
3. Suction valve (Arm) 20. Spool (Arm)
4. Suction valve (Boom) 21. Spool (Boom)
5. Suction valve (Left travel) 22. Spool (Left travel)
6. Suction valve (Right travel) 23. Spool (Right travel)
7. Suction valve (Right travel) 24. Spool (Swing)
8. Suction valve (Left travel)
9. Safety-suction valve (Boom)
10. Suction valve (Arm)
11. Suction valve (Bucket)
12. Safety-suction valve (Service)
13. Safety-suction valve
14. Main relief valve
15. Lift check valve
16. Unload valve
17. Unload valve
10-52 PC160LC-7
Unit: mm
Free length x Installed length Installed load Free length Installed load
25 Piston spring Outside diameter
4.9 N 3.9 N
16 × 16 12.6 
{0.5 kg} {0.4 kg}
2.0 N 1.6 N
26 Suction spring 10.5 × 7 6.8 
{0.21 kg} {0.17 kg}
5.5 N 4.4 N
27 Suction spring 46.8 × 7.5 40.6 
{0.56 kg} {0.45 kg}
5.1 N 4.1 N
28 Suction spring 39.2 × 4.5 33.5 
{0.52 kg} {0.42 kg}
231 N 185 N If damaged or

29 Spool return spring 45.6 × 28 43 
{23.5 kg} {18.8 kg} deformed,
replace spring
30 Spool return spring 45.7× 28 43 221 N  177 N
{22.6 kg} {18.1 kg}
221 N 177 N
31 Spool return spring 42.4 × 28 39 
{22.6 kg} {18.1 kg}
32 Spool return spring 42.1 × 28 39 221 N  177 N

{22.6 kg} {18.1 kg}
56 N 45 N
33 Spool return spring 27.1 × 25.8 25.5 
{5.7 kg} {4.6 kg}
34 Spool return spring 32.4 × 11 31.4 60 N  48 N

{6.1 kg} {4.9 kg}
141 N 113 N
35 Spool return spring 41.8 × 19 38.5 
{14.4 kg} {11.5 kg}
PC160LC-7 10-53
1 LS selector valve 11. Pressure compensation valve R (Right travel)

2. Cooler bypass valve 12. Pressure compensation valve R (Left travel)
3. Pressure compensation valve F (Service) 13. Pressure compensation valve R (Boom)
4. Pressure compensation valve F (Bucket) 14. Pressure compensation valve R (Arm)
5. Pressure compensation valve F (Arm) 15. Pressure compensation valve R (Bucket)
6. Pressure compensation valve F (Boom) 16. Variable pressure compensation valve (Service)
7. Pressure compensation valve F (Left travel) 17. Pump merge-divider valve spool
8. Pressure compensation valve F (Right travel)
F: Flow control valve
9. Pressure compensation valve F (Swing)
R: Pressure reducing valve
10. Pressure compensation valve R (Swing)
10-54 PC160LC-7
Unit: mm
18 Check valve spring Outside diameter
5.9 N 4.7 N
41.5 × 8.5 31.5 
{0.6 kg} {0.5 kg}
2.9 N 2.3 N
19 Check valve spring 20.3 × 13.7 16 
{0.3 kg} {0.24 kg} If damaged or
deformed,
9.8 N 7.8 N
20 Flow control valve spring 36.2 × 5.3 32  replace spring
{1 kg} {0.8 kg}
Pressure reducing valve 9.8 N 7.8 N

21 29.1 × 15 14.5 
spring {1 kg} {0.8 kg}
22 Pressure reducing valve 27.5 × 14.2 18 17.6 N  14 N

spring {1.8 kg} {1.4 kg}
Pressure reducing valve 13.7 N 11 N

23 28 × 14.4 14.5 
PC160LC-7 10-55
1. LS selector valve 12. Pressure compensation valve F (Right travel)

2. Pressure compensation valve F (Swing) 13. Pressure compensation valve R (Right travel)
3. Pressure compensation valve R (Swing) 14. Spool (Right travel)
4. Spool (Swing) 15. LS check valve
5. LS bleed valve 16. Suction valve (Right travel)
6. Pressure compensation valve F (Left travel) 17. Suction valve (Right travel)
7. Pressure compensation valve R (Left travel) 18. Self-pressure reducing valve
8. Spool (Left travel)
9. Travel junction valve + LS check valve
10-56 PC160LC-7
Unit: mm
19 Check valve spring Outside diameter
2.0 N 1.6 N If damaged or

21.9 × 5 15.8 
replace spring
20 Travel junction spool return 19.3 × 7.5 14 15.7 N  12.6 N
3.9 N 3.1 N
21 Bleed spool return spring 23.3 × 12.5 23 
{0.4 kg} {0.3 kg}
PC160LC-7 10-57
1. Merge-divider spool 10. Pressure compensation valve R (Arm)

2. LS bypass valve 11. Spool (Arm)
3. LS bypass valve 12. Suction valve (Arm)
4. Unload valve 13. Suction valve (Arm)
5. Unload valve 14. Hydraulic drift prevention valve (Arm)
7. Lift check valve
8. Cooler bypass valve
9. Pressure compensation valve F (Arm)
10-58 PC160LC-7
Unit: mm
15 Unload valve spring Outside diameter
180 N 144 N
47.2 × 17.3 32.5 
{18.9 kg} {14.7 kg}
83.4 N 66.7 N
16 Sequence valve spring 58.9 × 13 53 
{8.5 kg} {6.8 kg}
Pump merge-divider valve 98 N 78.4 N If damaged or

17 49.8 × 18.8 33 
spool return spring {10 kg} {8 kg} deformed,
replace spring
13.7 N 11 N
18 Check valve spring 16.4 × 8.9 11.5 
{1.4 kg} {1.1 kg}
135 N 108 N
19 Lift check valve spring 77.3 × 20.7 40 
{13.8 kg} {11 kg}
20 Cooler bypass valve spring 72.7 × 20.6 42.5 135 N  108 N

{13.8 kg} {11 kg}
5.9 N 4.7 N
21 Check valve spring 41.5 × 8.5 31.5 
{0.6 kg} {0.48 kg}
PC160LC-7 10-59
1. Hydraulic drift prevention valve (Boom) 12. Pressure compensation valve F (Service)
2. Pressure compensation valve F (Boom) 13. Variable pressure compensation valve (Service)
3. Pressure compensation valve R (Boom) 14. Spool (Service)
4. Spool (Boom) 15. Safety-suction valve
5. Suction valve 16. Safety-suction valve
6. Safety-suction valve 17. Safety-suction valve
7. Pressure compensation valve F (Bucket) 18. Air bleed plug
8. Pressure compensation valve R (Bucket)
9. Spool (Bucket)
10. Suction valve
11. Suction valve
10-60 PC160LC-7
Unit: mm
Free length x If damaged or

Installed length Installed load Free length Installed load
19 Lock valve spring Outside diameter deformed,
replace spring
26.5 N 21.2 N
33.9 × 17 21 
{2.7 kg} {2.2 kg}
PC160LC-7 10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- • The CLSS consists of a variable capacity single
tem, and has the following featues. piston pump, control valve, and actuators.
• Fine control not influenced by load • The pump body consists of the main pump, PC
• Control enabling digging even with fine control valve and LS valve.
• Ease of compound operation ensured by flow
divider function using area of opening of spoll
during compund operations
• Energy saving using variable pump control
10-62 PC160LC-7
BASIC PRINCIPLE
1. Control of pump swash plate angle
• The pump swash plate angle (pump discharge
amount) is controlled so that LS differential pres-
sure ∆PLS (the difference between pump (dis-
charge) pressure PP and control valve outlet port
LS pressure PLS) load pressure of actuator) is
constant.
(LS pressure ∆PLS=Pump discharge pressure
PP-LS pressure PLS)
• If LS differential pressure ∆PLS becomes lower

than the set pressure of the LS valve (when the
actuator load pressure is high), the pump swash
plate moves towards the maximum position; if
the set pressure becomes higher than the set
pressure of the LS valve (when the actuator load
pressure is low), the pump swash plate moves
towards the minimum position.
★ For details of the operation, see HYDRAULIC
PUMP.
PC160LC-7 10-63
2. Pressure compensation control between the upstream (inlet port) and down-
• A pressure compensation valve is installed to the stream (outlet port) the same, regardless of the
inlet port side of the control valve spool to bal- size of the load (pressure). In this way, the flow
ance the load. of oil from the pump is divided (compensated) in
When to actuators are operated together, this proportion to the area of openings S1 and S2 of
valve acts to make pressure difference ∆P each valve when it is operated.
10-64 PC160LC-7
OPERATION FOR EACH FUNCTION AND VALVE

Hydraulic circuit diagram and name of valves
10-66 PC160LC-7
1. Unload valve
3. Pressure compensation valve
5. Suction valve
6. Lift check valve
8. LS selector valve
9. Swing bleeding valve
10. Travel junction valve
11. Boom hydraulic drift prevention valve
12. Arm check valve
PC160LC-7 10-67
SPECIFICATION WITH ARM LOCK VALVE
10-68 PC160LC-7
1. Unload valve
3. Pressure compensation valve
5. Suction valve
6. Lift check valve
8. LS selector valve
9. Swing bleeding valve
10. Travel junction valve
11. Boom hydraulic drift prevention valve
12. Arm check valve
13. Arm hydraulic drift prevention valve
PC160LC-7 10-69
Unload valve
1. When control valve is at HOLD
Function Operation
• When the control valve is at HOLD, pump dis- • Pump discharge pressures P1 and P2 are acting
charge amount Q discharged by the minimum on the left end of unload spool (1) and LS pres-
swash plate angle is released to the tank circuit. sures LS1 and LS2 are acting on the right end.
At this time, pump discharge pressure P1/P2 is (P1 = P2, LS1 = LS2)
set by spring (2) in the valve. (LS pressure LS1/ • When the control valve is at HOLD, LS pres-
LS2 = 0 MPa {0 kg/cm2}) sures LS1 and LS2 are not generated, so only
• Since the pump merge-divider valve is at the pump discharge pressures P1 and P2 act, and
merge position, pump discharge pressures P1 P1 and P2 are set by only the load of spring (2).
and P2 are merged. LS pressures LS1, LS2, • As pump discharge pressure P1/P2 rises and
and LS3 are also merged. reaches the load of spring (2), spool (1) is moved
to the right. Pump discharge pressures P1 and
P2 are connected to tank circuit T through the
cut of spool (1)
10-70 PC160LC-7
2. When work equipment valve is operated
Function Operation
• When any work equipment valve is operated if • When any work equipment valve is operated for
the demand flow for the actuator becomes a long stroke, LS pressures LS1 and LS2 are
greater than the pump discharge from the mini- generated and act on the right end of unload
mum swash plate angle, the oil flow to tank cir- spool (1) (P1 = P2, LS1 = LS2).
cuit T is cut off, and all pump discharge amount • For this reason, the difference between pump
Q flows to the actuator circuit. discharge pressure P1/P2 and LS pressure LS1/
• Since the pump merge-divider valve is at the LS2 does not reach the load of spring (2), so
merge position, pump discharge pressures P1 spool (1) is pushed to the left by spring (2).
and P2 are merged. LS pressures LS1, LS2, • As a result, pump discharge pressures P1 and
and PLS3 are also merged. P2 and tank circuit T are shut off, and all pump
discharge amount Q flows to the actuator circuit.
PC160LC-7 10-71
3. During fine control of both travel valves
Function Operation
• When the difference between pump discharge • When fine control is carried out on both travel
pressure P1/P2 and LS pressure LS1/LS2 valves, LS pressures LS1 and LS2 are gener-
reaches the load of spring (2), unload spool (1) ated and act on the right end of spool (1) (P1,
opens, so excessive oil (maximum pump dis- P2, LS1, and LS2 are separated).
charge mount - demand flow) flows into the tank • When this happens, the area of the opening of
circuit. both travel valve spools is small, so LS pres-
• Since the pump merge-divider valve is at the sures LS1 and LS2 are very different from pump
separate position, pump discharge pressures P1 discharge pressures P1 and P2.
and P2 are separated. LS pressures LS1 and • When the difference between pump discharge
LS2 are also separated. pressure P1/P2 and LS pressure LS1/LS2
• The swash plate angle of the pump becomes reaches the load of spring (2), spool (1) moves to
maximum, so the pump discharge amount the right, and pump discharge pressures P1 and
becomes maximum. (For details, see the sec- P2 are connected to tank circuit T and the exces-
tions on the pump merge-divider valve.) sive oil (maximum pump discharge mount -
demand flow) flows.
• In other words, the excessive oil (maximum
pump discharge mount - demand flow) above the
strokes of both travel valves flows into tank cir-
cuit T.
10-72 PC160LC-7
4. When both travel valves are operated
Function Operation
• During operation of both travel valves, when the • When both travel valves are operated to the
demand flow becomes maximum, the oil flow to stroke ends, LS pressures LS1 and LS2 are
tank circuit T is cut off, and all pump discharge generated and act on the right end of unload
amount Q flows to both travel circuits. spool (1) (P1, P2, LS1, and LS2 are separated).
• Since the pump merge-divider valve is at the • When this happens, the area of the openings of
separate position, pump discharge pressures P1 both travel valve spools is large, so LS pressures
and P2 are separated. LS pressures LS1 and LS1 and LS2 are not so different from pump dis-
LS2 are also separated. charge pressures P1 and P2.
• The swash plate angle of the pump becomes • For this reason, the difference between pump
maximum, so the pump discharge amount discharge pressure P1/P2 and LS pressure LS1/
becomes maximum. (For details, see the sec- LS2 does not reach the load of spring (2), so
tions on the pump merge-divider valve .) spool (1) is pushed to the left by spring (2).
• As a result, pump discharge pressures P1 and
P2 and tank circuit T are shut off, and all pump
discharge amount Q flows to the actuator circuit.
PC160LC-7 10-73
5. When either travel valve is operated
Function • When this happens, the area of the openings of

• The demand flow decided by the valve stroke is both travel valve spools is large, so LS pressures
sent to the travel circuit on the operated travel LS1 is not so different from pump discharge
valve side and the all pump discharge amount is pressures P1.
sent to the tank circuit on the non-operated travel • For this reason, the difference between pump
valve side. discharge pressure P1 and LS pressure LS1
• Since the pump merge-divider valve is at the does not reach the load of spring (2), so spool
separate position, pump discharge pressures P1 (1) is pushed to the left by spring (2).
and P2 are separated. LS pressures LS1 and • As a result, pump discharge pressures P1 and
LS2 are also separated. tank circuit T are shut off, and all pump dis-
• The swash plate angle of the pump becomes charge amount QP1 on the P1 side flows to the
maximum, so the pump discharge amount left travel circuit.
becomes maximum. (For details, see the sec- • Since the right travel valve is at HOLD, LS pres-
tions on the pump merge-divider valve.) sure LS2 is not generated, so only pump dis-
charge pressure P2 acts.
Operation • When pump discharge pressure P2 reaches the
When left travel valve is operated to stroke end and load of spring (2), spool (1) moves to the right,
right one is at HOLD. and all pump discharge amount QP2 on the P2
• When the left travel valve is operated to the side flows into tank circuit T.
stroke end, LS pressure LS1 is generated and
acts on the right end of unload spool (1).
10-74 PC160LC-7
Merge-divider valve
Function
1. When oil is merged: PS = 0 kg/cm2
• Pump discharge pressures P1 and P2 are • At this time, P1 = P2 and LS1 = LS2 = LS3 and
merged in pump merge-divider spool (3). LS1, the pump swash plate is controlled by the differ-
LS2, and LS3 are also merged. ence between P and LS.
2. When oil is divided: PS = 30 kg/cm2
• Pump discharge pressures P1 and P2 are • As a result, there is not difference between P
divided in pump merge-divider spool (3). LS1, and LS and the pump swash plate is set to the
LS2, and LS3 are also divided. maximum position.
• At this time, higher one of P1 and P2 is applied
through pump merge-divider spool (3) to the out-
put port of the LS pressure.
PC160LC-7 10-75
Introduction of LS pressure
1. Work equipment valve
Function Operation
• The LS pressure is the actuator load pressure at • When spool (1) is operated, pump discharge
the outlet port end of the control valve. pressure PP flows from flow control valve (2)
• Actually, pump discharge pressure PP is through notch (a) in the spool and bridge pas-
reduced by reducing valve (3) of the pressure sage (b) to actuator circuit A.
compensation valve to the same pressure as • At the same time, reducing valve (3) also moves
actuator circuit pressure A and sent to LS circuit to the right, so pump discharge pressure PP is
PLS. reduced by the pressure loss at notch (c). It goes
• In the travel valve, actuator circuit pressure A is to LS circuit PLS, and then goes to spring cham-
directly introduced to LS circuit PLS. ber PLSS.
• When this happens, LS circuit PLS is connected
to tank circuit T from LS bypass plug (4) (See the
section on the LS bypass plug).
• The areas at both ends of reducing valve (3) are
the same (SA = SLS), and actuator circuit pres-
sure PA acts on the SA end. The reduced pump
discharge pressure PP acts on SLS at the other
end.
• As a result, reducing valve (3) is balanced at a
position where actuator circuit pressure PA and
the pressure of spring chamber PLSS are the
same. Pump discharge pressure PP reduced at
notch (c) becomes actuator pressure A and is
introduced into LS circuit PLS.
10-76 PC160LC-7
2. Travel valve.
Operation
• When spool (1) is operated, pump discharge
pressure PP flows from flow control valve (2)
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit A.
• Actuator circuit pressure PA (= A) is introduced
through the check valve into LS circuit PLS.
★ The travel circuit is different from the work equip-
ment circuit: actuator circuit pressure PA is
directly introduced into LS circuit PLS.
PC160LC-7 10-77
LS bypass plug
When work equipment valve is operated
When both travel valves are operated
Function PLS1, PLS2, and PLS3 flows from tip filter

• The LS bypass plug releases the residual pres- (a) of LS bypass plug (2) through orifice (b)
sure of LS pressure PLS. to tank circuit T.
• This lowers the rising speed of LS pressure PLS. 2. When either or both travel valves are operated
In addition, the discarded throttled flow causes a (Including operation of only one travel valve)
pressure loss in the throttled flow in the reducing • Since pump merge-divider spool (1) is at the
valve, and that lowers the effective LS differential separate position, LS circuits PLS1,and
pressure to improve the stability. PLS2 are separated.
• The hydraulic oil PLS1 flows from tip filter (a)
Operation of LS bypass plug (2) on the P1 side through
1. When work equipment valve is operated (includ- orifice (b) to tank circuit T.
ing compound operation of work equipment + • The hydraulic oil PLS2 flows from tip filter (a)
travel) of LS bypass plug (3) on the P2 side through
• Since pump merge-divider spool (1) is at the orifice (b) to tank circuit T.
merge position, the hydraulic oil in LS circuits
10-78 PC160LC-7
Pressure compensation valve

Function
• When the load pressure becomes lower than another actuator and the flow is going to increase during a
compound operation, this valve compensates the load pressure. (At the time, the load pressure of another
actuator under compound operation (the upper side) is higher than that of the actuator on this side (the
lower side).
PC160LC-7 10-79
Operation
• When the load pressure of another actuator side
(the upper side) rises during a compound opera-
tion, the flow in the actuator circuit Aa on this
side (the lower side) is apt to increase.
• In this case, the LS pressure PLS of another
actuator is applied to the spring chamber PLS1
and pushes the pressure reducing valve (1) and
the flow control valve (2) to the left side.
• The flow control valve (2) throttles the opening
area between the pump circuit PP and the spool
upstream PPA and causes a pressure loss
between PP and PPA.
• The flow control valve (2) and the pressure
reducing valve (1) balance each other where the
pressure difference between PA applied to the
both end faces of the pressure reducing valve (1)
and PLS becomes the same as the pressure
loss between PP before and after the flow control
valve and PPA.
• So, the pressure differences between the
upstream pressures PPA and the downstream
pressures PA of the both spools under com-
pound operation become the same, and the
pump flow is distributed in proportion to the
opening area of each spool notch a.
10-80 PC160LC-7
Area ratio of pressure compensation valve

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

• When the ratio is 1.00 : The expression [Pump (discharge) pressure PP – Spool notch upstream pressure
PPB] [LS circuit pressure PLS – Actuator circuit pressure PA (= A)] can be held,
and the flow is distributed as per the spool opening area ratio.
• When the ratio is more than 1.00: The expression PP – PPB > PLS – PA (= A) can be held, and the flow is
distributed less than the spool opening area ratio.
• When the ratio is less than 1.00 : The expression PP – PPB < PLS – PA (= A) can be held, and the flow is
distributed more than the spool opening area ratio.
PC160LC-7 10-81
Variable pressure compensation valve

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

• The pump discharge pressure PP and the LS 2. Pressure reducing valve
pressure PLS depends on other work equip- 3. Poppet
ment. 4. Spring
• When the pressure in the a chamber reaches the 5. Screw
set pressure of the spring (4), the poppet (3) will 6. Lock nut
open, and the throttle b maintains the pressure in 7. Polyethylene cap
the a chamber below the pump discharge pres-
sure PP.
• Therefore, the force F, which is required for the
pressure reducing valve (2) to close the flow
control valve (1), becomes smaller.
• This means that the flow control valve (1) moves
in the right direction and the flow from the pump
to the service valve increases just like the area
ratio has reduced.
10-82 PC160LC-7
Boom regeneration circuit

1. At boom lower and own weight fall
Function
• When the boom is lowered and falls due to its
own weight because the bottom pressure A in
the cylinder (1) is higher than the head pressure
B, this circuit brings the return flow on the bottom
side to the head side to increase the cylinder
speed.
Operation
• When the boom is lowered and falls due to its • At the time, part of the return flow on the bottom
own weight, the bottom side pressure A in the side passes through the regeneration passage a
boom cylinder (1) will rise above the head side of the boom spool (2), pushes the check valve
pressure B. (3) to open it and flows to the head side.
• This increases the boom lower speed.
PC160LC-7 10-83
2. At boom lower load process

Function
• When the head pressure B of the cylinder (1) is
higher than the bottom pressure A while the
boom is lowered and the boom is in the load pro-
cess, the check valve (3) will be closed, and the
circuits on the head side and the bottom side will
be interrupted.
Operation
• When the boom is lowered and is in the load pro- • At the time, the head side pressure B and the
cess, the head side pressure B of the boom cyl- spring (4) close the check valve (3), and the cir-
inder (1) rises above the bottom side pressure A. cuits on the head side and the bottom side are
interrupted.
10-84 PC160LC-7
Arm regeneration circuit

1. At arm in and own weight fall
Function
• When the arm falls due to its own weight
because the head pressure A in the arm cylinder
(1) is higher than the bottom pressure B during
arm digging, this circuit brings the return flow on
the head side to the bottom side to increase the
cylinder speed.
Operation
• When the arm falls for digging due to its own 1. Arm cylinder
weight, the head side pressure A in the arm cyl- 2. Arm spool
inder (1) will rise above the bottom side pressure 3. Check valve
B.
• At the time, part of the return flow on the head A : Head circuit (pressure)
side passes through the regeneration passage a B : Bottom circuit (pressure)
of the arm spool (2), pushes the check valve (3) PP : Pump circuit (pressure)
to open it and flows to the bottom side.
• This increases the arm digging speed.
PC160LC-7 10-85
2. At arm in process
Function
• When the bottom pressure B of the cylinder (1)
rises above the head pressure A and the arm
enters the digging process, the check valve (3)
will be closed and the circuits on the head side
and the bottom side will be interrupted.
Operation
• When the arm is in the digging process, the bot- 1. Arm cylinder
tom side pressure B of the arm cylinder (1) will 2. Arm spool
rise, close the check valve (3) and interrupt the 3. Check valve
circuits on the head side and the bottom side.
A : Head circuit (pressure)
B : Bottom circuit (pressure)
PP : Pump circuit (pressure)
10-86 PC160LC-7
Hydraulic drive prevention valve

(Boom and arm)
1. When boom is raised and arm is moved out
Function Operation
• While the boom and arm levers are not operated, • If the boom is raised and the arm is moved out,
the hydraulic drift prevention valve prevents oil the main pressure from the control valve pushes
from leaking from the boom bottom and arm up poppet (5). As a result, the main pressure
head through spool (1) to prevent the boom and from the control valve flows through the valve
arm from drifting hydraulically. into the boom cylinder bottom.
PC160LC-7 10-87
2. When boom and arm are set in neutral
Operation
• If the control lever is returned to the neutral posi-
tion while the boom is raised and the arm is
moved out, the holding pressure in the boom cyl-
inder bottom and arm cylinder head is blocked
by poppet (5) and the pressurized oil flowing in
through orifice a is blocked by pilot spool (3).
Accordingly, the boom and arm are held.
10-88 PC160LC-7
3. When boom is lowered and arm is moved in
Operation
• If the boom is lowered and the arm is moved in • If the pressure in chamber b is lowered below
pilot pressure P1 from the PPC valve pushes the pressure in port Aa, poppet (5) opens and
pilot spool (3) and the pressurized oil in chamber the pressurized oil from port Ab flows through
b in the poppet is drained. port Aa into the control valve.
• The oil pressure in port Ab is raised by the pres-
surized oil from the boom cylinder bottom and
arm cylinder head, but the oil pressure in cham-
ber b is lowered by orifice a.
PC160LC-7 10-89
Swing bleeding valve
Function Operation (In fine control operation)

• When the machine swings, the bleeding valve • The pressure reducing valve moves to the right
installed to the pressure reducing valve works so and notch a connects to the LS circuit. As a
that the LS pressure rises gradually and the result, pump circuit PP, bleed-off circuit, and Ls
machine swings smoothly. circuit are connected through piston (2).
• Bleeding spool (3) moves to the left in proportion
as swing PPC pressure PA rises. In the fine con-
trol area, notch b chokes the bleed-off circuit and
determines the intermediate pressure before the
lowered pressure is applied to pump discharge
pressure PP and Ls pressure PLS.
• Accordingly, the intermediate pressure is set
lower than pump discharge pressure PP and
raised as bleeding spool (3) moves. As a result,
Ls pressure PLS rises gradually.
• When the lever is in neutral or operated fully, the
bleed-off circuit is closed.
10-90 PC160LC-7
LS select valve
Function
• At the time of simultaneous operation of swing +
boom RAISE, this valve prevents high swing LS
pressure from entering the LS circuit PLS and
also prevents the boom RAISE speed from
reducing by securing the pump flow at the time of
swing drive.
1. During normal operation
Operation
• The pilot pressure is not generally applied to the
pilot port BP except for boom RAISE operation.
• In this state, the pump discharge pressure PP
pushes the valve (1) to open it and is led to the
pressure reducing valve (4) of the swing valve.
At the time of swing operation, there occurs the
LS pressure PLS suitable for the load pressure,
and the pressure is led to the pump LS valve.
PC160LC-7 10-91
2. At simultaneous operation of swing + boom RAISE
Operation
• At the simultaneous operation of swing + boom
RAISE, the signal pressure of the PPC circuit is
led to the pilot port BP.
• When this pilot pressure BP is applied to the pis-
ton (2) and reaches a pressure that is stronger
than the spring (3), the piston (2) will be pushed
to the left side, the valve (1) will close and the
pump discharge pressure PP will not come to
flow to the pressure reducing valve (4) of the
swing valve.
• Then, the swing pressure does not cause LS
pressure PLS, but the LS pressure PLS cause
the boom RAISE pressure is led to the pump LS
valve, and the pump delivery is controlled with
the boom RAISE LS pressure.
• The pilot pressure BP depends on the control
lever stroke.
10-92 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE

Function Operation
• This valve connects both travel circuits to each When pilot pressure is turned ON
other so that hydraulic oil will be supplied evenly • If the pilot pressure from the travel junction sole-
to both travel motors and the machine will travel noid valve becomes higher than the force of
straight. spring (2), travel junction spool (1) moves to the
• When the machine is steered, outside pilot pres- left stroke end and the junction circuit between
sure PST doses the travel junction valve to pore PTL (Left travel circuit) and PTR (Right
secure high steering performance. travel circuit) is closed.
PC160LC-7 10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
Function When abnormally high pressure is generated

• The self-reducing pressure valve lowers the dis- • If the PR pressure of the self-reducing pressure
charge pressure of the main pump and supplies valve is raised abnormally, ball (6) separates
it as the control pressure for the solenoid valves, from the seat against the force of spring (5). As
PPC valves, etc. a result, the hydraulic oil flows from output port
PR to TS and the PR pressure lowers.
Operation • Accordingly, the devices receiving the oil pres-
• If the PR pressure rises higher than the set level, sure (PPC valves, solenoid valves, etc.) are pro-
poppet (1) opens and the hydraulic oil flows from tected from abnormally high pressure.
port PR through orifice a in spool (4) and open-
ing of poppet (1) into seal drain port TS.
• Accordingly, differential pressure is generated
over orifice a in spool (4) and spool (4) moves in
the direction to close the opening between ports
P and PR. The P pressure is lowered and con-
trolled to a constant pressure (set pressure) by
the opening ratio at this time and supplied as the
PR pressure.
10-94 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
1. Cover A1. To L.H. travel motor port PB D1. To R.H. travel motor port PB
2. Body A2. From control valve port A5 D2. From control valve port B2
3. Slipper seal B1. To L.H. travel motor port PA E. To L.H. and R.H. travel motors port P
4. O-ring B2. From control valve port B5 T1. From L.H. and R.H. travel motors port T
5. Shaft C1. To R.H. travel motor port PA T2. To tank
C2. From control valve port A2
Unit: mm
Standard size Standard clearance Repair limit
6 Clearance between rotor and
Replace
shaft
80 – –
PC160LC-7 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
1. Valve plate 6. Swing machine assembly

2. Oil level gauge 7. Motor case
3. Brake piston 8. Plate
4. Piston 9. Disc
5. Drive shaft 10. Cylinder block
10-96 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMV110ADT-2
P : From travel speed solenoid valve SPECIFICATIONS

T : To tank
PA : From control valve
Type HMV110ADT-2
PB : From control valve
MA : MA pressure pickup port Min. 5.5 cm3/rev
Theoretical
MB : MB pressure pickup port
Delivery Max. 95.4 cm3/rev
Set pressure 37.3 MPa {380 kg/cm2}
Min.
2,851 rpm
Capacity
Rated speed
Max.
1,644 rpm
Capacity
Brake releasing pressure 1.2 MPa {12 kg/cm2}

Travel speed
Differential
switching 0.8 MPa {8 kg/cm2}
pressure
pressure
PC160LC-7 10-97
1. Regulator piston 9. Check valve spring 17. Valve plate

2. Spring 10. Output shaft 18. Counterbalance valve
3. Regulator valve 11. Rocker cam 19. Ring
4. Spring 12. Retainer guide 20. Spool return spring
5. Motor case 13. Pin 21. Brake piston
6. Suction safety valve spring 14. Piston 22. Plate
7. Suction safety valve 15. Retainer 23. Disc
8. Check valve 16. Cylinder 24. Ball
10-98 PC160LC-7
Unit: mm
Free length x Out- Installed

1 Check valve spring side diameter length Installed load Free length Installed load
7.16 N 5.69 N
32.5 × 6.5 24.2 
{0.73 kg} {0.58 kg} If damaged or
1.96 N 1.57 N deformed,
2 Check valve spring 13.0 × 6.5 9.5 {0.2 kg}  {0.16 kg} replace spring
427 N 341 N
3 Return spring 58.43 × 30 42.0 
{43.5 kg} {34.8 kg}
55 N 44 N
4 Regulator valve spring 21.5 × 11.1 17.1 
{5.6 kg} {4.5 kg}
PC160LC-7 10-99
OPERATION OF MOTOR
1) Motor swash plate angle at maximum
• The solenoid valve is deactivated, so the pilot • At the same time, the pressurized oil at regulator
pressure oil from the main pump does not flow to piston (15) passes through orifice c in regulator
port P. valve (9) and is drained to the motor case.
• For this reason, regulator valve (9) is pushed to • As a result, rocker cam (4) moves in the maxi-
the right in the direction of the arrow by spring mum swash plate angle direction, the motor
(10). capacity becomes maximum.
• Because of this, it pushes check valve (22), and
the main pressure oil from the control valve
going to end cover (8) is shut off by regulator
valve (9).
• Fulcrum a of rocker cam (4) is eccentric to point
of force b of the combined force of the propulsion
force of cylinder (6), so the combined force of the
piston propulsion force acts as a moment to
angle rocker cam (4) in the direction of the maxi-
mum swash plate angle.
10-100 PC160LC-7
2) Motor swash plate angle at minimum
• When the solenoid valve is excited, the pilot

pressure oil from the main pump flows to port P,
and pushes regulator valve (9) to the left direc-
tion of the arrow.
• Because of this, the main pressure oil from the
control valve passes through passage d in regu-
lator valve (9), enters regulator piston (15) at the
bottom, and pushes regulator piston (15) to the
right in the direction of the arrow.
• As a result, rocker cam (4) moves in the mini-
mum swash plate angle direction, the motor
capacity becomes minimum.
PC160LC-7 10-101
OPERATION OF PARKING BRAKE

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

When the travel lever is placed in neutral, coun-
terbalance valve spool (19) returns to the neutral
position and the circuit to the parking brake is
closed.
The pressurized oil in chamber A of brake piston
(12) is drained to the case from the orifice in the
brake piston, and brake piston (12) is pushed to
the right in the direction of the arrow by spring
(11).
As a result, plate (13) and disc (14) are pushed
together, and the brake is applied. A time delay
is provided by having the pressurized oil pass
through a throttle in slow return valve (22) when
the brake piston returns, and this ensures that
the brake is still effective after the machine
stops.
10-102 PC160LC-7
OPERATION OF BRAKE VALVE

• The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a cir-
cuit as shown in the diagram on the right. (Fig. 1)
• The function and operation of each component is
as given below.
1) Counterbalance valve, check valve

Function
• When traveling downhill, the weight of the
machine makes it try to travel faster than the
speed of the motor.
As a result, if the machine travels with the engine
at low speed, the motor will rotate without load
a n d t h e m a c h i n e w i l l r u n aw a y, w h i c h i s
extremely dangerous.
To prevent this these valves act to make the
machine travel according to the engine speed
(pump discharge amount).
Operation when pressure oil is supplied

• When the travel lever is operated, the pressur-
ized oil from the control valve is supplied to port
PA. It pushes open suction safety valve (18A)
and flows from motor inlet port MA to motor out-
let port MB.
However, the motor outlet port is closed by suc-
tion safety valve (18B) and spool (19), so the
pressure at the supply side rises. (Fig. 2)
• The pressurized oil at the supply side flows from

orifice E1 and E2 in spool (19) to chamber S1.
When the pressure in chamber S1 goes above
the spool switching pressure, spool (19) is
pushed to the right in the direction of the arrow.
As a result, port MB and port PB are connected,
the outlet port side of the motor is opened, and
the motor starts to rotate. (Fig. 3)
PC160LC-7 10-103
Operation of brake when traveling downhill

• If the machine tries to run away when traveling
downhill, the motor will turn under no load, so the
pressure at the motor inlet port will drop, and the
pressure in chamber S1 through orifices E1 and
E2 will also drop. When the pressure in chamber
S1 drops below the spool switching pressure,
spool (19) is returned to the left, in the direction
of the arrow by spring (20), and outlet port MB is
throttled.
As a result, the pressure at the outlet port side
rises, resistance is generated to the rotation of
the motor, and this prevents the machine from
running away.
In other words, the spool moves to a position
where the pressure at the outlet port MB bal-
ances the pressure at the inlet port and the force
generated by the weight of the machine. It throt-
tles the outlet port circuit and controls the travel
speed according to the amount of oil discharged
from the pump. (Fig. 4)
2) Safety valve
Function
• When travel is stopped (or when traveling down-
hill), the circuits at the inlet and outlet ports of the
motor are closed by the counterbalance valve,
but the motor is rotated by inertia, so the pres-
sure at the outlet port of the motor will become
abnormally high and damage the motor or pip-
ing. The safety valve acts to release this abnor-
mal pressure and send it to the inlet port side of
the motor to prevent damage to the equipment.
Operation
1. When travel is stopped (or when traveling
downhill, rotating to right)
• When the motor inlet port pressure (pressure
PA) goes down, the pressure in chamber S1 also
goes down. When it goes below the switching
pressure of the spool, spool is returned to the left
by spring (20), and outlet port passage B1 is
throttled. When this happens, the motor contin-
ues to rotate under inertia, so the outlet pressure
(pressure MB) rises. (Fig. 5)
• If the pressure goes above the set pressure of
suction-safety valve (18A), the poppet opens.
The oil then passes through large notch A1 in
counterbalance valve spool (19) and flows to
chamber MA in the circuit on the opposite side.
(Fig. 6)
2. When rotating to left
The operation is the reverse of when rotating to
the right.
10-104 PC160LC-7
2) When starting travel (or during normal travel)

• When the travel lever is operated, the pressure
oil from the pump moves counterbalance valve
spool (19) to the right. When this happens, the
passage to the suction-safety valve becomes
the circuit flowing through the small notch B2 in
the counterbalance valve spool. As a result, a
big difference in pressure is created, and the
pump pressure rises to provide a powerful draw-
bar pull. (Fig. 7)
PC160LC-7 10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
WORK EQUIPMENT • SWING PPC VALVE
P: From main pump P1: Left: Arm OUT / Right: Boom LOWER
T: To tank P2: Left: Arm IN / Right: Boom RAISE
P3: Left: Swing RIGHT / Right: Bucket CURL
P4: Left: SwingLEFT / Right: Bucket DUMP
10-106 PC160LC-7
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm

Centering spring Installed load Free length Installed load
12 (For P3 and P4) side diameter length
17.1 N 13.7 N If damaged or

42.4 × 15.5 34 {1.8 kg}  {1.4 kg} deformed,
replace spring
Centering spring 29.4 N 23.5 N
13 44.4 × 15.5 34 
(For P1 and P2) {3.0 kg} {2.4 kg}
16.7 N 13.7 N
14 Metering spring 26.5 × 8.2 24.9 {1.7 kg}  {1.4 kg}
PC160LC-7 10-107
OPERATION
1) At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1).
2) During fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the main pump
passes through fine control hole f and goes from
port P1 to port A.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP. At
almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is bal-
anced with the pressure at port P1. The relation-
ship in the position of spool (1) and body (10)
(fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP)
does not change until retainer (9) contacts spool
(1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P1 also
rises in proportion to the travel of the control
lever. In this way, the control valve spool moves
to a position where the pressure in chamber A
(the same as the pressure at port P1) and the
force of the control valve spool return spring are
balanced.
10-108 PC160LC-7
3) During fine control (when control lever is

returned)
• When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows in from fine control hole f’
in the valve on the side that is not working. The
oil passes through port P2 and enters chamber B
to fill the chamber with oil.
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the main
pump passes through fine control hole f and
flows to chamber A from port P1, and pushes the
control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f’ and flows to
drain chamber D.
PC160LC-7 10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From main pump P3 : Right reverse

T : To tank P4 : Right forward
P1 : Left reverse P5 : Travel signal
P2 : Left forward P6 : Steering signal
10-110 PC160LC-7
1. Plate 6. Metering spring

2. Body 7. Valve
3. Piston 8. Damper
4. Collar 9. Steering signal
5. Centering spring 10. Steering signal valve spring
PC160LC-7 10-111
Unit: mm

Installed load Free length Installed load
1 Centering spring side diameter length
129 N 107 N If damaged or

47.5 × 15.5 32.8 
replace spring
16.7 N 13.7 N
2 Metering spring 26.5 × 8.15 24.9 
{1.7 kg} {1.4 kg}
8.8 N 7.1 N
3 Steering signal spring 12.8 × 7.3 8.5 
{0.9 kg} {0.72 kg}
10-112 PC160LC-7
OPERATION
1) At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1).
2) Fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed. Spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D. At almost the same time,
it is connected to pump pressure chamber PP,
and the pilot pressure of the main pump is sent
from port A through fine control hole f to port P1.
When the pressure at port P1 rises, spool (1) is
pushed back. Fine control hole f is shut off from
pump pressure chamber PP. At almost the same
time, it is connected to drain chamber D, so the
pressure at port P1 escapes.
As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port P1.
The relationship of the position of spool (1) and
body (10) (fine control hole f is in the middle
between drain hole D and pump pressure cham-
ber PP) does not change until retainer (9) con-
tacts spool (1).
Therefore, metering spring (2) is compressed in
proportion to the travel of the control lever, so the
pressure at port P1 also rises in proportion to the
travel of the control lever. In this way, the spool of
the control valve spool moves to a position
where the pressure of chamber A (same as
pressure at port P1) and the force of the return
spring of the control valve spool are balanced.
PC160LC-7 10-113
3) Fine control (control lever returned)

When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
Because of this, fine control hole f is connected
to drain chamber D, and the pressurized oil at
port P1 is released.
If the pressure at port P1 drops too much, spool
(1) is pushed up by metering spring (2), so fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, so the pressure at port P1
supplies the pump pressure until the pressure
recovers to a pressure equivalent to the position
of the lever.
When the control valve returns, oil in drain cham-
ber D flows in from fine control hole f’ of the
valve on the side that is not moving.
It passes through port P2 and goes to chamber
B to charge the oil.
4) At full stroke
Lever (5) pushes down piston (4), and retainer
(9) pushes down on spool (1). Fine control hole f
is shut off from drain chamber D, and is con-
nected to pump pressure chamber PP. There-
fore, the pilot pressure oil from the main pump
passes through fine control hole f and flows to
chamber A from port P1 to push the control valve
spool. The return oil from chamber B passes
from port P2 through fine control hole f’ and
flows to drain chamber D.
10-114 PC160LC-7
Travel signal/Steering function

• Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the
travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.
• Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the higher
one of the PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neu-
tral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
OPERATION
1) While in NEUTRAL
The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not out-
put.
PC160LC-7 10-115
2) While travelling straight

(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also
operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and
right spring chamber ( l ) of steering signal valve ( j ) are set high. Accordingly, the steering signal valve is
kept in neutral and the steering signal (Port P6) is not output.
10-116 PC160LC-7
3) When steered or pivot-turned

(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the dif-
ference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output
as the steering signal.
In the case of the following drawing, the pressure in left spring chamber ( k ) of steering signal valve ( j ) is
P2. The pressure in right spring chamber ( l ) is P4.
If (P4 – P2) x (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow
and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the
steering signal to port P6.
PC160LC-7 10-117
4) When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is
operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber ( l ) of
steering signal valve ( j ) is set high. Accordingly, the steering signal valve moves to the left and outputs the
steering signal (port P6).
10-118 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
T : To tank
P : From main pump
P1 : Port
P2 : Port
Unit: mm

9 Centering spring Installed load Free length Installed load
side diameter length If damaged or
deformed,
124.5 N 100 N
33.9 × 15.3 28.4  replace spring
{12.7 kg} {10.2 kg}
16.7 N 13.7 N
10 Metering spring 22.7 × 8.1 22 
{1.7 kg} {1.4 kg}
PC160LC-7 10-119
OPERATION
At neutral
• The pressurized oil from the main pump enters
from port P and is blocked by spool (1).
• Ports A and B of the control valve and ports a
and b of the PPC valve are connected to drain
port T through fine control hole X of spool (1).
WHEN OPERATED
• When lever (5) is moved, metering spring (2) is
pushed by piston (4) and retainer (7), and spool
(1) is pushed down by this.
• As a result, fine control portion Y is connected
with port a, and the pressurized oil from port P
flows from port a to port A of the control valve.
10-120 PC160LC-7
• When the pressure at port a becomes higher,

spool (1) is pushed back by the force acting on
the end of the spool, and fine control portion Y
closes.
• As a result, spool (1) moves up and down to bal-
ance the force at port a and the force at metering
spring (2).
• Therefore, metering spring (2) is compressed in
proportion to the amount the control lever is
moved. The spring force becomes larger, so the
pressure at port a also increases in proportion to
the amount the control lever is operated.
• In this way, the control valve spool moves to a
position where the pressure of port A (the same
as the pressure at port a) is balanced with the
force of the return spring of the control valve
spool.
PC160LC-7 10-121
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing holding brake, merge-divider, travel junction solenoid valves
1. PPC lock solenoid valve T : To tank A6 : To main valve (2-stage relief

2. Travel junction solenoid valve A1 : To PPC valve valve)
3. Merge-divider solenoid valve A2 : To main valve (Travel junction P1 : From main pump
4. Travel speed solenoid valve valve) ACC : To accumulator
5. Swing holding brake solenoid A3 : To main valve (Merge-divider
valve valve)
6. 2-stage relief solenoid valve A4 : To both travel motors
A5 : To swing motor
10-122 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
1. Connector
2. Moving core
3. Coil
4. Spool
5. Block
6. Spring
OPERATION
WHEN SOLENOID IS TURNED OFF
• Since the signal current does not flow from the
controller, solenoid (3) is turned off.
Accordingly, spool (4) is pressed by spring (6)
against the left side.
By this operation, the pass from P to A is closed
and the hydraulic oil from the main pump does
not flow into the actuator.
At this time, the oil from the actuator is drained
through ports A and T into the tank.
WHEN SOLENOID IS TURNED ON

• The signal current flows from the controller to
solenoid (3), and the latter is turned on.
Accordingly, spool (4) is pressed against to the
right side.
By this operation, the hydraulic oil from the main
pump flows through port P and spool (4) to port
A, then flows into the actuator.
At this time, port T is closed and the oil does not
flow into the tank.
PC160LC-7 10-123
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATIONS
Gas capacity:300 cc (for PPC)
10-124 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETURN OIL FILTER
RETURN OIL FILTER

FOR BREAKER
1. Drain plug SPECIFICATIONS

2. Filter
3. Case Rated pressure : 6.9 MPa {70 kg/cm2}
4. Head cover Flow : 200 /min
5. Relief valve Relief valve cracking pressure:
0.34 ± 0.05 MPa
{3.5 ± 0.5 kg/cm2}
Filter mesh size : 6 µm
Filtering area : 4,570 cm2
PC160LC-7 10-125
ATTACHMENT CIRCUIT SELECTOR
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE
ATTACHMENT CIRCUIT SELECTOR VALVE
1. Spool V : To control valve

2. Spring T : To hydraulic tank
ATT : To attachment
ACC : To accumulator
P1 : From attachment circuit selector solenoid valve
TS : To hydraulic tank
Unit: mm
Replace spring if
3 Spool return spring Installed load Free length Installed load any damages or
side diameter length deformations are
833 N 666 N found
132.0 × 29 114.5 {85.0 kg}

{68.0 kg}
10-126 PC160LC-7
ATTACHMENT CIRCUIT SELECTOR
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE
Function
When a breaker is installed, the return oil from the
breaker does not pass through the main valve, but
returns directly to the hydraulic tank. When other
attachments (crusher, etc.) are installed, the attach-
ment and the main valve are interconnected.
Operation
1. When attachment other than breaker is
installed
Spool (1) is pushed fully to the left by the force of
spring (2), ATT port and port V are intercon-
nected, and ATT port and port T are shut off, so
the attachment and main valve are intercon-
nected.
2. When breaker is installed

When the pilot pressure from the attachment cir-
cuit selector solenoid valve overcomes the force
of spring (2), the spool (1) moves fully to the
right. ATT port and port V are shut off and ATT
port and port T are interconnected, so the oil
returning from the breaker does not pass through
the main valve, but passes through port T and
returns directly to the hydraulic tank.
PC160LC-7 10-127
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-128 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
Unit: mm

Tolerance Standard
Cylinder Standard size Repair limit
clearance
Shaft Hole
– 0.030 + 0.279
Clearance Boom 75 0.096 – 0.355 0.445
1 between piston rod – 0.076 + 0.065 Replace
bushing
and bushing – 0.030 + 0.222
Arm 85 0.083 – 0.312 0.445
– 0.090 + 0.047
– 0.030 + 0.259
Bucket 70 – 0.076 + 0.063 0.093 – 0.335 0.445
– 0.030 + 0.190
Boom 70 – 0.060 + 0.070 0.100 – 0.250 1.0
Clearance
between piston rod – 0.030 + 0.175
2 Arm 80 0.105 – 0.251 1.0
support pin and – 0.076 + 0.075
bushing
– 0.030 + 0.170
Bucket 70 0.100 – 0.246 1.0
– 0.076 + 0.070 Replace pin
– 0.030 + 0.190 or bushing
Boom 70 – 0.060 + 0.070 0.100 – 0.250 1.0
Clearance
between cylinder – 0.030 + 0.175
3 bottom support pin Arm 80 – 0.076 + 0.075 0.105 – 0.251 1.0
and bushing
– 0.030 + 0.170
Bucket 70 0.100 – 0.230 1.0
– 0.060 + 0.070
PC160LC-7 10-129
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
10-130 PC160LC-7
Unit: mm

Tolerance Standard
Clearance between connect- clearance
Shaft Hole
1 ing pin and bushing of revolv-
ing frame and boom
– 0.030 + 0.134
80 – 0.060 + 0.074 0.104 – 0.194 1.0
Clearance between connect-

– 0.030 + 0.136
2 ing pin and bushing of boom 80 0.106 – 0.196 1.0
– 0.060 + 0.076
and arm

– 0.030 + 0.158
3 ing pin and bushing of arm 70 0.108 – 0.234 1.0
– 0.076 + 0.078 Replace
and link
Clearance between connect- – 0.030 + 0.135

4 ing pin and bushing of arm 70 0.104 – 0.211 1.0
– 0.076 + 0.074
and bucket

5 ing pin and bushing of link 70 – 0.030 + 0.157 0.108 – 0.233 1.0
– 0.076 + 0.078
and bucket

– 0.030 + 0.154
6 ing pin and bushing of link 70 – 0.076 + 0.074 0.104 – 0.230 1.0
and link
PC160LC-7 10-131
1. DIMENSION OF ARM
10-132 PC160LC-7
Unit: mm
Model
No. PC160LC-7
+ 0.1
1 80 0
2 99.3 + 01.5
0
3 286– 0.5
– 0.036
4 90 – 0.071
5 414.7 ± 1.0
6 196.3 ± 0.5
7 747.4 ± 1.0
8 2,603
9 2,001.7 ± 1.0
10 330 ± 1.0
11 583 ± 0.5
12 524 ± 0.5
13 400.8
14 1,347
15 70
16 311.5 ± 1.0
17 70
0
Arm as individual part 276 – 0.5
18
When pressfitting bushing 310
Min. 1,501
19
Max. 2,528
PC160LC-7 10-133
2. DIMENSION OF BUCKET
10-134 PC160LC-7
Unit: mm
Model
No. PC160LC-7
1 400.5 ± 0.5
2 14.8 ± 0.5
3 97° 7’
4 400.8
5 1,334.7
6 180.7
7 –
8 0
+ 0.2
9 70 0
10 311.5 ± 1
11 50
12 96
13 440.5
14 18
15 130
16 160
17 135
18 112
19 80
20 80
21 339.5 ± 1
22 44
PC160LC-7 10-135
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Hot water pickup piping A. Fresh air

2. Air conditioner compressor B. Recirculated air
3. Condenser C. Hot air/cold air
4. Refrigerant piping
5. Receiver tank
6. Hot water return piping
7. Air conditioner unit
8. Duct
10-136 PC160LC-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Starting switch OUTLINE

2. Fuel control dial
• The engine can be started and stopped with only
3. Starting motor
starting switch (1).
4. Governor motor
• The engine throttle and pump controller(8) rev-
5. Linkage
eives the signal of fuel control dial (2) and trans-
6. Battery relay
mits the drive signal to governor motor (4) to
7. Battery
control the governor lever angle of fuel injection
8. Engine throttle and pump controller
pump (9) and control the engine speed.
9. Fuel injection pump
PC160LC-7 10-137
1. OPERATION OF SYSTEM
Starting engine
• When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start the
engine.
When this happens, the engine throttle and
pump controller checks the signal from the fuel
control dial and sets the engine speed to the
speed set by the fuel control dial.
Engine speed control

• The fuel control dial sends a signal to the engine
throttle and pump controller according to the
position of the dial. The engine throttle and pump
controller calculates the angle of the governor
motor according to this signal, and sends a sig-
nal to drive the governor motor so that it is at that
angle.
When this happens, the operating angle of the
governor motor is detected by the potentiometer,
and feedback is sent to the engine throttle and
pump controller, so that it can observe the opera-
tion of the governor motor.
Stopping engine
• When the starting switch is turned to the STOP
position, the engine throttle and pump controller
drives the governor motor so that the governor
lever is set to the NO INJECTION position.
• When this happens, to maintain the electric
power in the system until the engine stops com-
pletely, the engine throttle and pump controller
itself drives the battery relay.
10-138 PC160LC-7
2. COMPONENT
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
FUNCTION
• The fuel control dial is installed under the monitor
panel, and a potentiometer is installed under the
knob. The potentiometer shaft is turned by turn-
ing the knob.
• As the potentiometer shaft is turned, the resis-
tance of the variable resistor in the potentiometer
changes and a throttle signal is sent to the
engine throttle and pump controller.
The hatched area in the graph shown at right is
the abnormality detection area.
PC160LC-7 10-139
Governor motor
1. Potentiometer OPERATION
2. Cover
While motor is stopped
3. Shaft
• Electric power is applied to both phases A and B
4. Dust seal
of the motor.
5. Bearing
6. Motor
While motor is running
7. Gear
• The engine throttle and pump controller supplies
8. Connector
a pulse current to phases A and B, and the motor
revolves, synchronizing to the pulse.
FUNCTION
• The motor is turned according to the drive signal
from the engine throttle and pump controller to
control the governor lever of the fuel injection
pump.
This motor used as the motive power source is a
stepping motor.
• A potentiometer for feedback is installed to moni-
tor the operation of the motor.
• Revolution of the motor is transmitted through
the gear to the potentiometer.
10-140 PC160LC-7
Engine throttle and pump controller
10-142 PC160LC-7
Input and output signals
CN-1 CN-2 CN-3

Input/ Input/ Input/
Pin No. Signal name Pin No. Signal name Pin No. Signal name
output output output
CN1-1 NC Input CN2-1 NC Output CN3-1 VB (Controller PWR) Input
CN1-2 R pump pressure sensor Input CN2-2 Swing prolix SW Input CN3-2 VIS (Solenoid PWR) Input
CN1-3 NC Input CN2-3 NC Input SOL_COM
CN3-3
(Solenoid common GND)
CN1-4 Signal GND CN2-4 232C-RxD Input
CN3-4 Battery relay drive Output
Abnormal auto grease CN2-5 NC Input
CN1-5 controller Input
CN3-5 Governor motor phase A (+) Output
Overload alarm effective
CN1-6 NC Input CN2-6 SW Input
CN3-6 NC Output
CN1-7 Overload sensor (Analog) Input CN2-7 Model selection 4 Input CN3-7 Travel junction SOL Output
CN1-8 F pump pressure sensor Input ATT circuit selector SOL CN3-8 NC Output
CN2-8 Output
signal 1
CN1-9 NC Input CN3-9 Bucket CURL pressure SW Input
Low-temperature start
CN2-9 Output
CN1-10 Signal GND SOL relay CN3-10 Boom raise pressure SW Input
CN1-11 Knob SW Input CN2-10 NC Input
CN3-11 VB (Controller PWR) Input
CN1-12 NC Input CN2-11 NC Output
CN3-12 VIS (Solenoid PWR) Input
Governor motor FB CN2-12 CAN shield SOL_COM
CN1-13 Input CN3-13
potentiometer (Solenoid common GND)
CN2-13 Model selection 5 Input
CN1-14 NC Input
CN2-14 232C_TxD Output CN3-14 KEY_SIG Input
CN1-15 NC Input
CN2-15 NC Input CN3-15 Governor motor phase A (–) Output
CN1-16 SENS_PWR Output CN3-16 PC-EPC Output
Travel steering signal
CN2-16 pressure SW Input
CN1-17 Key SW (Terminal C) Input Pump merge-divider sole-
CN3-17 Output
CN1-18 NC Input CN2-17 Model selection 3 Input noid
CN2-18 NC Output CN3-18 Heater relay drive Output
CN1-19 Throttle potentiometer Input
Low water temperature CN2-19 NC Output CN3-19 Bucket dump pressure SW Input
CN1-20 Input
sensor CN3-20 Boom lower pressure SW Input
CN2-20 NC Input
CN1-21 GND (Analog GND)
Input/ CN3-21 GND (Controller GND)
CN2-21 S_NET output
CN1-22 POT_PWR Output CN3-22 VIS (Solenoid PWR) Input
CN2-22 CAN0_L Input/
CN1-23 Key SW (Terminal ACC) Input output SOL_COM
CN3-23
CN1-24 NC Input Input/ (Solenoid common GND)
CN2-23 CAN1_L output CN3-24 KEY_SIG Input
Flash memory write
CN2-24 permission signal Input CN3-25 Governor motor phase B (+) Output
CN2-25 NC Input Service flow adjustment

CN3-26 Output
EPC (1) *1
CN2-26 NC Input CN3-27 Travel Hi/Lo selector SOL Output
CN2-27 Model selection 2 Input CN3-28 2-stage relief SOL Output
CN2-28 NC Input CN3-29 Swing pressure SW Input
CN2-29 GND (Pulse GND) CN3-30 Arm IN pressure SW Input
CN2-30 NC Input CN3-31 GND (Controller GND)
CN2-31 GND (S_NET GND) CN3-32 GND (Controller GND)
CN2-32 CANO_H Input/
output CN3-33 GND (Controller GND)
Input/ CN3-34 NC
CN2-33 CAN1_H
output
CN3-35 Governor motor phase B (–) Output
CN2-34 GND (232C GND)
CN3-36 NC Output
Service valve pressure
CN2-35 SW *1 Input
CN3-37 Swing holding brake SOL Output
CN2-36 NC Input CN3-38 NC Output
CN2-37 Model selection 1 Input CN3-39 Travel pressure SW Input
CN2-38 Swing lock SW Input CN3-40 Arm OUT pressure SW Input
CN2-39 GND (Pulse GND) Input
*1. Only ATT specification
CN2-40 Engine speed sensor Input
*1. Only ATT specification
PC160LC-7 10-143
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM

Control function
1
Engine/Pump composite control function
2
Pump/Valve control function
3
One-touch power maximizing function
4
Auto-deceleration function
5
Auto-warm-up/Overheat prevention function
Electronic control system

6
Low-temperature engine startability improving function
7
Swing control function
8
Travel control function
9
ATT flow control, circuit selector function (if equipped)
Self-diagnosis function
★ For the self-diagnosis function, see "TROUBLE SHOOTING".
PC160LC-7 10-145
MACHINE CONTROL SYSTEM DIAGRAM
10-146 PC160LC-7
PC160LC-7 10-147
1. Engine and Pump control function
10-148 PC160LC-7
FUNCTION
• The operator can set the work mode switch on
the monitor panel to mode A, E, B and L and
select proper engine torque and pump absorp-
tion torque according to the type of work.
• The engine throttle and pump controller detects
the speed of the engine governor set with the
fuel control dial and the actual engine speed and
controls them so that the pump will absorb all the
torque at each output point of the engine,
according to the pump absorption torque set in
each mode.
PC160LC-7 10-149
1) Control method in each mode
Mode A
• Matching point in mode A: Rated speed
Model
Mode PC160LC-7
Travel A 82 kW/2,150 rpm {110 HP/2,150 rpm}

Work A 81 kW/2,036 rpm {108 HP/2,036 rpm}
• If the pump load increases and the pressure

rises, the engine speed lowers. At this time,
the pump discharge is reduced and con-
trolled so that the engine speed will be near
the rated output point.
If the pressure lowers in reverse, the pump
discharge is increased and control so that
the engine speed will be near the rated out-
put point.
These operations are repeated to keep the
engine speed near the rated output point.
10-150 PC160LC-7
Mode E / Mode B / Mode L

Mode E B L
Partial output point 91% 75% 65%
Model PC160LC-7
Mode E 73.5 kW/1,870 rpm {99 HP/1,870 rpm}
Mode B 60.3 kW/1,860 rpm {81 HP/1,860 rpm}
Mode L 52.2 kW/1,573 rpm {70 HP/1,573 rtpm}
• At this time, the controller keeps the pump

absorption torque along the constant horse-
power curve and lower the engine speed by
the composite control of the engine and
pump.
• By this method, the engine is used in the low
fuel consumption area.
PC160LC-7 10-151
2) Function to control pump during travel

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

pump drive switch is turned ON
• Even if the controller or a sensor has a trou-
ble, the functions of the machine can be
secured with pump absorption torque almost
equivalent to mode E by turning on emer-
gency pump drive switch (10).
In this case, a constant current flows from
the battery to the PC-EPC valve and the oil
pressure is sensed by only the PC-EPC
valve.
10-152 PC160LC-7
2. Pump/Valve control function
FUNCTION
• The machine is matched to various types of work
properly with the 2-stage relief function to
increase the digging force, etc.
PC160LC-7 10-153
1) Cut-off function
• When the cut-off function is turned on, the
PC-EPC current is increased to near the
maximum value.
By this operation, the flow rate in the relief
state is lowered to reduce fuel consumption.
• Operating condition for turning on cut-off
function.
Condition
• The average value of the front and rear pres-
sure sensors is above 27.9 MPa {285 kg/cm2}
and the one-touch power maximizing function is
not turned on
The cut-off function does not work, however,
while the machine is traveling in mode A, the
lock switch is turned on, or the arm IN switch is
turned on.
2) 2-stage relief function

• The relief pressure in the normal work is 34.8
MPa {355 kg/cm2}. If the 2-stage relief func-
tion is turned on, however, the relief pressure
rises to about 37.2 MPa {380 kg/cm2}.
By this operation, the hydraulic force is
increased further.
• Operating condition for turning on 2-stage
relief function
Condition Relief pressure
• During travel
• When swing lock switch is 34.8 MPa
turned on {355 kg/cm2}
• When boom is lowered ⇓
• When one-touch power maxi- 37.2 MPa
mizing function is turned on {380 kg/cm2}
• When L mode is operated
10-154 PC160LC-7
3. One-touch power maximizing function
FUNCTION
• Power can be increased for a certain time by
operating the left knob switch.
PC160LC-7 10-155
1) One-touch power maximizing function

• When the operator needs more digging force
to dig up a large rock, etc., if the left knob
switch is pressed, the hydraulic force is
increased about 7% to increase the digging
force.
• If the left knob switch is turned on in working
mode "A" or "E", each function is set auto-
matically as shown below.
⇓
Software cut-off function
Working Engine/Pump
2-stage relief function Operation time
mode control
34.8 MPa {355 kg/cm2}
Matching at rated Automatically
A, E ⇓ Cancel
output point reset at 8.5 sec
37.2 MPa {380 kg/cm2}
10-156 PC160LC-7
4. Auto-deceleration function
FUNCTION
• If the all control levers are set in NEUTRAL while
waiting for a dump truck or work, the engine
speed is lowered to the medium level automati-
cally to reduce the fuel consumption and noise.
• If any lever is operated, the engine speed rises
to the set level instantly.
PC160LC-7 10-157
OPERATION
When control levers are set in neutral
• If all the control levers are set in NEUTRAL while
the engine speed is above the decelerator oper-
ation level (about 1,400 rpm), the engine speed
lowers instantly to the first deceleration level
about 100 rpm lower than the set speed.
• If 4 more seconds pass, the engine speed lowers
to the second deceleration level (about 1,400
rpm) and keeps at that level until any lever is
operated again.
When any control lever is operated

• If any control lever is operated while the engine
speed is kept at the second deceleration level,
the engine speed rises instantly to the level set
with the fuel control dial.
10-158 PC160LC-7
5. Auto-warm-up/Overheat prevention function
FUNCTION
• After the engine is started, if the engine cooling
water temperature is low, the engine speed is
raised automatically to warm up the engine. If
the engine cooling water temperature rises too
high during work, the pump load is reduced to
prevent overheating.
PC160LC-7 10-159
1) Auto-warm-up function
• After the engine is started, if the engine cool-
ing water temperature is low, the engine
speed is raised automatically to warm up the
engine.
Operating condition (All) Operated
Water temperature: Below 30°C.

Engine speed: Max. 1,200 rpm ⇒ Engine speed: Max. 1,200 rpm
⇓
Resetting condition (Any one) Reset
⇒
Water temperature: Above 30°C
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec. or
Manual
longer
2) Overheat prevention function • This function is turned on when the water

• If the engine cooling water temperature or temperature rises above 95°C.
the hydraulic oil temperature rises too high,
th e p u m p l o a d an d e n g i n e s p e e d a r e
reduced to prevent overheating and protect
the engine and hydraulic equipment.
Operating condition Operation/Remedy Resetting condition

Water and oil temperature: Below
105?C
⇒ ⇒
Work mode: Any mode Fuel control dial: Return to low
Water and oil temper- Engine speed: Low idle idle position once.
ature: Above 105°C Monitor alarm lamp: Lights up • Under above condition, control-
Alarm buzzer: Sounds ler is set to condition before
operation of function. (Manual
reset)

Water and oil temperature: Below
Work mode: Mode A, E,
⇒ ⇒
102°C
OR B
Water and oil temper- • Under above condition, control-
Engine speed: Keep as is.
ature: Above 102°C ler is set to condition before
Monitor alarm lamp: Lights up.
operation of function. (Auto-
Lower pump discharge.
matic reset)

Water and oil temperature:
⇒ ⇒
Work mode: Mode A Below 100°C
Lower pump discharge.
matic reset)

Water and oil temperature:
⇒ ⇒
Work mode: Travel Below 97°C
Lower travel speed.
matic reset)
10-160 PC160LC-7
6. Low-temperature engine startability improving function
FUNCTION
• When the engine is started, if the engine cooling
water temperature is low (below 0°C), the low-
temperature starting solenoid is turned on to
increase the fuel injection ratio temporarily so
that the engine will start easily. (The condition
for turning on this function is different from that
for turning on the auto-warm-up function. A spe-
cial water temperature sensor is used for this
function.)
PC160LC-7 10-161
7. Swing control function
FUNCTION
The swing lock and swing holding brake functions
are installed.
10-162 PC160LC-7
1) Swing lock and swing holding brake func- 2) Quick hydraulic oil warm-up function
tions when swing lock switch is turned on
• The swing lock function (manual) is used to • If swing lock switch (4) is turned on, the
lock the machine from swinging at any posi- pump-cut function is cancelled and the relief
tion. pressure rises from 34.8 MPa {355 kg/cmð}
The swing holding brake function (automatic) to 37.2 MPa {380 kg/cmð}. If the work equip-
is interlocked with the swing operation and ment is relieved under this condition, the
used to prevent hydraulic drift while the hydraulic oil temperature rises quickly and
machine is not swinging. the warm-up time can be shortened.
• Swing lock switch and swing lock/holding
brake
Lock Lock
Function Operation
switch lamp
If swing lever is set in neu-
tral, swing brake operates in
Swing
about 5 sec. If swing lever
OFF OFF holding
is operated, brake is
brake
released and machine can
swing freely.
Swing lock operates and
machine is locked from
Swing swinging. Even if swing
ON ON
lock lever is operated, swing lock
is not reset and machine
does not swing.
Operation of swing holding brake release

switch
• If the controller, etc. has a problem, the
swing holding brake does not work normally,
and the machine cannot swing, the swing
lock can be reset with the swing holding
brake release switch.
Swing holding ON OFF
brake release (When control has (When controller is
switch trouble) normal)
Swing lock
ON OFF ON OFF
switch
Swing Swing Swing Swing
lock is lock is lock is holding
Swing brake turned canceled. turned brake is
on. on. turned
on.
★ If the swing lock is reset, swinging is stopped

by only the hydraulic brake of the safety
valve. Accordingly, if swinging is stopped on
a slope, the upper structure may drift hydrau-
lically.
PC160LC-7 10-163
8. Travel control function
FUNCTION
• The pumps are controlled and the travel speed is
changed manually or automatically, to secure
proper travel performance matched to the type of
work and jobsite during travel.
10-164 PC160LC-7
1) Pump control function during travel

• If the machine travels in a work mode other
than mode A, the work mode and the engine
speed are kept as they are and the pump
absorption torque is increased.
★ For details, see ENGINE/PUMP COMPOS-
ITE CONTROL FUNCTION.
2) Travel speed change function

i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo, and Hi, the governor/pump
controller controls the pump capacity and
motor capacity at each gear speed as
shown at right to change the travel
speed.
Travel speed Lo Hi
switch (Low speed) (High speed)
Pump capacity (%) 100 100
Motor capacity Max. Min.
Travel speed
3.4 5.5
(km/h)
ii) Automatic change by engine speed

If the engine speed is lowered to 1,500
rpm or less with the fuel control dial dur-
ing travel;
• The travel speed does not change even if
the travel speed switch is changed from
Lo to Hi.
• The travel speed changes to Lo automat-
ically if the travel speed has been Hi.
iii) Automatic change by pump discharge
pressure
While the machine is traveling with the
travel speed switch at Hi, if the load is
increased because of an upslope
ground, etc. and the travel pressure
keeps above 29.4 MPa {300 kg/cm2} for
0.5 seconds, the travel motor capacity is
changed automatically and the travel
speed is lowered (to the Lo level).
While the machine is traveling at the Lo
speed on an upslope ground with the
travel speed switch at Hi, if the load is
reduced on a flat or downslope ground
and the travel pressure keeps below 15.3
MPa {156 kg/cm2} for 0.5 seconds, the
travel motor capacity is changed auto-
matically and the travel speed is set to
the Hi level again.
PC160LC-7 10-165
9. ATT flow control, circuit selector function

(if equipped)
FUNCTION
This function is available only with the ATT specifica-
tion. The function acts as follows according to the
flow command and working mode from the monitor.
1) It throttles the ATT PPC pressure and controls
the flow when the pedal is depressed fully.
2) In mode B and the other modes, it switches to
ATT single acting (B) or double acting (other
modes).
10-166 PC160LC-7
10. System component parts

1) Engine revolution sensor
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
FUNCTION
• The engine revolution sensor is installed to the
ring gear of the engine flywheel. It electrically
calculates the number of the gear teeth which
pass in front of it and transmits the result to the
engine throttle and pump controller.
• A magnet is used to sense the gear teeth. Each
time a gear tooth passes in front of the magnet, a
current is generated.
PC160LC-7 10-167
2) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
SPECIFICATIONS
Type of contacts: Normally open contacts
Operating (ON) pressure: 0.5 ± 0.1 MPa
{5.0 ± 1.0 kg/cm2}
Resetting (OFF) Pressure:0.3 ± 0.5 MPa
{3.0 ± 0.5 kg/cm2}
FUNCTION
• The junction block has 9 pressure switches,
which check the operating condition of each
actuator by the PPC pressure and transmit it to
the engine throttle and pump controller.
10-168 PC160LC-7
3) Pump pressure sensor
1. Sensor
2. Connector
FUNCTION
• The pump pressure sensor is installed to the inlet
circuit of the control valve. It converts the pump
discharge pressure into a voltage and transmits
it to the engine thtottle and pump controller.
OPERATION
• The oil pressure applied from the pressure intake
part presses the diaphragm of the oil pressure
sensor, the diaphragm is deformed.
• The gauge layer facing the diaphragm measures
the deformation of the diaphragm by the change
of its resistance, then converts the change of the
resistance into a voltage and transmits it to the
amplifier (voltage amplifier).
• The amplifier amplifies the received voltage and
transmits it to the engine throttle and pump con-
troller.
• Relationship between pressure P (MPa {kg/
cm2}) and output voltage (V) is as follows.
V = 0.08 {0.008} x P + 0.5
PC160LC-7 10-169
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MULTI MONITOR SYSTEM
• The monitor system monitors the condition of the • The monitor panel also has various mode selec-
machine with sensors installed on various parts tor switches and functions to operate the
of the machine. It processes and immediately machine control system.
displays the obtained information on the panel
notifying the operator of the condition of the
machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles
2. Gauge section to display the condition con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
10-170 PC160LC-7
Monitor panel
OUTLINE
• The monitor panel has the functions to display
various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Process-
ing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
PC160LC-7 10-171
Input and output signals
CN-1 CN-2 CN-3

Pin Input/ Pin Input/ Pin Input/
Signal name Signal name Signal name
No. output No. output No. output
1 Key ON Input 1 Engine coolant temperature Input 1 NC Input
2 Key ON Input 2 Fuel level Input 2 NC Input
3 Washer motor output Output 3 Radiator coolant level Input 3 NC Input
4 Starting signal Input 4 (Hydraulic oil level) Input 4 NC Input
5 Limit switch (W) Input 5 Air cleaner clogging Input 5 NC Input
6 GND 6 NC Input 6 NC Input
7 GND 7 Engine oil pressure Input 7 RS230C CTS Input
8 VB + Input 8 Engine oil level Input 8 RS230C RXD Input
9 Wiper motor (+) Output Input/ Input/
9 N/W signal 9 RS230C RXD
10 Wiper motor (–) Output Output Output
11 Buzzer ON signal Input Input/ Input/
10 N/W signal Output 10 RS230C RXD Output
12 Limit switch (P) Input
11 Battery charge Input 11 BOOTSW Input
Hydraulic oil temperature 12 NC Input
12 Input
(analog) 13 GND
13 GND (for analog signal) 14 CAN (SHIELD) Input
14 Personal code relay Output 15 CAN (+) Input
15 Limit SW (window) Input 16 CAN (–) Input
16 Buzzer cancel Input
17 Swing lock Input
18 Preheat Input
19 Light switch Input
20 N/W GND
10-172 PC160LC-7
(5)
MONITOR CONTROL, DISPLAY PORTION

MONITOR PORTION
1. Wiper motor 10. Fuel gauge

2. Preheating monitor 11. Fuel level monitor
3. Swing lock monitor 12. Hydraulic oil temperature monitor
4. Engine coolant temperature monitor 13. Power max. monitor
5. Hydraulic oil temperature gauge 14. Auto-deceleration monitor
6. Engine coolant temperature gauge 15. Engine oil pressure caution
7. Working mode monitor 16. Battery charge caution
8. Service monitor 17. Radiator coolant level caution
9. Travel speed monitor 18. Engine oil level caution
19. Air cleaner clogging
20. Maintenance time warning caution
PC160LC-7 10-173
(5)
MONITOR ITEMS AND DISPLAY
Symbol Display item Display method
Swing holding brake

Swing lock switch release switch Swing lock monitor
OFF OFF OFF
Swing lock ON OFF ON
OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status
Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Power Max. switch status Power max. monitor status

Lights up but goes out after approx. 9
Power Max. Being pressed
sec. when kept pressed
Not being pressed Flashes
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
10-174 PC160LC-7
Gauge Range Temperature, volume Indicator Buzzer sound
A1 105 Red
A2 102 Red
A3 100 Green
Engine coolant tem-
perature (°C)
A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
B3 100 Green
Hydraulic oil tempera-
ture (°C)
B4 80 Green
B5 40 Green
B6 20 White
C1 289 Green
C2 244.5 Green
C3 200 Green
Fuel level ( )
C4 100 Green
C5 60 Green
C6 41 Red
PC160LC-7 10-175
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil
temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are dis-
played.
Check before
Symbol Display item starting item When engine is stopped When engine is running
Engine oil pressure q —

When abnormal, lights
up and buzzer sounds
Battery charge q —
Lights up when
abnormal
Radiator coolant level q Lights up when

abnormal
When abnormal, lights
up and buzzer sounds
Engine oil level q Lights up when

abnormal
—
Air cleaner clogging q —

Lights up when
abnormal
Lights up when there is a warning. Lights up for

Maintenance only 30 sec. after key is turned ON, then goes out.
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is dis-
played.
Condition of hydraulic oil Color of symbol

Low temperature (below B6 or equivalent) Black on white background
Normal (B6 – B2) No display
High temperature (below B2) White on red letters
10-176 PC160LC-7
(5)
Display category Symbol Display item Display range Display method
INT ON OFF Displays set

Wiper condition
Working Displays set

mode mode
Monitor
Travel speed Displays set

speed
Displays
Auto- actuation
deceleration ON OFF
status
Lights up when
Service meter Service meter When service meter is working service meter
indicator is working
PC160LC-7 10-177
(5)
SWITCHES
1. Working mode selector switch

2. Selector switch
3. LC monitor adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
10-178 PC160LC-7
• Working mode selector switch

The condition of the machine changes according Switch that is Working mode status
Display
to the switch that is pressed (A, E, L, B). It is pos- pressed after setting
sible to check the condition on the working mode [A] A A mode (default)
monitor display. The relationship between each
working mode and the monitor display is shown [E] E E mode
in the table on the right. [L] L L mode
• Selector switch [B] B B mode

This is used when making detailed settings in
each working mode. (For details, see ATTACH-
MENT FLOW CONTROL FUNCTION for modes
A and E.)
• Maintenance switch
Check the condition of the maintenance items.
(For details, see MAINTENANCE FUNCTION.)
• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON → OFF → ON → • • •.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically set
to ON.
• Travel speed selector switch Display Setting

Each time the travel speed selector switch is Crawler symbol + Lo Low speed (default)
pressed, the travel speed changes.
Lo → Hi → Lo → • • • Crawler symbol + Hi High speed
Use the travel speed monitor display to check
the present condition.
The relationship between the set speed and the
monitor display in the table on the right.
• Wiper switch Wiper actuation

Display Setting
status
Each time the wiper switch is pressed, the wiper
setting changes OFF → INT → ON → OFF → • • • Stowing stopped
None OFF
or now stowing
Use the wiper monitor display to check the
present condition. Intermittent
Wiper symbol + INT INT
actuation
The relationship between the wiper setting and
the monitor display is as shown in the table on Continuous
Wiper symbol + ON ON
actuation
the right.
PC160LC-7 10-179
• Window washer switch

While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.
• Control switch
This is used for control when using the mainte-
nance function or select function.
(For details, see each function.)
• LC monitor adjustment switch

Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)
10-180 PC160LC-7
SELECT MODE FUNCTION

• This is used when setting the flow in each work-
ing mode. It is possible to make the setting when
genuine attachment piping is installed and the
initial value setting function on the service menu
h a s b e e n u s e d t o s e t t o AT TA C H M E N T
INSTALLED.
• It is possible to check on the working mode mon-
itor if this function can be set.
Working mode Monitor display
A mode [A] + crusher symbol
E mode [E] + crusher symbol
B mode [B] + flow symbol
METHOD OF USE
★ Carry out the setting on the normal screen
1. A mode, E mode
1) Press select switch (1) on the monitor to
move to the adjustment screen.
2) Press control switch (2) to select the flow
level.
Control switch Actuation
Flow level bar graph

extends to the right

retracts to the left
3) After completing the level selection, press

input confirmation switch (3).
The selection flow level is confirmed and the
screen moves to the normal screen.
From the moment that the flow level is Flow level Flow ( /min.) Remarks
selected, the content of the selection is
reflected for the attachment flow. 8 290 ★ Default
★ Before the input confirmation switch is 7 240
pressed, the flow levelis not confirmed,
so press return switch (4) to return to the 6 170
normal screen. This function can be used 5 120
to return to the previously set flow.
The relationship between the set flow 4 100
level and the flow value is as shown in 3 80
the table on the right.
2 55
1 30
PC160LC-7 10-181
2. B mode
1) Press select switch (1) on the monitor to
move to the screen for selecting the 3-stage
flow level.
2) Press control switch (2), or input [01] - [03]
with the numeral 10-key pad to choose one
on the three flow levels.
No. 10-key pad operation
01 →
02 →
03 →

The selected flow level is selected.
★ Before the input confirmation switch is
pressed, the flow level is not confirmed,
so press return switch (4) to return to the
operator screen. This function can be
used to return to the previously set flow. No. Flow level (L/min.) Remarks
4) After the flow level is confirmed, the screen 01 140 ★ Default
changes to the screen shown in the diagram
on the right. 02 100
With this screen, it is possible to make fine
03 600
adjustment to the flow.
5) Press control switch (2) and select the flow
level.


10-182 PC160LC-7

When flow When flow When flow
The selected flow level is confirmed and the Flow
Remarks
level is 60 / is 100 / is 140 /
screen moves to the operator screen. min. min. min.
From the moment that the flow level is
7 90 130 170 Default
selected, the content of the selection is
reflected for the attachment flow. 6 80 120 160
★ Before the input confirmation switch is
pressed, the flow level is not confirmed, 5 70 110 150
se press return switch (4) to return to the 4 60 100 140
normal screen. This function can be used
to return to the previously set flow. 3 50 90 130
The relationship between the set flow 2 40 80 120
level and the flow value is as shown in
the table on the right. 1 30 70 110
7) Check the set value with the working mode
monitor.
The relationship between the display level
Display level Set value ( /min.)
and the set value is as shown in the table on
the right, and it is possible to check the level 8 160 or 170
of the flow that can be set.
7 140 or 150
6 120 or 130
5 100 or 110
4 80 or 90
3 60 or 70
2 40 or 50
1 70
PC160LC-7 10-183
MAINTENANCE FUNCTION
When the maintenance time for replacement,
inspection, or filling has approached for the 10 main-
tenance items, press maintenance switch (1) and the
caution display (yellow or red) appears on the moni-
tor display for 30 seconds after the key is turned ON
to remind the operator to carry out lubrication main-
tenance.
★ Maintenance items
No. Item Replacement inter-

val (hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic filter 1000
05 Hydraulic tank breather 500
06 Corrosion resistor (1000)

07 Damper case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
Option, so not set
★ The above replacement intervals are set for each

item, and the time remaining to maintenance is
reduced as the machine is operated.
The content of the caution display differs accord-
ing to the ramaining time. The relationship is as
shown in the table below.
Display Condition
Remaining time for main-
None tenance for all items is
more than 30 hours
There is one or more
Notice display (black sym-
items with less than 30
bol displayed on yellow
hours remaining time for
background)
maintenance
There is one or more
Warning display (wiper
items with less than 0
symbol displayed on red
hours remaining time for
background)
maintenance
10-184 PC160LC-7
METHOD OF CHECKING STATUS

MAINTENANCE ITEMS
★ Operate as follows when on the operator screen.
1. Press maintenance switch (1) and switch to the
maintenance list display screen.
★ The maintencance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad to
input the number (01 – 10) of the maintenance
item to select the item.
★ The cursor moves and the item is high-
lighted.
★ The display method is the same as
described on the previous page (relationship
between remaining time and caution dis-
play). If the remaining time is less than 30
hours, the item is displayed in yellow, and if it
is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION
1. After completing the selection, press input confir-
mation switch (3).
The screen will change to the maintenance reset
screen.
2. Use the maintenance reset screen to check the
content, and if there is any problem, press input
confirmation switch (3) to move to the check
screen.
If the wrong item is selected, press return switch
(4) to return to the maintenance list screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen returns
to the maintenance list display screen. To check
the remaining time, or if the wrong item is
selected, press return switch (4) to return to the
maintenance list screen.
★ The check screen shows the symbol for the
maintenance item and the set time in large
letters.
★ The background color of the symbol for the
item where the maintenance tiem was reset
is the same as the background of the screen,
so it is possible to check that it has been
reset.
PC160LC-7 10-185
BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION
This function is used to adjust the brightness and
contrast of the LC monitor.
ADJUSTMENT METHOD
★ Operate as follows when on the operator screen.
1. Press LC monitor adjustment switch (1) and
switch to the adjustment screen.
★ Relationship between menu symbol and content.
No. Symbol Content
01 Return mark Return
02 Contrast
03 Brightness
2. Press control switch (2), or use the 10-key pad to

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


10-186 PC160LC-7
SERVICE METER CHECK FUNCTION

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

• On the password input screen or on the normal
screen, if monitor return switch (1) and working
mode (A) switch are kept pressed at the same
time, all the LCD display will light up and the
whole screen will become white, so the display
can be checked.
• If any part of the display is black, the LCD is bro-
ken.
PC160LC-7 10-187
USER CODE DISPLAY FUNCTION

• If there is any problem in operating the machine,
the user code is displayed on the monitor to
advise the operator of the steps to take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis-
played on the portion for the hydraulic oil temper-
ature gauge.
• If more than one user code is generated at the

same time, the user codes are displayed in turn
for 2 seconds each to display all the user codes.
10-188 PC160LC-7
• While the user code is being displayed, if the

input confirmation switch is pressed, the service
code and failure code can be displayed.
• If there is more than one service code or failure

code, the display switches every 2 seconds and
displays all the service codes/failure codes that
caused the user code to be displayed.
Even if service codes/failure codes have
occurred, if they did not cause the user code to
be displayed, this function does not display
them.
• If the telephone number has been set using the

telephone number input on the service menu, it
is possible to switch on the service code/failure
code and display the telephone symbol and tele-
phone number.
For details of inputting and setting the telephone
number, see SPECIAL FUNCTIONS OF MONI-
TOR PANEL in the TESTING AND ADJUSTING
section.
PC160LC-7 10-189
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
7-SEGMENT MONITOR SYSTEM
• The monitor system monitors the condition of the • The monitor panel also has various mode selec-
machine with sensors installed on various parts tor switches and functions to operate the
of the machine. It processes and immediately machine control system.
displays the obtained information on the panel
notifying the operator of the condition of the
machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles
2. Gauge section to display the condition con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
PC160LC-7 10-191
(3)
1. Monitor panel
OUTLINE INPUT AND OUTPUT SIGNALS

• The monitor panel has the functions to display
CN-P01 CN-P02
various items and the functions to select modes
Pin Pin
and electric parts. No.
Signal neme
No.
Signal Name
The monitor panel has a CPU (Central Process- 1 Key switch (Battery) 1 Engine water temperature
ing Unit) in it to process, display, and output the 2 Key switch (Battery) 2 Fuel
information. 3 Washer motor output 3 Radiator water level
The monitor display unit consists of LCD (Liquid 4 Key switch (Terminal C) 4 NC
Crystal Display) and LED (Light Emitting Diode). 5 Wiper contact W 5 Air cleaner clogging sensor
The switches are flat sheet switches. 6 GND 6 NC
7 GND 7 Engine oil pressure sensor
8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (–) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
13 GND (For analog signal)
14 NC
15 Wind limit switch
16 Buzzer cancel
17 Swing lock
18 Preheating
19 Limit switch
20 Network (GND)
10-192 PC160LC-7
(3)
Display section of monitor
1. Service meter display

2. Coolant temperature gauge
3. Coolant temperature caution
4. Digital meter display
(Service code and user code are displayed when trouble occurs)
5. Fuel level caution
6. Fuel level gauge
7. Engine oil level caution lamp
8. Preheating pilot lamp
9. Swing holding brake pilot lamp
10. Oil maintenance pilot lamp
11. Battery charge caution lamp
12. Air cleaner clogging caution lamp
13. Engine oil pressure caution lamp
PC160LC-7 10-193
(3)
Monitored items and display
Symbol Displayed item Display range When engine is stopped While engine is running
Max. 1,500 rpm Lights when normal.

Max. 0.05 MPa (Goes off when
{0.5 kg/cm²} engine is started.) Flashes and buzzer
Engine oil pressure
Min. 1,500 rpm sounds when abnormal.
Max. 0.15 MPa
{1.5 kg/cm²}
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
Lights when normal.

When charge is (Goes off when
Charge level engine is started.) Flashes when abnormal.
abnormal
Flashes when abnor-

Engine oil level Below low level Goes off.
mal.
SAP00523
Lights up when swing is locked. Flashes when

Packing (Swing lock) When swing is locked
swing holding brake release switch is turned on.
SAT00098
Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.
Lights up for 30 sec. when starting switch is set to

Preheating When preheated HEAT. Then, flashes for 10 sec. to indicated com-
SAP00526
pletion of preheating.
Flashes at 102°C or higher. Flashes and

Coolant temperature
buzzer sounds at 105°C or higher.
Fuel level Flashes when below low level.
10-194 PC160LC-7
(3)
Oil maintenance function
1. Function and operation

At a set time after the engine oil is replaced, the
oil maintenance function is turned on to notify the
operator by the LED lamp on the monitor panel
that it is time to replace the oil. The function to
indicate the phone number of the place to make
contact for service on the LCD unit is installed,
too.
1) Check of elapsed time
Nothing is displayed normally until point B
shown in the figure at right after this function
is reset. If the key is turned on with the
buzzer cancel switch processed (for 2.5 sec-
onds), however, the elapsed time is dis-
played on the service meter section.
2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval

1) The time interval is set in the interval setting
mode. It can be set to "125h", "250h", "500h",
"Not set", or "Demo-mode". The default is
"Not set".
2) To enter the interval setting mode, press and
hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in the
interval setting mode, the clock display sec-
tion changes to "—" o "125" o "250" o
"500" o "d" in order. ("—" corresponds to
"Not set" and "d" corresponds to "Demo-
mode".)
4) To save the time interval, set a desired time
(mode) on the monitor panel and press and
hold the clock switch for 2.5 seconds.
PC160LC-7 10-195
(3)
3. Timing and contents of display

1) When replacement of oil is displayed
The elapsed time is displayed for 10 seconds
after all segments are turned on. Phone
number is displayed for the next 10 seconds.
If the phone number has not been input,
however, the elapsed time is displayed for 20
seconds after all segments are turned on.
2) When elapsed time is checked
The elapsed time is displayed for 10 seconds
after all segments are turned on.
4. Resetting elapsed time

1) When the replacement of oil and elapsed
time are displayed, press the buzzer cancel
switch 10 seconds after all segments are
turned on (while the elapsed time is dis-
played) and hold for 3 seconds. The elapsed
time is reset. After this operation, "0h" is dis-
played for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and replace-
ment of oil is displayed when the key is
turned on. The elapsed time does not
increase, however. The time can be reset in
this mode. Turn on the key 3 times in this
mode, and the time interval is automatically
set to "Not set" at the 4th time and after. The
elapsed time is set to "0h" and counting of
elapsed time is started.
10-196 PC160LC-7
(3)
Mode selector switches
1. Travel speed switch

2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch
(Including setting switch)
• There are 4 sets of the mode selector switches Operations table of switch section
on the switch section. Each time one switch is
pressed, the machine condition changes. The a The bold letters are the positions of the switches
current condition is indicated by the lighting of reset when the starting switch is turned on.
the LED above the switch.
Item Operation
• The initial setting of only the work mode after the
starting switch is turned on can be changed. Work mode Ai
oEi
oB
a For how to change the setting, see "Work mode
Auto-deceleration ON i
o OFF
default setting mode" in TROUBLESHOOTING-
Display and special functions of monitor panel. Wiper OFF i
o Intermittent i
o ON
Travel speed Hi i
o Lo
PC160LC-7 10-197
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of contact
type is always connected to the chassis ground.
Sensor When When

name Type of sensor normal abnormal
Engine oil Contact ON OFF
level (Closed) (Open)
Engine oil OFF ON
pressure Contact (Open) (Closed)
Hydraulic
oil tem- Resistance — —
perature
Coolant
tempera- Resistance — —
ture
Fuel level Resistance — —
Air cleaner ON OFF
clogging Contact (Closed) (Open)
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)

1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
10-198 PC160LC-7
(5)
Hydraulic oil temperature sensor (for normal temperature)
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
2. Body 5. Wire
Coolant temperature sensor
2. Body 5. Wire
PC160LC-7 10-199
(3)
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
10-200 PC160LC-7
(3)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE

Standard value table for engine related parts ........ 20- 2
Standard value table for chassis related parts......... 20- 3
TESTING AND ADJUSTING.................................. 20-101
TROUBLESHOOTING ........................................... 20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety
pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
PC160LC-7 20-1
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Applicable model PC160LC-7
Engine SAA4D102E-2
Standard value Service limit

Item Measurement condition Unit
for new machine value
High idling 2,350 ± 70 2,350 ± 70
Engine speed Low idling rpm 1,030 ± 50 1,030 ± 50
Rated speed 2,200 2,200
At sudden acceleration Bosch Max. 1.0 Max. 2.0

Exhaust gas color
At high idling index Max. 0.5 Max. 1.5
Valve clearance Intake valve 0.25 —

mm
(Normal temperature) Exhaust valve 0.51 —
Difference
Oil temperature: 40 – 60ºC MPa Min. 2.4 between cyinders
Compression pressure
Engine speed: 250rpm {kg/cm2} {Min. 24.6} Min. 1.0
{Min. 10.3}
(Water temperature: operating range) kPa Max. 1.2 5.1

Blow-by pressure
At rated output {mmH2O} {Max. 123} {520}
(Water temperature: operating range)

At high idling MPa 0.39 – 0.64 0.25
Oil pressure
{4.0 – 6.5} {2.6}
(SAE15W-40)
At low idling {kg/cm2} Min. 0.15 0.09
{Min. 1.5} {0.9}
Oil temperature Whole speed range (inside oil pan) ºC 80 – 110 120
Fuel injection timing Before Top Dead Center °(degree) 11 ± 1 11 ± 1
Fan belt tension mm 8 Min. 6, Max. 10

Deflection when pressed with finger
Air conditioner force of approx. 58.8 N{6 kg} mm 5–8 5–8
compressor belt tension
20-2 PC160LC-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
• Engine water temperature:
Within operation range
• Hydraulic oil temperature: Within
Pump at relief 2,145 ± 100 2,145 ±1 00
operation range
• Engine at high idling
• Arm OUT relief condition
• Engine water temperature:
Engine speed
Within operation range

At pump relief + one touch rpm
operation range 2,055 ± 100 2,055 ± 100
power up
• Arm OUT relief + One-touch power
max. switch in ON condition
• Auto-deceleration switch in ON
Speed when auto-
condition 1,400 ± 100 1,400 ± 100
deceleration is operated
• All control levers in NEUTRAL
condition
RAISE 8.0 ± 0.5 8.0 ± 0.5
Boom control valve
LOWER 9.5 ± 0.5 9.5 ± 0.5
Control valve
• Engine stopped
Spool stroke
IN 9.5 ± 0.5 9.5 ± 0.5

Arm control valve
OUT mm 8.0 ± 0.5 8.0 ± 0.5
Bucket control valve 8.0 ± 0.5 8.0 ± 0.5
Swing control valve • Engine stopped 7.5 ± 0.5 7.5 ± 0.5
Travel control valve 7.5 ± 0.5 7.5 ± 0.5
Boom control lever 85 ± 10 85 ± 10
Travel of control
Arm control lever • Engine stopped 85 ± 10 85 ± 10

Bucket control lever • At center of control lever grip 85 ± 10 85 ± 10
levers
• Max. reading up to stroke end mm

Swing control lever (excepting lever play in NEU- 85 ± 10 85 ± 10
Travel control lever TRAL position) 115 ± 12 115 ± 12
Play of control lever Max. 10 Max. 15
15.7 ± 3.9 Max. 24.5
Boom control lever
{1.6 ± 0.4} {Max. 2.5}
15.7 ± 3.9 Max. 24.5
Arm control lever
• Hydraulic oil temperature: Within {1.6 ± 0.4} {Max. 2.5}
of control levers
Operating force
operation range 12.7 ± 2.9 Max. 21.6

Bucket control lever
• Engine at high idling {1.3 ± 0.3} {Max. 2.2}
N{kg}
• At center of control lever grip 12.7 ± 2.9 Max. 21.6
Swing control lever • At tip in case of pedal {1.3 ± 0.3} {Max. 2.2}
• Max. reading up to stroke end 26.5 ± 6.6 Min. 43.1
Lever
{2.7 ± 0.7} {Min. 4.4}
Travel control lever
80.4 ± 20.1 Max. 117.6
Papel
{8.2 ± 2.0} {Max. 12}
PC160LC-7 20-3
(1)

Cate-
gory
• Hydraulic oil temperature: When
hydraulic oil Max. 5.9 Max. 5.9
Within operating range temperature {Max. 60} {Max. 60}
• Engine: High idling is about 50°C
Unload pressure • Working mode: A
• Measure pump outlet pres- When
hydraulic oil Max. 7.4 Max. 7.4
sure when all control levers temperature {Max. 75} {Max. 75}
are in neutral. is about 80°C
At normal 34.8 ± 1.0 33.3 – 36.8
Boom relief pres- relief {355 ± 10} {340 – 375}
sure At power-up 37.3 ± 1.0 36.3 – 39.2
• Hydraulic oil temperature: relief {380 ± 10} {370 – 400}
Within operating range At normal 35.1 ± 1.0 33.6 – 37.0
• Engine: High idling relief {358 ± 10} {343 – 378}
Arm relief pressure • Working mode: A
• Measure pump outlet pres- At power-up 37.3 ± 1.0 36.3 – 39.2
sure when circuit to be relief {380 ± 10} {370 – 400}
measured is relieved. At normal 34.8 ± 1.0 33.3 – 36.8
Oil pressure
Bucket relief pres- relief {355 ± 10} {340 – 375}

sure At power-up MPa 37.3 ± 1.0 36.3 – 39.2
2}
relief {kg/cm {380 ± 10} {370 – 400}
Swing relief pres- • Hydraulic oil temperature: Within 30.9 ± 1.5 28.9 – 32.9
sure operating range {315 ± 15} {295 – 335}
• Engine: High idling
• Working mode: A
Travel relief pres- • Measure pump outlet pressure when 37.3 ± 1.0 36.3 – 39.2
sure circuit to be measured is relieved. {380 ± 10} {370 – 400}
• Hydraulic oil temperature: Within operat-
ing range
Control circuit • Engine: High idling 3.23 ± 0.2 2.84 – 3.43
basic pressure • Measure outlet pressure of self-pressure {33 ± 2} {29 – 35}
reducing valve when all control levers are
in neutral.
• Hydraulic oil temperature: When all
Within operating range 4.5 ± 1.0 4.5 ± 1.0
levers are in
• Engine: High idling {46 ± 10} {46 ± 10}
LS differential neutral
• Working mode: A
pressure While bucket
• Measure difference 2.2 ± 0.1 2.2 ± 0.1
between pump pressure is digging
{22.5 ± 1} {22.5 ± 1}
and LS pressure. (Full)
• Hydraulic oil temperature: Within operat-
ing range
• Working mode: A deg Max. 100 Max. 130
Overrun of swing
• Measure deviation of swing circle when (mm) (–) (–)
upper structure stops swinging after one
turn.
• For measuring posture, see SWING 1.
• Hydraulic oil temperature:
Within operating range
• Engine: High idling 90 deg 3.0 ± 0.3 Max. 3.7
Swing
Time taken to start • Working mode: A

• Measure time taken to pass
swinging 90 degrees and 180
degrees after starting point. 180 deg 4.2 ± 0.4 Max. 5.5
• For measuring posture, see
SWING 1. sec
operating range
Time taken to • Engine: High idling
• Working mode: A 25 ± 2.5 Max. 30
swing • Measure time taken to swing 5 turns after
swinging 1 turn.
20-4 PC160LC-7
(1)

Cate-
gory
• Hydraulic oil temperature: Within operating
range
• Set upper structure at 90 degrees to
machine body on slope of 15 degrees.
Hydraulic drift of • Engine: Stopped
mm 0 0
swing • Make match marks on inner race and outer
race of swing circle.
Swing
• Measure deviation of match marks in 5 min-

utes.
range
Leakage from • Engine: High idling
/min Max. 5 Max. 10
swing motor • Swing lock switch: ON
• Measure leakage for 1 minutes while swing
circuit is relieved.
operating range
Lo 44.3 ± 4.4 39.9 – 50.7
Travel speed • Working mode: A
(Free rotation) • Measure time taken to rotate track
shoes 5 turns after 1 turn.
• For measuring posture, see Hi 27.4 ± 1.4 26.0 – 30.8
TRAVEL 1.
• Hydraulic oil temperature: Within sec

operating range
Lo 21 ± 2.5 21.5 – 27.5
• Working mode: A
Travel speed
• Ground: Hard and level
(Actual travel)
• Measure time taken to travel 20 m
after running up 10 m. Hi 13 ± 1.0 12.0 – 15.0
TRAVEL 2.
range
Travel
• Working mode: A
• Travel speed: Lo
Travel deviation Max. 150 Max. 250
• Ground: Hard and level
• Measure travel deviation in travel of 20 m
after running up 10 m.
• For measuring posture, see TRAVEL 2 and
3. mm

range
• Stop machine on slope of 12 degrees with
Hydraulic drift of sprocket directed up bias.
0 0
travel • Engine: Stopped
• Measure hydraulic drift of travel in 5 min-
utes.
• For measuring posture, see TRAVEL 4.
range
Leakage from • Engine: High idling
/min 13.6 27.2
travel motor • Lock sprocket.
• Measure leakage for 1 minutes while travel
circuit is relieved.
PC160LC-7 20-5
(1)

Cate-
gory
Whole work range
• Ground Level and flat Max. 600 Max. 900
equipment
• Bucket: Full of dirt and sand or filled with
Hydraulic drift of work equipment
rated load (1,080 kg)

• Level boom top, retract arm cylinder fully,
Boom cylin- and extract bucket cylinder fully.
Max. 18 Max. 27
der • Engine: Stopped
• Work equipment control lever: Neutral
• Start measuring just after setting machine mm
and measure every 5 minutes for 15 min-
utes.
Arm cylinder Max. 160 Max. 240
• Whole work equipment: Hydraulic drift of
tooth tip
• Boom cylinder: Retraction of cylinder
• Arm cylinder: Extraction of cylinder
Bucket cylin- • Bucket cylinder: Retraction of cylinder Max. 40 Max. 58
der • For measuring posture, see WORK
EQUIPMENT 1.

RAISE
operating range
• Engine: High idling 3.5 ± 0.4 Max. 4.9
• Working mode: A
Work equipment
• Time required from raise stroke

Boom speed
end till bucket touches ground
(Raise until cushion starts oper-
LOWER
ates for raising stroke). 2.4 ± 0.3 Max. 3.7

WORK EQUIPMENT 2.

Work equipment speed
operating range +0.4

Max. 4.5
IN
• Engine: High idling 3.3 - 0.2

• Working mode: A
• Time required from dumping
Arm speed sec
stroke end to digging stroke end
(between starting points of cush-
OUT
ion). 2.8 ± 0.3 Max. 3.5

WORK EQUIPMENT 3.

CURL
operating range 2.8 ± 0.3 Max. 3.5

Bucket • Working mode: A
speed • Time required from dumping
stroke end to digging stroke end.
DUMP
• For measuring posture, see 2.2 ± 0.2 3.0

WORK EQUIPMENT 4.
20-6 PC160LC-7
(1)

Cate-
gory
range
• Engine: Low idling
• Working mode: A
Boom time
• Lower boom from RAISE stroke end and Max. 1.0 Max. 1.2
lag
measure time taken to lift up front side of
machine after bucket touches ground.
• For measuring posture, see WORK
EQUIPMENT 5.
range
Time lag
• Working mode: A
Arm time lag • Move in arm from OUT stroke end and sec Max. 3.0 Max. 4.2
Work equipment
measure time taken to start moving arm

again after it is stopped.
EQUIPMENT 6.
range
• Working mode: A
Bucket time
• Curl bucket from DUMP stroke end and Max. 1.0 Max. 3.6
lag
measure time taken to start moving bucket
again after it is stopped.
EQUIPMENT 7.
Leakage • Hydraulic oil temperature: Within operating

4.5 20
Oil leakage
from cylinder range

cc/min
Leakage • Working mode: A
from center • Relieve cylinder to be measured or travel 10 50
swivel joint circuit and measure leakage in 1 minute.
Compound operation
range
performance
Travel deviation in • Engine: High idling

compound opera- • Working mode: A
mm Max. 200 Max. 220
tion of work equip- • Travel speed: Lo
ment and travel • Ground: Hard and level
• Measure travel deviation in travel of 20 m
after running up 10 m.
Hydraulic pump
— See HYDRAULIC PUMP PERFORMANCE.
performance
PC flow control characteristics

range
Time taken to
• Working mode: A
swing 90 degrees
• Bucket: Filled with rated load
in compound 4.0 ± 0.4
• Ground: Hard and level sec
operation of rais- (Reference)
• Set arm vertically and lower back of bucket
ing boom and
to ground.
starting swinging
• Raise boom and start swinging simulta-
neously from above posture and measure
time taken to pass 90 degrees.
PC160LC-7 20-7
(1)
HYDRAULIC PUMP PERFORMANCE

Cate-
gory
Discharge amount of hydraulic pump (A mode)
Performance of hydraulic pump
• Pump speed: At 2,200 rpm, PC-EPC current 350 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) ( /min) ( /min)
As desired P1 P2 P1+P2 See graph See graph

PP =
2
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of mea-
surement, and use them as a base for calculating the pump discharge amount at the specified speed.
20-8 PC160LC-7
(1)
Posture of machine for measuring performance Travel 2: Travel speed (Actual travel), travel devia-
and measuring method tion
Swing 1: Overrun of swing, time taken to start swing,

time taken to swing
Travel 3: Travel deviation
Swing 2: Hydraulic drift of swing
Travel 4: Hydraulic drift of travel
Travel 1: Travel speed (Free rotation)
PC160LC-7 20-9
(1)
Work equipment 1: Hydraulic drift of work equipment Work equipment 4: Bucket speed
Work equipment 2: Boom speed Work equipment 5: Boom time lag
Work equipment 3: Arm speed Work equipment 6: Arm time lag
20-10 PC160LC-7
(1)
Work equipment 7: Bucket time lag
PC160LC-7 20-11
(1)
TESTING AND ADJUSTING
Tools for testing, adjusting and troubleshooting .......................................................................................... 20-102

Inspection and adjustment of engine rpm ................................................................................................... 20-104
Measurement of exhaust gas color ............................................................................................................. 20-106
Adjustment of valve clearance .................................................................................................................... 20-107
Measurement of compression pressure...................................................................................................... 20-109
Measurement of blow-by pressure...............................................................................................................20-110
Inspection and adjustment of fuel injection timing .......................................................................................20-111
Measurement of engine oil pressure............................................................................................................20-113
Adjustment of engine speed sensor.............................................................................................................20-114
Inspection and adjustment of air compressor belt tension ...........................................................................20-115
Measurement of clearance in swing circle bearings ....................................................................................20-116
Inspection and adjustment of track shoe tension .........................................................................................20-117
Inspection and adjustment oil pressure in work equipment, swing, and travel circuits ................................20-118
Inspection and adjustment of control circuit oil pressure ............................................................................ 20-121
Inspection and adjustment of pump PC control circuit oil pressure ............................................................ 20-122
Inspection and adjustment pump LS control circuit oil pressure ................................................................. 20-125
Measurement of solenoid valve output pressure ........................................................................................ 20-128
Measurement of PPC valve output pressure .............................................................................................. 20-131
Adjustment of work equipment and swing PPC valve................................................................................. 20-132
Inspection of locations of hydraulic drift of work equipment........................................................................ 20-133
Testing and adjusting travel deviation ......................................................................................................... 20-135
Release of residual pressure from hydraulic circuit .................................................................................... 20-137
Measurement of oil leakage ........................................................................................................................ 20-138
Bleeding air from each part ......................................................................................................................... 20-140
Inspection procedures for diode.................................................................................................................. 20-142
Special function of monitor panel ................................................................................................................ 20-143
Special functions of 7-segments monitor panel........................................................................................... 20-169
Preparations for troubleshooting electrical system ..................................................................................... 20-186
Pm-Tune up Service ................................................................................................................................... 20-187
PC160LC-7 20-101
(3)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q’ty
Test, measurement item Part No. Part Name Remarks
1 799-205-1100 Tachometer KIT 1 Digital display: 6 – 99,999.9 rpm

Engine speed A
2 795-790-2500 adapter 1 For 102-Series engine
Handy smoke
1 799-201-9001 checker 1
Exhaust gas color B Bosch index = 0 – 9
Commercially
2 available Smoke meter 1
1 795-799-1131 Gear 1 For 102-Series engine

Engine valve clearance C
Commercially Intake : 0.25 mm
2 available Thickness gauge 1 Exhaust: 0.51 mm
1 795-502-1205 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}

Compression pressure D
2 795-502-1700 Adapter 1 For 102-Series engine
1 799-201-1504 Blow-by KIT 1 0 – 4.9 kPa {0 – 500 mmH2O}
Blow-by pressure E
2 795-790-1950 Tool (Nozzle) 1
1 795-799-1131 Gear 1
Fuel injection timing F 2 795-799-1900 Pin assembly 1

3 795-799-1950 Lock pin 1
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 KIT (analog type) 1 {25, 60, 400, 600 kg/cm2}
1
Engine oil pressure G Oil pressure gauge
790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
2 799-401-2320 Oil pressure gauge 1 Pressure gauge: 0.98 MPa {10kg/cm2}
Swing circle bearing H Commercially

clearance available Dial gauge 1
1
Hydraulic oil pressure of Oil pressure gauge
work equipment, swing and J 790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
travel circuit
799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1
1
Oil pressure gauge
Control circuit basic pres- K 790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
sure
799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1
799-101-5002 Oil pressure gauge 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
(analog type) {25, 60, 400, 600 kg/cm2}
1
Pump PC control circuit oil 790-261-1204 Oil pressure gauge 1 Pressure gauge: 58.8 MPa {600kg/cm2}
L (digital type)
pressure
799-101-5220 Nipple 3 10 x 1.25 mm
2
07002-11023 O-ring 3
20-102 PC160LC-7
(4)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q’ty
Test, measurement item Part No. Part Name Remarks
799-101-5002 Oil pressure gauge 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
KIT (analog type) {25, 60, 400, 600 kg/cm2}
1
Oil pressure gauge
Pump LS control circuit oil M
pressure 799-101-5220 Nipple 3 10 x 1.25 mm
2
07002-11023 O-ring 3
3 799-401-2701 Differential pressure

gauge 1
1
Oil pressure gauge
Solenoid vallve output N 790-261-1204 KIT (digital type) 1 Pressure gauge: 58.8 MPa {600kg/cm2}
pressure
799-401-3100 Adapter 1 02 size
2
799-401-3200 Adapter 1 03 size
PPC vallve output pressure P 1
Oil pressure gauge
Q Commercially
Oil leakage available Measuring cylinder 1
Water temperature, oil – Digital thermometer

temperature 799-101-1502 gauge 1 – 99.9 – 1,299°C
79A-264-0021 1 0 – 294 N {0 – 30 kg}

Operating force – Push-pull scale
79A-264-0091 1 0 – 490 N {0 – 50 kg}
– Commercially
Stroke, hydraulic drift available Scale 1
– Commercially
Work equipment Speed available Stopwatch 1
– Commercially
Voltage, resistance available Tester 1
For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Connector
arrangement drawing and electric circuit diagram of each system.
PC160LC-7 20-103
(4)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM
INSPECTION AND ADJUSTMENT OF ENGINE RPM

Engine inspection and maintenance tools 3. Fit adapter A2, and connect pickup set [1] and
meter [2] of multi-tachometer A1.
Mark Part No. Part Name
1 799-205-1100 Tachometer KIT
A
2 795-790-2500 Adapter
Engine RPM may be detected using a monitor-

ing function in the monitor panel (special func-
tion furnished to the monitor panel).
4. Measure the engine RPM after setting each

measurement condition.
1) RPM at low idling:
i) Set the fuel dial at low idling (MIN).
ii) Move all the control levers of work
equipment, swing and travel to the NEU-
TRAL position.
Be careful not to touch the strongly heated por- 2) RPM at high idling:
tion of the engine by accident while installing a i) Turn the auto-decelerator OFF.
measurement equipment. ii) Set the fuel dial at high idling (MAX).
iii) Move all the control levers of work
Inspection equipment, swing and travel to the NEU-
1. Open the engine hood and remove the guard of TRAL position.
the air conditioner compressor belt. 3) RPM at fuel pump relief
i) Set the fuel dial at high idling (MAX)
2. Remove cover (1). ii) Put the arm in the OUT relief position.
Use a filter wrench to take off the cover. 4) RPM when pump relief and one-touch power
max. switch are set (near rated RPM)
i) Set the fuel dial at high idling (MAX).
ii) Put the arm in OUT relief position and
keep the one-touch max. power switch
depressed.
The one-touch power max. function is
automatically released in 8.5 seconds,
even if the knob switch is kept de-
pressed. Take measurement during the
period.
5) RPM when auto-decelerator is set
i) Turn the auto-decelerator ON.
ii) Set the fuel dial at high idling (MAX).
iii) Move all the control levers of work
equipment, swing and travel to the NEU-
TRAL position.
Approx. 5 seconds after all the control le-
vers are moved to the NEUTRAL posi-
tion, the rpm falls automatically. That is
when the rpm with the auto-decelerator
in motion should be measured.
20-104 PC160LC-7
(4)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM
5. Detach all the measurement tools after the

inspection, and make sure that the machine is
back to normal condition.
Adjustment
1. Adjustment of RPM at low idling
If the rpm at low idling deviates from the stan-
dard value, make adjustment using the ad-
justment function provided in the monitor
panel.
For the adjustment procedures, refer to the
section, "Special Function of Monitor Panel"
2. Adjustment of high idling deviates

If the rpm at high idling deviates from the
standard value, or it is unsteady (hunting),
adjust the governor spring securing dimen-
sions, using the adjustment function in the
monitor panel.
For the adjustment procedures, refer to the
section, "Special Function of Monitor Panel"
PC160LC-7 20-105
(1)
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR
MEASUREMENT OF EXHAUST GAS COLOR

Exhaust gas color measurement tool

1 799-201-9001 Handy Smoke Checker
B
2 Commercial product Smoke Meter
Be careful not to touch the highly heated parts,

while fitting and detaching a measurement tool.
If no compressed air or power is not available in
the field, use Handy Smoke Checker B1. For
recording official data, use Smoke Meter B2.
1. Measurement with Handy Smoke Checker B1

1) Fit a filtering paper to Handy Smoke Checker
B1. 2) Connect the probe hose, accelerator switch
2) Insert the exhaust gas intake pipe into the outlet and air hose to the Smoke Meter B2.
exhaust pipe (1). Keep the pressure of the supplied com-
3) Start the engine and keep it running until the pressed air below 1.5 MPa {15 kg/cm2}.
engine cooling water temperature comes 3) Connect the power cable to an outlet of
within the operating range. AC100V.
4) Let the exhaust gas stay on the filtering Confirm that the Smoke Meter power
paper by operating a handle of Handy switch is in the OFF position, before con-
Smoke Checker B1, when the engine speed necting the power cable to an outlet.
is suddenly accelerated or kept at high 4) Fit a filtering paper by loosening the suction
idling. pump cap nut.
Fit the filtering paper securely so that air
may not leak.
5) Move the Smoke Meter B2 power switch to
the ON position.
5) Take out the filtering paper and compare it

with the attached scale for judgement.
6) Detach the measurement tool after the mea-
surement, and make sure the machine is 6) Start the engine and keep it running until the
back to normal condition. engine water temperature rises to the oper-
ating range.
2. Measurement with Smoke Meter B2 7) Let the exhaust gas stay on the filtering
1) Insert probe [1] of the Smoke Meter B2 into paper by depressing the accelerator pedal of
the exhaust gas pipe outlet, and fasten it to Smoke Meter B2, when the engine speed is
the outlet with a clip. suddenly accelerated or kept at high idling.
8) Put the polluted filtering paper on non-pol-
luted filtering paper (more than 10 sheets) in
the filtering paper holder, and read the indi-
cated value.
9) Detach the measurement tool after the mea-
surement, and make sure that the machine
is back to normal condition.
20-106 PC160LC-7
(4)
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE CLEARANCE

Valve clearance adjustment tools

1 795-799-1131 Gear
C
2 Commercial product Thickness Gauge
1. Open the engine hood and remove the guard of

the air conditioner compressor belt.
2. Remove all cylinder head covers (1).
5. While No. 1 cylinder is at the compression top

dead center, adjust the valve clearances marked
with q in the valve arrangement diagram
according to the following procedure.
Valve arrangement diagram
3. Take off cap (2) and fit gear C1.
1) Insert thickness gauge C2 in clearance (b)

between rocker arm (4) and valve stem (5)
and adjust the valve clearance with adjust-
ing screw (6).
For the adjustment, turn the adjusting
screw with filler gauge C2 inserted to the
extent that filler gauge C2 can be lightly
4. Rotate the crankshaft forward with gear C1 and
moved.
match yellow paint (a) of the crank pulley to the
2) Fix adjusting screw (6) and then tighten lock
tip of pointer (3) to set No. 1 cylinder to the com-
nut (7).
pression top dead center.
Lock nut: 24±4 Nm{2.45±0.41kgm}
When No. 1 cylinder is at the top dead cen-
Check the valve clearance again after
ter, its rocker arm can be manually moved as
tightening lock nut (7).
much as the valve clearance. If it cannot be
Proceed to the next step once all the adjust-
moved, that means that No. 1 cylinder is not
ments of valve clearance indicated with a
yet at the top dead center. In that case, rotate
black bullet mark (q) have been completed.
it by one more turn.
PC160LC-7 20-107
(1)
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
6. Rotate the crankshaft forward with gear C1 and

match red paint (a) of the crank pulley to the tip
of pointer (3) to set No. 4 cylinder to the com-
pression top dead center.
7. When No. 4 cylinder is at the top dead center,

adjust valve clearances indicated with a white
bullet mark (Q) in the chart.
The adjustment procedures are the same as
introduced in Item 5 above.
8. After the adjustment, make sure that the

machine is back to normal condition.
Cylinder head cover securing bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
20-108 PC160LC-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF COMPRESSION PRESSURE

Compression pressure measurement tools
6. Remove governor spring (2). Fix governor lever
Mark Part No. Part Name (3) of the fuel injection pump to the stopper on
1 795-502-1205 Compression Gauge the STOP side.
D
2 795-502-1700 Adapter
If the governor lever is not fixed, the engine
may start when it is cranked. Accordingly,
Be careful not to get burnt by touching the ex- be sure to fix the governor lever to the STOP
haust manifold or muffler, or get caught with a ro- side.
tating parts, while taking measurement of
compression pressure.
1. Adjust the valve clearances.

For the adjustment, refer to the section, "Ad-
justment of Valve Clearance".
2. Make preparations for measuring the engine

rpm.
For the preparations, refer to the section, "In-
spection and adjustment of Engine RPM".
3. Warm up the engine until the engine oil tempera-

ture rises up to 40 – 60°C.
4. Open the engine hood and remove nozzle 7. Crank up the engine with the engine starting
holder (1) of the cylinder to be measured. motor, and measure the compression pressure.
Read off the value, when the needle of the
compression gauge steadies itself.
When taking measurement of the compres-
sion pressure, be sure to measure the engine
rpm, too, so that it stays within the range of
designated measurement conditions.
8. Detach the measurement tools after the mea-

surement, and make sure that the machine is
Nozzle holder:
Seizure preventive (Molycoat 100)
Nozzle holder:
60 ± 9 Nm {6.12 ± 0.92 kgm}
5. Fit Adapter D2 to the nozzle holder mounting,

and connect with gauge ass'y [1] of compression
gauge D1.
Adapter: 60 ± 9 Nm {6.12 ± 0.92 kgm}
PC160LC-7 20-109
(1)
TESTING AND ADJUSTING MEASUREMENT OF BLOW-BY PRESSURE
MEASUREMENT OF BLOW-BY PRESSURE

Blow-by pressure measurement tools Read off the blow-by pressure value, when
the needle of the gauge steadies itself.
1 799-201-1504 Blow-by Kit
E
2 795-790-1950 Tool (Nozzle)
1. Fit tool E2 to blow-by hose (1) and connect it

with gauge [1] of blow-by kit E1.

2. Start the engine, and lock (left and right) the

travel.
Insert pin [2] in between the sprocket and the
track frame to make sure to block the travel.
3. Start the engine and keep it running until the

engine cooling water temperature rises to the
operating range.
4. Measure the blow-by pressure at high idling and

under the following conditions.
• Working mode: A mode
• Work equipment, swing and travel:
Left and right travel relief
20-110 PC160LC-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

Fuel injection timing inspection and adjustment 4. Fix the fuel injection pump drive gear to match
tools injection timing by pushing drive gear timing pin
(3) in the direction of the front cover.
Mark Part No. Part Name Injection timing requires adjustment of high
1 795-799-1131 Gear precision. Be sure to fix the drive gear with
F 2 795-799-1900 Pin Ass'y timing pin (3) so as to match injection timing.
3 795-799-1950 Lock Pin Push-in depth: 8 mm
If timing pin (3) cannot be pushed in, turn the
Inspection crankshaft a bit fore or aft with gear F1.
1. Open the engine hood and remove the guard of If it is found difficult to confirm the push-in
the air conditioner compressor belt. depth with timing pin (3) as installed in the fly-
wheel housing, metallic pin ass'y F2 may well
2. Take off cover (1) and fit gear F1. be used instead.
3. Rotate the crankshaft forward with gear F1 and 5. Disconnect plug (4) of the fuel injection pump.
match yellow paint (a) of the crank pulley to the
tip of pointer (2) to set No. 1 cylinder to the com- 6. Reverse and push in timing pin (5) of the fuel
pression top dead center. injection pump, and confirm its cut-out portion
Take off the cylinder head cover for No.1 cyl- matches with protruding portion b inside the
inder, and confirm that its rocker arm can be pump.
manually moved as much as the valve clear- If timing pin (5) can be pushed in smoothly,
ance. If it cannot be moved, that means that then injection timing is correct.
No.1 cylinder is not yet at the top dead cen- If timing pin (5) cannot be pushed in smooth-
ter. In that case, rotate it by one more turn. ly, injection timing is incorrect and requires
adjustment.
If it is found difficult to confirm the push-in
depth with timing pin (5) as installed in the
engine, metallic pin ass'y F3 may well be
used instead.
PC160LC-7 20-111
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
2. Dismantle the fuel injection pump.

7. Detach the measurement tools after the mea- For dismantling the fuel injection pump, refer
surement, and make sure that the machine is to the section, "FUEL INJECTION PUMP
back to normal condition. ASSEMBLY" in the chapter of "DISASSEM-
BLY AND ASSEMBLY".
Cylinder head cover securing bolt:
24 ± 4 Nm {2.45 ± 0.45 kgm}
3. Reverse and push in timing pin (5) of the fuel
Do not forget to bring driving gear timing pin
injection pump, then match the pin cut-out por-
(3) and injection pump timing pin (5) back to
tion and protruding portion "b" inside the fuel
the pre-inspection condition.
injection pump by turning the shaft.
In case the adjustment follows, leave gear F1
After fuel timing has been set, fix it by fitting
and timing pin (3) as they are.
plug (4).
Adjustment
! If fuel injection timing is found incorrect, adjust it
in the following manner.
1. Confirm that drive gear injection timing is fixed
with driving gear timing pin (3).
If timing pin (3) was pulled back after the in-
spection had been completed, push it in
again following the foregoing inspection pro-
cedures.
4. Mount the fuel injection pump.

For dismantling the fuel injection pump, refer
to the section, "FUEL INJECTION PUMP
ASSEMBLY" in the chapter of "DISASSEM-
BLY AND ASSEMBLY".
5. Detach the measurement tools after the adjust-

ment, and make sure that the machine is back to
normal condition.
Before starting the engine again, check that
driving gear timing pin (3) and fuel injection
pump timing pin (5) have been brought back
to the pre-adjustment condition.
20-112 PC160LC-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE
MEASUREMENT OF ENGINE OIL PRESSURE

Engine oil pressure measurement tools 4. Measure engine oil pressure at low idling as well
as at high idling.
799-101-5002 Hydraulic Tester
1 Digital type
G 790-261-1204
hydraulic tester
2 799-401-2320 Hydraulic Tester
A nipple (quick coupler) is installed to the engine

oil pressure pickup port of the Pm clinic specifi-
cation machine.
1. Take off engine oil pressure measurement plug

(1) on top of the engine filter.

2. Install fitting [1] of the hydraulic tester G1, and

connect it to hydraulic tester G2.

engine cooling water temperature rises to the
operating range.
PC160LC-7 20-113
(4)
TESTING AND ADJUSTING ADJUSTMENT OF ENGINE SPEED SENSOR
ADJUSTMENT OF ENGINE SPEED SENSOR

Detach engine speed sensor (1) before the
adjustment, then check that there is no metal
dust stuck or damage at the tip and fit it again.
1. Screw in sensor (1) until its tip comes to contact

with the tip of flywheel ring gear teeth (2).
Threaded portion:
Gasket sealant (LG-6)
2. Screw back sensor (1) from that position by the

prescribed angle.
Screw-back angle: 1±1/6 turn
Adjust clearance "a" between the sensor tip
and gear tooth tip to be 1.25 – 1.75 mm.
3. Fix sensor (1) and tighten nut (3).

Nut: 49.0 – 68.6 Nm{5 – 7 kgm}
4. After the adjustment, confirm that correct engine

speed is displayed in the monitor panel, using
the special monitoring function.
For monitoring engine speed, refer to the
section, "Special Function of Monitor Panel".
20-114 PC160LC-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT

TENSION
Inspection
1. Open the engine hood and remove the guard of
the air conditioner compressor belt.
2. Check belt deflection amount a when depressing

the mid point between the fan pulley and the
compressor with a thumb.
• Belt depressing force: Equivalent to 58.8 N {6
kg}
Adjustment
If the belt deflection amount is not proper, adjust
it in the following manner.
1. Loosen two compressor bracket (1) securing
bolts (upper and lower).
2. Loosen lock nut (2), and adjust the belt (3) ten-
sion by shifting the position of compressor
bracket (1).
3. Fix adjusting bolt (3) and tighten locknut (2).
4. Tighten two compressor bracket (1) securing

bolts (upper and lower).
5. Check the belt tension again after the adjust-

ment.
PC160LC-7 20-115
(1)
TESTING AND ADJUSTING MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS

Swing circle bearing clearance measurement 4. Hold the arm nearly perpendicular to the ground,
tools and lower the boom until the track shoes will be
lifted at the machine front.
Mark Part No. Part Name The upper structure is raised at the front and
H Commercial Product Dial Gauge lowered at the rear at that time.
Follow the steps explained below, when measur- 5. Read off the value in dial gauge H in this condi-
ing clearance in the swing circle bearing in the tion.
actual machine. The value indicated in dial gauge H express-
Be careful not to put a hand or foot under the un- es clearance in the bearings.
dercarriage, while taking measurement.
1. Fasten dial gauge H to swing circle outer race

(1) or inner race (2), and contact the probe with
the end surface of inner race (2) or outer race (1)
on the opposite side.
Set dial gauge H at the machine front or rear.
6. Return the machine to the posture in Item 2

above, and confirm reading of dial gauge H is
zero.
If zero value is not indicated, repeat the steps
in Items 3 through 5.
2. Keep the work equipment in the max. reach pos-

ture and keep the height of the bucket teeth tip
level with the lower height of the revolving frame.
3. Set dial gauge H at zero point.
20-116 PC160LC-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION

Inspection
1. Travel the machine forward by the length of track
on ground, keeping the engine at low idling, and
stop the machine slowly.
2. Place straight bar [1] on the track shoe between

the idler and the 1st carrier roller.
L beam is recommended for bar [1], because
of its deflection-free nature.
3. Measure max. clearance a between bar [1] and

the track shoe.
• Max. standard clearance a: 10 – 30 mm
Adjustment
If the track shoe tension is not proper, adjust it in
the following manner.
1. When the tension is too strong

Discharge grease by loosening valve (1).
Do not loosen valve (1) by more than one
turn, because grease will spurt out due to its
internal high pressure.
2. When the tension is too weak

Add grease through valve (1).
If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.
PC160LC-7 20-117
(1)
INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT,
TESTING AND ADJUSTING SWING, AND TRAVEL CIRCUITS
INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK

EQUIPMENT, SWING, AND TRAVEL CIRCUITS
Instruments for inspecting and adjusting oil pres- • (2): Rear pump discharge pressure pick-
sure in work equipment, swing, and travel cir- up plug
cuits
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
J Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
A nipple (quick coupler) is installed to the pump
discharge pressure pickup port of the Pm clinic
specification machine.
The oil pressure (pump discharge pressure) in
the work equipment, swing, and travel circuits
can be checked with the monitoring function of
the monitor panel (special function of the monitor
panel). 2) Install nipple J2 and connect it to oil pres-
sure gauge [1] of hydraulic tester J1.
Use the oil pressure gauge of 58.8 MPa
{500 kg/cm2}.
The measuring instruments installed to
the front pump discharge pressure pick-
up port are shown in the figure.
Measurement
1. Preparation work
Lower the work equipment to the ground and
stop the engine. Operate the control lever
several times to release the residual pres-
sure from the piping, and then loosen the oil
filler cap of the hydraulic tank slowly to re- 3) Run the engine and heighten the hydraulic
lease the residual pressure from the tank. oil temperature to the operating range.
1) Remove oil pressure pickup plugs (1) and
(2).
• (1): Front pump discharge pressure pick-
up plug
20-118 PC160LC-7
(4)
2. Combination of pump, actuator, and valve 5. Measurement of swing circuit relief pressure
When the pump is separated, the front pump 1) Start the engine and turn the swing lock
and rear pump act independently on each ac- switch ON.
tuator as shown in the table. Note that differ- 2) Run the engine at high idling and swing to
ent actuators relieve different valves. the right and left to relieve the swing circuit
When the work equipment circuit or swing and measure the oil pressure at this time.
circuit are relieved singly, the oils of the The pressure measured when the swing
pumps are merged. When the travel circuit is motor safety valve is relieved is indicat-
relieved singly, the oils of the pump are divided.
ed. The swing motor relief pressure is lower
The actuators in the table are arranged in the than the main relief valve.
order when the control valve is seen from the
front of the machine (and 1 attachment is in- 6. Measurement of travel circuit relief pressure
stalled to the service valve). 1) Start the engine and lock the travel mecha-
nism.
Pump Actuator Valve relieved
(Centralized safety valve) Set pin [2] between the sprocket and
Service Safety-suction valve track frame to lock the travel mechanism
securely.
Bucket Main relief valve
Rear Arm Main relief valve
RAISE: Main relief valve
Boom
LOWER: Safety-suction valve
(Front unload valve) (Rear unload valve) (Main relief valve)
(Pump merge-divider valve) (Self-pressure reducing valve)
Front Left travel Main relief valve
Right travel Main relief valve
Rear
Swing Swing motor safety valve
(LS separate valve)
3. Measurement of unload pressure

1) Start the engine.
2) Run the engine at high idling and set the all
control levers in neutral and measure the oil 2) Run the engine at high idling and relieve the
pressure at this time. travel circuit and measure the oil pressure at
The pressure measured when the front this time.
and rear unload valves are unloaded is The pressure measured when the main
indicated. relief valve is relieved is indicated. The
travel circuit is always relieved at high
4. Measurement of work equipment circuit relief pressure.
pressure
1) Start the engine and move the cylinder to be Adjusting
measured to the stroke end. The unload valve and the boom lowering safety-
2) Run the engine at high idling and relieve the suction valve cannot be adjusted.
cylinder and measure the oil pressure at this
time. 1. Adjusting main relief pressure
The pressure measured when the main If the relief pressure of the work equipment
relief valve is relieved is indicated. circuit and/or travel circuit is abnormal, adjust
If the one-touch power maximizing main relief valve (3) according to the follow-
switch is released, the valve is relieved at ing procedure.
low pressure. If the former is pressed, Adjust only the low relief pressure of the main
the lower is relieved at high pressure. relief valve. (If the low relief pressure is ad-
If the swing lock switch is turned ON, the justed, the high relief pressure is adjusted
constant 2-stage relief valve is turned automatically.)
ON and the valve is relieved at high pres- The low relief pressure is the pressure ap-
sure. Accordingly, keep the swing lock plied when the 2-stage relief solenoid valve is
switch turned OFF. turned OFF and the pilot pressure is not ap-
plied to the selector port.
PC160LC-7 20-119
(1)
1) Disconnect pilot hose (4). 1) Fixing screw (9), loosen locknut (10).
2) Fixing holder (5), loosen locknut (6). Fix the screw with a hexagonal wrench.
3) Turn holder (5) to adjust the pressure. 2) Turn screw (9) to adjust the pressure.
If the holder is If the screw is
• Turned to the right, the pressure • Turned to the right, the pressure
rises. rises.
• Turned to the left, the pressure • Turned to the left, the pressure
lowers. lowers.
Quantity of adjustment per turn of holder: Quantity of adjustment per turn of screw:
Approx. 20.5 MPa {Approx. 209 kg/cm2} Approx. 9.8 MPa {Approx. 100 kg/cm2}
4) Fixing holder (5), tighten locknut (6). 3) Fixing screw (9), tighten locknut (10).
Lock nut: Lock nut:
49.0 – 58.8 Nm {5 – 6 kgm} 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
5) Connect pilot hose (4). 4) After finishing adjustment, check again that
6) After finishing adjustment, check again that the pressure is normal according to the pro-
the pressure is normal according to the procedure for measurement described above.
cedure for measurement described above.
2. Adjusting swing relief pressure

If the relief pressure of the swing circuit is ab-
normal, adjust swing motor safety valves (7)
and (8) according to the following procedure.
• (7): Right swing relief safety valve
• (8): Left swing relief safety valve
20-120 PC160LC-7
(1)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL

PRESSURE
Control circuit oil pressure inspection and adjust- 3. Start the engine and keep it running until the
ment tools hydraulic oil temperature rises to the operating
range.
799-101-5002 Hydraulic Tester 4. Measure oil pressure with the engine running at
1 Digital Type high idling and all the control levers in the NEU-
790-261-1204
Hydraulic Tester TRAL position.
K
Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
A nipple (quick coupler) is installed to the control

circuit basic pressure pickup port of the Pm clinic
stop the engine. After the engine stops, operate
the control lever several times to release the re-
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy-
draulic tank.
1. Remove oil pressure measurement plug (1).

• (1): Control circuit basic pressure pickup plug 5. Detach all the measurement tools after the mea-
The relief valve for the control circuit basic pres-
sure cannot be adjusted.
2. Fit nipple K2 and connect it to oil pressure

gauge [1] of hydraulic tester K1.
Use an oil pressure gauge with the capacity
of 5.9 MPa {60 kg/cm2}.
PC160LC-7 20-121
(4)
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE

CIRCUIT OIL PRESSURE
Pump PC control circuit oil pressure inspection • (2): Rear pump discharge pressure pick-
and adjustment tools up plug

799-101-5002 Hydraulic Tester
1 Digital Type
790-261-1204
Hydraulic Tester
L
Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
A nipples (quick couplers) are installed to the

pump discharge pressure pickup port, PC valve
output pressure pickup port, and PC-EPC valve
output pressure pickup port of the Pm clinic
• PC valve output pressure pickup plug
Measurement
Implement measuring the pump PC control cir-
cuit oil pressure after confirming that the work
equipment, swing and travel circuit oil pressure
as well as the control circuit original oil pressure
are normal.
stop the engine. After the engine stops, operate
the control lever several times to release the re-
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy-
draulic tank.
1. Measurement of PC valve output pressure

(servo piston inlet pressure) 2) Fit nipple L2 and connect to oil pressure
Measure the PC valve output pressure (ser- gauge [1] of hydraulic tester L1.
vo piston inlet pressure) and pump discharge Use an oil pressure gauge with the ca-
pressure (both F and R) simultaneously and pacity of 58.8 MPa {600 kg/cm2}.
compare them with each other. The measuring instruments installed to
1) Remove oil pressure pickup plugs (1), (2), the PC valve output pressure pickup port
and (3). are shown in the figure.
• (1): Front pump discharge pressure pick-
up plug
3) Start the engine and keep it running until the

hydraulic oil temperature rises to the operat-
ing range.
20-122 PC160LC-7
(4)
• (4): PC-EPC valve output pressure pick-

up plug
4) Measure the pump delivery pressure and PC

valve output pressure (servo piston inlet
2) Fit nipple L2 and connect it to oil pressure
pressure) together with the engine running at
gauge [1] of hydraulic tester L1.
high idling, after setting the machine at the
Use an oil pressure gauge with the ca-
following conditions.
pacity of 5.9 MPa {60 kg/cm2}.
• Working mode: A mode
• Swing lock switch: ON (switched to high
pressure relief with 2-stage relief turned
ON)
• Work equipment, swing and travel cir-
cuit: Arm digging relief
Judgement method:
When the ratio between the pump deliv-
ery pressure (Higher one of F and R) and
PC valve output pressure (servo piston
inlet pressure) reaches the following val-
ues, both pressures are judged normal.
Pressure to be
Pressure ratio
measured
Pump delivery 3) Start the engine and keep it running until the
1
pressure hydraulic oil pressure rises to the operating
PC valve outlet Approx: 0.6 range.
pressure (Approx. 3/5)
If there is any abnormality with PC valve

or servo piston, the PC valve output
pressure (servo piston inlet pressure)
equals to the pump delivery pressure, or
approximates to 0 pressure.
5) After finishing measurement, remove the
measuring instruments and return the re-
moved parts.
2. Measurement of PC-EPC valve output pres-

sure
1) Remove oil pressure pickup plug (4).
4) Measure the hydraulic oil pressure with all

the control levers kept in the NEUTRAL
position and the engine running at high idling
and at low idling.
PC160LC-7 20-123
(1)
If the PC-EPC valve output pressure 3. Tighten locknut (7).

changes as shown below, it is normal. Lock nut:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
Control
Engine Oil pressure
lever
2.9 MPa
Low idling
{30 kg/cm2}
Neutral
0 MPa
High idling
{0 kg/cm2}

moved parts.
Adjusting
If the following phenomena occur and PC valve
(5) seems to be defective, adjust PC valve (5)
according to the procedure shown below. 4. After finishing adjustment, check that the PC
• When the working load is increased, the en- valve output pressure (servo piston inlet pres-
gine speed lowers largely. sure) is normal according to the procedure for
• The engine speed is normal but the working measurement described above.
speed is low.
1. Loosen locknut (7).

The width across flats of the PC valve locknut
is 13 mm and that (inside width) of the adjust-
ing screw is 4 mm. All the locknuts and ad-
justing screws other than them affect the
hydraulic pump performance. Accordingly,
do not turn any of them.
Before loosening the locknut, make match
marks at the end of the adjusting screw so
that you can see the position of the adjusting
screw before adjustment (and you can return
the adjusting screw to that position).
2. Turn the adjusting screw (6) to the right or left.

Turn the adjusting screw in the following di-
rections.
• If the work equipment speed is low, turn
the adjusting screw to the right (to in-
crease the pump absorption torque).
• If the engine speed is low, turn the ad-
justing screw to the left (to decrease the
pump absorption torque).
20-124 PC160LC-7
(1)
INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE

OIL PRESSURE
Inspecting and adjusting instruments for pump • (2): Rear pump discharge pressure pick-
LS control circuit up plug

1
Nipple
799-101-5220
M 2 (10 x 1.25 mm)
07002-11023 O-ring
Differential pressure
3 799-401-2701
gauge
A nipples (quick couplers) are installed to the

pump discharge pressure pickup port, LS valve
output pressure pickup port, and LS pressure
pickup port of the Pm clinic specification
machine.
• (3): LS valve output pressure pickup plug
Measurement
Before measuring the pump LS control circuit oil
pressure, check that the work equipment, swing
and travel circuit oil pressures are normal.
stop the engine. Operate the control lever sev-
eral times to release the residual pressure from
the piping, and then loosen the oil filler cap of the
hydraulic tank slowly to release the residual
pressure from the tank.
1. Measurement of LS valve output pressure

(Servo piston inlet pressure)
Measure the LS valve output pressure (servo
piston inlet pressure) and pump discharge 2) Install nipple M2 and connect oil pressure
pressure (both F and R) simultaneously and gauge [1] of hydraulic tester M1.
compare them with each other. Use the oil pressure gauge of 58.8 MPa
1) Remove oil pressure pickup plugs (1), (2), {600 kg/cm2}.
and (3). The measuring instruments installed to
• (1): Front pump discharge pressure pick- the LS valve output pressure pickup port
up plug are shown in the figure.
3) Run the engine and heighten the hydraulic

oil temperature to the operating range.
PC160LC-7 20-125
(4)
4) Run the engine at high idling under the fol- • (2): Rear pump discharge pressure pick-
lowing condition and measure the pump dis- up plug
charge pressures (both F and R) and LS
pressure) simultaneously.
• Working mode: A
• Measure with all of work equipment,
swing, and travel levers in neutral and
with the bucket curled (the bucket lever
at stroke end).
Judging method
If the ratio of the pump discharge pres-
sure (higher one of F and R) to the LS
pressure) is as follows, those pressures
are normal.
Measured oil When bucket 2) Install nipple M2 and connect it to differential

When in neutral
pressure is curled pressure gauge M3 or oil pressure gauge [2]
Pump discharge of hydraulic tester M1.
1
pressure Almost same The measuring instruments installed to
LS valve output pressure Approx. 0.6 the LS pressure pickup plug are shown
pressure (Approx. 3/5) in the figure.
When using the differential pressure
5) After finishing measurement, remove the gauge:
measuring instruments and return the re- Connect the pump pressure (either of F
moved parts. and R) to the high pressure side (back
side) and connect the LS pressure to the
2. Measurement of LS differential pressure low pressure side (lower side). Since the
Measure the pump discharge pressure (ei- differential pressure gauge needs a 12V
ther of F and R) and LS pressure (actuator power source, connect it to a battery.
load pressure) simultaneously and calculate When using oil pressure gauge:
the difference between them and use the re- Use the oil pressure gauge of 58.8 MPa
sult as the LS differential pressure. {600 kg/cm2}.
1) Remove oil pressure pickup plugs (1), (2), Since the differential pressure is about
and (4). 2.5 MPa {25 kg/cm2} at maximum, mea-
• (1): Front pump discharge pressure pick- sure it by installing the same gauge to
up plug the pickup plugs alternately.
• (4): LS pressure pickup plug
20-126 PC160LC-7
(1)
Adjustment
If the LS differential pressure is abnormal, adjust
LS valve (5) according to the following proce-
dure.
3) Run the engine and heighten the hydraulic oil

temperature to the operating range.
1. Fixing adjusting screw (6), loosen locknut (7).
2. Turn adjusting screw (6) to adjust the LS differ-

ential pressure.
If the adjusting screw is
• Turned to the right, the differential
pressure rises.
• Turned to the left, the differential
pressure lowers.
Quantity of adjustment per turn of adjusting
screw: Approx. 1.3 MPa {Approx. 13.3 kg/cm2}
3. Fixing adjusting screw (6), tighten locknut (7).

4) Run the engine at high idling under the fol- Lock nut: 49 – 64 Nm {5 – 7 kgm}
lowing condition and measure the pump dis-
charge pressures (either of F and R) and LS
pressure (actuator load pressure) simulta-
neously.
• Working mode: A
• Measure when all of work equipment,
swing, and travel levers are in neutral
and when the bucket is curled (the buck-
et lever is at stroke end).
Calculation of LS differential pressure
(When oil pressure gauge is used):
LS differential pressure =
Pump pressure – LS pressure
If the LS differential pressure is as fol-
lows, it is normal.
4. After finishing adjustment, check again that the
Operation of lever LS differential pressure LS differential pressure is normal according to
When all levers are Unload pressure the procedure for measurement described
in neutral (See standard value) above.
When bucket is Standard LS differential
curled (lever is at pressure
stroke end) (See standard value)

moved parts.
PC160LC-7 20-127
(1)
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

Measuring instruments for solenoid valve output Since hoses (2) – (6) are installed under the
pressure control valve, remove the control valve un-
dercover.
1
N
799-401-3100 Adapter (Size: 02)
2
799-401-3200 Adapter (Size: 03)
Before measuring the solenoid valve output

pressure, check that the control circuit basic
pressure is normal.
2. Install adapter N2 and connect the disconnected
hoses again.
1. Disconnect hoses (1) – (6) of the solenoid valves
to be measured.
3. Install nipple [1] of hydraulic tester N1 and con-
No. Solenoid valve to be measured nect it to oil pressure gauge [2].
1 PPC lock solenoid valve Use the oil pressure gauge of 5.9 MPa {60
2 2-stage relief solenoid valve kg/cm2}.
3 Swing holding brake solenoid valve The measuring instruments installed to the
4 Travel speed selector solenoid valve outlet hose of the PPC lock solenoid valve
5 Travel junction solenoid valve are shown in the figure.
6 Pump merge-divider solenoid valve
Since hose (1) is installed under the cab, re-

move the cab undercover (rear one).
4. Run the engine and heighten the hydraulic oil

temperature to the operating range.
20-128 PC160LC-7
(4)
5. Run the engine at high idling and operate the

control levers and switches and measure the
pressure when each solenoid valve is turned ON
or OFF.
For the conditions for turning each solenoid
valve ON and OFF, see the table for function-
ing conditions of each solenoid valve.
The operating conditions of the solenoid
valves can be checked with the monitoring
function of the monitor panel (special func-
tion of the monitor panel).
If the output pressure of a solenoid valve is
as follows, that solenoid valve is normal.
Solenoid valve Output pressure
OFF (Demagnetized) 0 MPa {0 kg/cm2}
Almost same as control basic
ON (Magnetized) pressure
(See standard values table)
6. After finishing measurement, remove the mea-

suring instruments and return the removed parts.
Table for Functioning Conditions - PPC lock

solenoid valve
Operating condition Functioning
LOCK OFF
Safety lock lever
RESET ON
PC160LC-7 20-129
(1)
Table for Functioning Conditions - 2-stage relief solenoid valve

Functioning Condition Functioning
When overheat setting of the 1st stage is ON
When overheat setting of the 2nd stage is ON OFF
When all the signals for work equipment, swing and travel are OFF
When swing lock switch is ON
When travel signal is ON
When working mode is L mode ON
When boom LOWER signal is ON
When working mode is A or E When left knob If signals other than swing operation only is ON
mode switch is ON If swing operation only is ON
OFF
In conditions other than above
Table for Functioning Conditions - Swing holding brake solenoid

When all of them is OFF OFF
Work equipment, swing, travel, signaling
When any of them is ON ON
Table for Functioning Conditions - Travel speed shifting solenoid valve

When overheat setting of the 2nd stage is ON
When the fuel dial indicates less than 1500 rpm
When the travel speed switch is at Lo
OFF
The travel signal is OFF
If front or rear pump pressure is
When the travel speed switch is at Hi The travel 29.4 MPa{300 kg/cm2}
signal is ON If front or rear pump pressure is
15.3 MPa{156 kg/cm2} ON
In conditions other than above
Table for Functioning Conditions - Travel junction solenoid valve

When machine travels without operating any work equipment
ON
(When work equipment, swing, and/or service signals are OFF)
When the travel signal is ON When machine travels and operates work equipment simulta-
neously (When work equipment, swing, and/or service signals
are ON) OFF
When the travel signal is OFF
Table for Functioning Conditions - Merge/divide solenoid valve

When machine travels without operating any work equipment
ON
(When work equipment, swing, and/or service signals are OFF)
When travel signal is ON When machine travels and operates work equipment simulta-
neously (When work equipment, swing, and/or service signals
are ON) OFF
When travel signal is OFF
20-130 PC160LC-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

PPC valve output pressure measurement tools 2. Fit fitting [1] of hydraulic tester P and connect oil
pressure gauge [2].
Mark Part No. Part Name Use an oil pressure gauge with the capacity
799-101-5002 Hydraulic Tester of 5.9 MPa {60 kg/cm2}.
P Digital Type The measuring instruments installed to the
790-261-1204
Hydraulic Tester mounting part of the boom RAISE PPC oil
pressure switch are shown in the figure.
Measure PPC valve output pressure after con-
firming that control circuit original pressure is
normal.
1. Remove PPC oil pressure switches (1) through

(10) in the hydraulic circuits to be measured.
Circuit to be Circuit to be
No. No.
measured measured
1 Boom, RAISE (S06) 7 Swing, left (S03)
2 Boom, LOWER (S02) 8 Swing, right (S07)
3 Arm, IN (S04) 9 Travel (black) (S30)
4 Arm, OUT (S08) 10 Steering (red) (S31)
5 Bucket, CURL (S01)
6 Bucket, DUMP (S05)
(1) – (8) are installed to the PPC junction hydraulic oil temperature rises to the operating
block in the rear of the cab. range.
Since (9) and (10) are installed under the 4. Measure the pressure when the engine is run-
cab, remove cab undercover (front one). ning at high idling and the control lever of the cir-
cuit to be measured is kept in the NEUTRAL
position and at the full stroke.
If PPC valve output pressure is at the level
shown below, it is judged normal.
Lever Control Hydraulic Pressure
In NEUTRAL 0 MPa {0 kg/cm2}
Nearly equal to control
At full stroke original pressure
(see standard value table)
5. Detach all the measurement tools, and make

sure that the machine is back to normal condi-
tion.
PC160LC-7 20-131
(4)
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE

If the work equipment/swing lever has large play,
adjust the PPC valve according to the following
procedure.
1. Remove work equipment and swing PPC valve

assembly.
2. Take off boot (1).
3. Loosen lock nut (2) and screw in disc (3) until it

contacts the heads of four pistons (4).
Do not move the piston while doing this work.
4. Keep disc (3) in place and tighten lock nut (2) to

the specified tightening torque.
Lock nut: 98 – 127Nm {10 – 13 kgm}
5. Install boot (1).
6. Install work equipment and swing PPC valve

ass'y.
20-132 PC160LC-7
(4)
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF
TESTING AND ADJUSTING WORK EQUIPMENT
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK

EQUIPMENT
If there is any hydraulic drift in the work equip-
ment (cylinders), check in the following manner
to determine if the cause is in the cylinder pack-
ing or in the control valve.
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
Fill the bucket with earth or apply the rat-
ed load to the bucket.
2) Operate the arm control lever to move the

arm to the digging side.
• If the lowering speed increases, the cyl-
inder piston ring is defective.
• If there is no change, the control valve is
defective.
Operate the control lever with the engine
starting switch in the ON position.
If the pressure in the accumulator of the
PPC circuit is low, heighten it by running
the engine for about 10 seconds.
2) Operate the control lever to the RAISE posi- [Reference]If the cause of the hydraulic drift is in the
tion or the bucket control lever to the CURL defective piston ring, and the above
position. operation is carried out, downward
• If the lowering speed increases, the cyl- movement is accelerated for the follow-
inder piston ring is defective. ing reasons.
• If there is no change, the control valve is 1) If the work equipment is set to the above posture
defective. (holding pressure applied to the bottom end), the
Operate the control lever with the engine oil at the bottom end leaks to the head end.
starting switch in the ON position. However, the volume at the head end is small
If the pressure in the accumulator of the than the volume at the bottom end by the volume
PPC circuit is low, heighten it by running of the rod end, so the internal pressure at the
the engine for about 10 seconds. head end increases because of the oil flowing in
from the bottom end.
2. Inspection of arm cylinder 2) When the internal pressure at the head end
1) Operate the arm cylinder to move the arm to increases, the pressure at the bottom end also
the position 100 mm before the digging rises in proportion to this. The balance is main-
stroke end, and stop the engine. tained at a certain pressure (this differs accord-
ing to the amount of leakage) by repeating this
procedure.
3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit at the head end is opened to
the drain circuit (the bottom end is closed by the
pressure compensation valve), so the oil at the
head end flows to the drain circuit and the down-
ward movement becomes faster.
PC160LC-7 20-133
(1)
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF
TESTING AND ADJUSTING WORK EQUIPMENT
3. Inspection of boom lock valve

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

1) Set the work equipment at the maximum
reach with the boom top in level and stop the
engine.
2) Heighten the pressure in the PPC accumula-
tor and set the safety lock lever in the LOCK/
FREE position and measure the hydraulic
drift of the work equipment.
Operate the safety lock lever while the
starting switch is in the ON position.
If the pressure in the accumulator of the
PPC circuit is low, heighten it by running
the engine for about 10 seconds.
If there is any difference in the hydraulic
drift between LOCK and FREE positions,
the PPC valve is defective (some internal
failure).
20-134 PC160LC-7
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION
TESTING AND ADJUSTING TRAVEL DEVIATION
Inspection
1. Run the engine and heighten the hydraulic oil
temperature to the operating range and set the
machine in the travel posture.
To set the machine in the travel posture, ex-
tract the bucket cylinder and arm cylinder ful-
ly and set the boom angle to 45 degrees.
2. Set the working mode to A and travel speed to

Lo.
3. Run up for 10 m with the engine speed at high

idling and continue travel under the same condi-
tion for 20 m and measure the deviation (a).
Install an oil pressure gauge and check that
the F and R discharge pressures of the hy- Adjustment
draulic pump are even. If the machine deviates, it can be corrected by
partially draining the oil discharged more from
the pump through the travel deviation adjusting
plug. (If the travel deviation is corrected by this
method, howev er, the pump disc har ge is
reduced. As a result, the travel speed, work
equipment speed in compound operation, and
relief pressure may lower.)
PC160LC-7 20-135
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRAVEL DEVIATION
If the machine deviates in the same direction

regardless of the travel direction, correct it
according to the following procedure. (If the
deviating direction of the machine depends on
the travel direction, the cause of deviation may
not be in the hydraulic pump. In this case, carry
out troubleshooting.)
Only when the travel deviation is 200 mm or
less, it can be corrected by the following method.
If the adjusting plug is loosened more than the
adjustment limit, high-pressure oil will spout out.
Take care extremely.
3. Loosen plug (3) to adjust the travel deviation.
• Quantity of adjustment of deviation per turn
of plug: 150 mm (Reference)
The plug is fully tightened when shipped. Ad-
just the deviation by the loosening angle of
1. Check the deviating direction and the locations
the plug from the fully tightened position.
of travel deviation adjusting plugs (1) and (2).
If the plug is turned together with the locknut,
• (1): Right deviation adjusting plug (F pump)
tighten it fully again, then start adjustment.
• (2): Left deviation adjusting plug (R pump)
The plug can be loosened by 2 turns (720 de-
Loosen only the plug on either side for ad-
grees) from the fully tightened position.
justment. Do not loosen the plugs on both
sides.
4. Fixing plug (3) with a hexagonal wrench, tighten
locknut (4).
Locknut: 2.9 – 4.9 Nm {0.3 – 0.5 kgm}
After tightening the locknut, seal its hole with
a vinyl tape.
5. After finishing adjustment, check travel deviation

again according to the procedure for inspection
described above.
2. Fixing plug (3) with a hexagonal wrench (Width

across flats: 4 mm), loosen locknut (4).
If the locknut is sealed with a vinyl tape, re-
move that tape.
Before loosening the locknut, make match
marks on it and pump case.
• Loosening angle of locknut: Approx. 90 – 180
degrees
20-136 PC160LC-7
(1)
TESTING AND ADJUSTING RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT
RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

1. Release of residual pressure from hydraulic 3. Release of residual pressure from swing
tank motor circuit
Release the residual pressure from the swing
The hydraulic tank is enclosed and pressur-
motor circuit by performing the procedure for
ized. When removing a hose or a plug con-
2. release of residual pressure from hydraulic
nected to the hydraulic tank, release the
cylinder circuit.
residual pressure from the hydraulic tank ac-
cording to the following procedure.
4. Release of residual pressure from travel
1) Lower the work equipment to the ground in a
motor circuit
stable posture and stop the engine.
Since the control valve spool of the travel
2) Slowly loosen oil filler cap (1) of the hydraulic
motor is open, release the residual pressure
tank to release the air from the tank.
from the travel motor circuit by performing
the procedure for 1. Release of residual pres-
sure from hydraulic tank.
2. Release of residual pressure from hydraulic

cylinder circuit
When disconnecting the piping between a
hydraulic cylinder and the control valve, re-
lease the residual pressure from the piping
1) Referring to 1. Release of residual pressure
from hydraulic tank, release the residual
pressure from the hydraulic tank.
Leave the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to the ON position
and set the safety lock lever in the FREE po-
sition, and then operate the work equipment
control levers on both sides forward, back-
ward, to the right, and to the left.
The control valve is driven with the pres-
sure in the accumulator. If it is operated
2 - 3 times, the pressure lowers.
3) Start the engine and run it at low idling for 5
seconds to heighten the pressure in the ac-
cumulator.
4) Repeat above steps 2) and 3) 2 – 3 times,
and all residual pressure is released from the
piping.
PC160LC-7 20-137
(1)
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE
MEASUREMENT OF OIL LEAKAGE

Measuring instruments for oil leakage 2) Disconnect hose (2) on the cylinder head
side and block it with a plate.
Take care not to disconnect the hose on
Q Commercially available Measuring cylinder
the cylinder bottom side.
1. Measurement of leakage from boom cylinder

temperature to the operating range and raise
the boom to the stroke end.
Referring to RELEASE OF RESIDUAL
PRESSURE FROM HYDRAULIC CIR-
CUIT, release the residual pressure
from the piping on the boom cylinder
head side (Operate the lever only in the
RAISE direction, however).
2) Disconnect hoses (1) on the cylinder head
side and block it with a plate.
Take care not to disconnect the hose on 3) Run the engine at high idling and relieve the
the cylinder bottom side. arm cylinder by operating the arm control le-
ver in the IN direction
Take care not to operate the arm control
lever in the OUT direction.
4) Start measuring the oil leakage 30 seconds
after the arm cylinder is relieved and mea-
sure for 1 minute.
5) After finishing measurement, return the
parts.
3. Measurement of leakage from bucket cylinder

temperature to the operating range and curl
the bucket to the stroke end.
3) Run the engine at high idling and relieve the PRESSURE FROM HYDRAULIC CIR-
boom cylinder by operating the boom control CUIT, release the residual pressure
lever in the RAISE direction from the piping on the bucket cylinder
Take care not to operate the boom con- head side (Operate the lever only in the
trol lever in the LOWER direction. CURL direction, however).
4) Start measuring the oil leakage 30 seconds 2) Disconnect hose (3) on the cylinder head
after the boom cylinder is relieved and mea- side and block it with a plate.
sure for 1 minute. Take care not to disconnect the hose on
5) After finishing measurement, return the the cylinder bottom side.
parts.
2. Measurement of leakage from arm cylinder

temperature to the operating range and
move in the arm to the stroke end.
PRESSURE FROM HYDRAULIC CIR-
CUIT, release the residual pressure
from the piping on the arm cylinder head
side (Operate the lever only in the IN di-
rection, however).
20-138 PC160LC-7
(1)
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE
3) Run the engine at high idling and relieve the

bucket cylinder by operating the bucket con-
trol lever in the CURL direction
Take care not to operate the bucket
control lever in the DUMP direction.
4) Start measuring the oil leakage 30 seconds
after the bucket cylinder is relieved and mea-
sure for 1 minute.
parts.
4. Measurement of leakage from swing motor

1) Disconnect drain hose (4) and plug it.
3) Disconnect drain hose (5) of the travel motor

and plug it.
2) Turn the swing lock switch ON.

3) Run the engine at high idling and relieve the
swing circuit and measure the oil leakage.
Start measuring the oil leakage 30 sec- 4) Run the engine at high idling and relieve the
onds after the swing motor circuit is re- travel circuit and measure the oil leakage.
lieved and measure for 1 minute.
Since wrong operation of the levers can
After measuring 1 time, swing the upper
cause an accident, make signs and con-
structure 180 degrees and measure
firmation securely.
again.
Start measuring the oil leakage 30 sec-
onds after the swing motor circuit is re-
parts.
lieved and measure for 1 minute.
Measure the oil leakage several times,
5. Measurement of leakage from travel motor
moving the motor little by little (changing
1) Remove the travel motor cover.
the positions of the valve plate and cylin-
2) Start the engine and lock the travel mecha-
der and those of the cylinder and piston).
nism.
Set pin [1] between the sprocket and parts.
track frame to lock the travel mecha-
nism securely.
PC160LC-7 20-139
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
BLEEDING AIR FROM EACH PART

Air bleeding item Air bleeding procedure
1 2 3 4 5 6
Bleeding Bleeding Bleeding Checking

Bleeding
air from Starting air from air from oil level and
Contents of work air from
hydraulic engine swing travel starting
cylinder
pump motor motor work
• Replacement of hydraulic oil

q q q q q q
• Cleaning of strainer (See note) (See note)
• Replacement of return filter element q q
• Replacement or repair of hydraulic pump

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

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

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

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

• Removal of travel motor piping
q q q
Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases.
1. Bleeding air from hydraulic pump If the engine water temperature is low and
Keep the oil filler cap of the hydraulic tank the automatic warm-up operation is started,
loosened while the air is bled from the hy- stop the engine temporarily and reset the au-
draulic pump. tomatic warm-up operation with the fuel con-
1) Loosen air bleeder (1) and check that oil ooz- trol dial (Set the starting switch in the ON
es out from it. position and hold the fuel control dial in the
2) After oil containing no bubbles flows out, MAX position for 3 seconds, and the auto-
tighten air bleeder (1). matic warm-up operation is reset).
Air bleeder:
27.5 – 35.3 Nm {2.8 – 3.6 kgm} 3. Bleeding air from cylinder
If a cylinder was replaced, bleed air from it
before connecting the work equipment. In
particular, the boom cylinder does not move
to the lowering stroke end, if it is installed to
the work equipment.
1) Run the engine at low idling for about 5 min-
utes.
2) Running the engine at low idling, raise and
lower the boom 4 – 5 times.
Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil.
3) Running the engine at high idling, perform
step 2).
4) Running the engine at low idling, move the
2. Starting engine piston rod to the stroke end and relieve the
When running the engine after performing step oil.
1, keep its speed at low idling. 5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
20-140 PC160LC-7
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
4. Bleeding air from swing motor If the oil level is below line L, add new oil.
1) Run the engine at low idling.
2) Swing to the right and left slowly to bleed air.
5. Bleeding air from travel motor

1) Run the engine at low idling.
2) Loosen air bleeder (2) and check that oil ooz-
es out from it.
3) After oil containing no bubbles flows out,
tighten air bleeder (2).
Air bleeder:
27.5 – 35.3 Nm {2.8 – 3.6 kgm}
6. Checking oil level and starting work

1) Run the engine, retract the arm cylinder and
bucket cylinder to the stroke ends, lower the
work equipment to the ground, and stop the
engine.
2) Check the oil level by sight gauge (3) of the

hydraulic tank.
If the oil leakage is between lines H and
L, it is normal.
PC160LC-7 20-141
(1)
TESTING AND ADJUSTING INSPECTION PROCEDURES FOR DIODE
INSPECTION PROCEDURES FOR DIODE

Check an assembled-type diode (8 pins) and
single diode (2 pins) in the following manner.
2. When using analog type circuit tester

1) Switch the testing mode to resistance range.
The conductive direction of each diode is 2) Check the needle swing in case of the fol-
marked on its surface as shown below. lowing connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe (–) to
the cathode (N) of diode.
ii) Put the red probe (+) of the test lead to
the cathode (N) and the black probe (–)
to the anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
• If the needle does not swing in Case i),
but swings in Case ii): Normal (but the
breadth of swing (i.e. resistance value)
will differ depending on a circuit tester
type or a selected measurement range)
1. When using digital type circuit tester • If the needle swings in either case of i)
1) Switch the testing mode to diode range and and ii): Defective (short-circuited inter-
confirm the indicated value. nally)
Voltage of the battery inside is displayed • If the needle does not swing in any case
with conventional circuit testers. of i) and ii): Defective (short-circuited in-
2) Put the red probe (+) of the test lead to the ternally)
anode (P) and the black probe (–) to the
cathode (N) of diode, and confirm the dis-
played value.
3) Determine if a specific diode is good or no
good with the indicated value.
• No change in the indicated value: No
continuity (defective).
• Change in the indicated value: Continuity
established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.
20-142 PC160LC-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
SPECIAL FUNCTION OF MONITOR PANEL
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
PC160LC-7 20-143
(1)
Monitor panel functions - conventional and special

The monitor panel is provided with conventional and special functions, and various kind of information are
shown in the multi-display. Display items consists of automatic display items that are preset in the monitor panel
and others that are shown by switch operations.
1. Conventional function: Operator's Menu

This is a function by which an operator can set or show displays by switch operations. The display contents
are those which are normally shown.
2. Special function: Service Menu

This is a function by which a service mechanic can set or show displays by special switch operations. The
display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trou-
ble-shooting or special setting of machines.
Operator's Menu Service Menu

1 Function for inputting and setting password 16 Function for monitoring [01]
2 Function for showing Komatsu's logo Function for fail- Electrical system
17
Function for machine inspection before starting ure history [02] Mechanical system
3
day's work 18 Function for maintenance history [03]
4 Function for showing machine maintenance 19 Function for maintenance mode change [04]
5 Function for showing precaution items 20 Function for recording phone No. [05]
Function for confirming working mode and Mode with key on
6
travel speed (Change)
Function for initial Language
7 Function for display of ordinary items
21 value setting and Unit
Function for adjusting display luminance and default [06]
8 Attachment installed/No
contrast
attachment installed
Function for adjusting breaker and attachment
9 Adjustment of governor
flow rate
lever stroke
Function for confirming maintenance informa-
10 Fuel pump
tion
Function for absorbin torque
22
11 Function for showing service meter reading adjustment [07]
RPM at low idling
12 Function for checking display LCD
Adjustment of oil flow to
Function for showing occurrence of caution attachment
13
item
14 Function for showing users' code No.
Function for showing error code No. and failure
15
code No.
20-144 PC160LC-7
(1)
Operation of Operator's Menu and

Display
This section introduces only the outline of the
operator's menu. For details on the contents and
operation steps of each menu, refer to the oper-
ation and maintenance manual or the chapter of
"STRUCTURE AND FUNCTION" in this shop
manual.
1. Function for inputting and setting password

When the engine starting switch is turned ON,
the password inputting display is shown.
This display is shown only when a password
is registered.
2. Function for showing KOMATSU logo

When a password is inputted, or when the
engine starting switch is turned ON, KOMATSU
logo is shown for two seconds.
3. Function for machine inspection before start-

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

Following the display of machine inspection
before starting day's work, the maintenance
mark appears for 30 seconds, if there is an oil fil-
ter whose maintenance time is approaching or
has just passed.
This display appears only when the mainte-
nance function is set.
PC160LC-7 20-145
(1)
5. Function for showing precaution items

If there is any item of machine inspection before
starting day's work that indicates some abnor-
mality, a corresponding symbol mark is shown
after the display of machine inspection before
starting day's work.
6. Function for confirming working mode and

travel speed
After the display of machine inspection before
day's work, amplified symbol marks for working
mode and travel speed are shown for two sec-
onds to urge an operator to confirm the setting.
7. Function for display of ordinary items

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

contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.
20-146 PC160LC-7
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9. Function for adjusting breaker and attach-

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

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

Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
• Switching operation: [ ] + [ ] (synchro-
nized switching operation)
12. Function for checking display LCD

Display of the Display LCD can be confirmed by
the following switching operation in the display of
inputting and setting password as well as in the
display of ordinary items
• Switching operation: [ ] + [A] (synchronized
switching operation)
All the LCD light up, turning the entire screen
white. If there is no showing in black, the dis-
play is normal.
This display returns to the immediately pre-
ceding one, if making any other switching op-
eration.
PC160LC-7 20-147
(1)
13. Function for showing occurrence of caution

item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for two
seconds and thereafter stays on the display as a
small symbol mark until it is dissolved.
14. Function for showing users' code No.

When a trouble occurs on the machine, the
user's code is automatically displayed depend-
ing on the magnitude of the trouble to call atten-
tion of the operator for a proper action.
This display turns to the display of service
code and failure code, if operating the switch
(Refer to Item No. 15)
Relation between User Code and Action Directed to Operator
User
Failed System Action Directed to Operator
Code
Error in pump Turn the emergency pump driving switch ON (Set it in the emergency position), and you can
E02
control system operate the machine normally. Have the machine inspected immediately, however.
Turn the swing holding brake release switch (ON) (Set it in the release position) to release
Error in swing the brake. To apply the swing brake, operate the swing lock switch manually. The brake
E03
brake system may not be released, depending on the cause of the fault. Have the machine inspected
immediately in any case.
Error in governor
E05 The governor cannot be controlled. Have the machine inspected immediately in this case.
system
20-148 PC160LC-7
(1)
15. Function for showing error code No. and fail-

ure code No.
If the following switching operation is made while
the users' code No. is shown, a phone symbol (if
registered), phone numbers (if registered), error
code No. and failure code No. are shown in turn.
• Switching operation: [ ] (keep the switch
depressed)
The following display is repeated in turn,
while the switch is depressed.
(1) Telephone symbol mark
(2) Telephone No.
(3) Error code No. and failure code No.

The telephone symbol mark and telephone
No. are shown only when they are registered
in the monitor panel.
For registration, correction and deletion of
telephone No., use Service Menu.
For details on the displayed error code No.
and failure code No., refer to the Table for er-
ror and Failure Code Nos.
PC160LC-7 20-149
(1)
Table for Error and Failure Code Nos.
Classification
Error Code Failure Code
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
Abnormality in
– E101 Abnormal data in error history DAF0KT Monitor controller
controller
Short circuit in wiper motor drive, normal rota-
Windshield wiper motor (nor-
– E112 DY2DKB Short circuit
tion system mal rotation)
Short circuit in wiper motor drive, reverse rota-
Windshield wiper motor
– E113 DY2EKB Short circuit
tion system (reverse rotation)
– E114 Short circuit in windshield washer drive system
DY2CKB Windshield washer motor Short circuit
– E115 Abnormality of windshield wiper in motion
DY20KA Windshield wiper motor Disconnection
– E116 Abnormality of windshield wiper in retraction
DY20MA Windshield wiper motor Malfunctioning
– E201 Short circuit in travel junction solenoid
DW91KB Travel neutral solenoid valve Short circuit
Swing holding brake sole-
E03 E203 Short circuit in swing holding brake solenoid DW45KB Short circuit
noid valve
Pump merge/divider sole-
– E204 Short circuit in merge/divider solenoid DWJ0KB Short circuit
noid valve
– E205 Short circuit in 2-stage relief solenoid DWK0KB 2-stage relief solenoid valve Short circuit
Travel Hi-Lo shifting solenoid
– E206 Short circuit in travel speed shifting solenoid DW43KB Short circuit
valve
– E211 Disconnection in travel junction solenoid DW91KA Travel neutral solenoid valve Disconnection
Swing holding brake sole-
E03 E213 Disconnection in swing holding brake solenoid DW45KA Disconnection
noid valve
Pump merge/divider sole-
– E214 Disconnection in merge/divider solenoid DWJ0KA Disconnection
noid valve
– E215 Disconnection in 2-stage relief solenoid DWK0KA 2-stage relief solenoid valve Disconnection
Electrical system
Travel Hi-Lo shifting solenoid
– E216 Disconnection in travel speed shifting solenoid DW43KA Disconnection
valve
Nonconfor-
S-NET communication of
– E217 Abnormality in model code input DA2SKQ mance in model
governor pump controller
selecting signal
S-NET communication of
– E218 Disconnection in S_NET signal DA2SKA Disconnection
governor pump controller
– E224 Abnormality in F pump pressure sensor DHPAMA F pump pressure sensor Malfunctioning
– E225 Abnormality in R pump pressure sensor DHPBMA R pump pressure sensor Malfunctioning
Power source output of gov- Lowering in out-
– E226 Abnormality in pressure sensor power source DA25KP
ernor pump controller put voltage
– E227 Abnormality in engine revolution sensor DLE2MA Engine revolution sensor Malfunctioning
– E228 Short circuit in ATT return switching relay D196KB ATT switching relay Short circuit
E02 E232 Short circuit in PC-EPC solenoid DXA0KB TVC solenoid valve Short circuit
E02 E233 Disconnection in PC-EPC solenoid DXA0KA TVC solenoid valve Disconnection
– E238 Disconnection in ATT return switching relay D196KA ATT switching relay Disconnection
Short circuit in ATT flow rate adjusting EPC Solenoid of attachment flow
– E245 DXE4KB Short circuit
solenoid rate PPC adjustment valve
Disconnection in ATT flow rate adjusting EPC Solenoid of attachment flow
– E246 DXE4KA Disconnection
solenoid rate PPC adjustment valve
– E306 Abnormality in governor potentiometer DK54KZ Body positioner sensor Short circuit
E05 E308 Abnormality in fuel dial DK10KZ Throttle potentiometer Short circuit
Short-circuiting in low-temperature starting Low-temperature starting
– E311 D199KB Short circuit
solenoid relay solenoid relay
Short-circuiting in low-temperature starting Low-temperature starting
– E312 D199KA Disconnection
solenoid relay solenoid relay
– E315 Short circuit in battery relay output D110KB Battery relay Short circuit
– E316 Abnormality in governor motor step-out DY10K4 Governor motor Out of control
20-150 PC160LC-7
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system Classification
Error Code Failure Code
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
Electrical
E05 E317 Disconnection in both governor motors A and B DY10KA Governor motor Disconnection
E05 E318 Short circuit in both governor motors A and B DY10KB Governor motor Short circuit
– None Engine high idling out of rate A000N1 Engine Overrunning
Low-idling speed
– None Engine low idling out of rate A000N2 Engine
heightened
– None Air cleaner clogged AA10NX Air cleaner element Clogging
Insufficient
Mechanical system
– None Charging voltage abnormally low AB00KE Alternator
charging
Oil pressure low-
– None Engine oil pressure abnormally low B@BAZG Engine oil
ered
– None Engine oil level abnormally low B@BAZK Engine oil Oil level lowered
– None Engine cooling water overheated B@BCNS Engine cooling water Overheating
Cooling water
– None Radiator water level abnormally low B@BCZK Engine cooling water
level lowered
– None Hydraulic oil overheated B@HANS Hydraulic oil Overheating
Auto-lubrication system con-
– None Auto-lubrication system abnormal DA80MA Malfunction
troller Ass‘y
This table is arranged in the sequence of Error Code No.

In case there is no number assigned in the column of User Code No., or in case "none" is described in the
column of Code No. of Error Code, the corresponding service code or failure code is not shown in the dis-
play of ordinary items, even if some abnormality occurs. It is recorded only in the failure history (either in
electrical system or mechanical system) of Service Menu.
History Classification indicates that a specific failure is classified as belonging to either electrical system or
mechanical system, when it is recorded in Service Menu.
"E" at the head of Code No. of Error Code means the following status of a specific failure.
• With "E": The failure is yet to be dissolved and continues.
• Without "E": The failure has already been dissolved.
PC160LC-7 20-151
(1)
Operation and Display of Service Menu
Way of switching to Service Menu

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

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

00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
06 AAAAA / Default
07 Adjustment
08 –
4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent display of Service Menu, do that
through any one of the following methods.
• Depress [ ] switch. (This method may be
used for terminating any display)
• If "Return" switch is shown, depress it.
• If "Return" menu is shown, call that menu
and depress [ ] switch.
20-152 PC160LC-7
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16. Function of monitoring [01]

The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Moni-
tored information can be put in display or con-
firmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
2) Setting of monitoring item

Select or register an item to be monitored
through the following switch operation.
• [ ] switch: Selection
• [ ] switch: Selection
• [ ] switch: Registration
A monitoring item can be set in any number
between the min. one to the max. four. (De-
pending upon the selected item, the max.
number is less than four)
In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
• Keep [ ] switch depressed. (For about
3 seconds)
• Select Menu 999 and depress [ ]
switch.
The display automatically moves to the dis-
play of monitored information, when all of the
registrable items have been duly registered.
Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communica-
tion speed. If truly real time monitoring is re-
quired, reduce the selected items to the
minimum.
For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.
PC160LC-7 20-153
(1)
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while op-
erating the machine.
4) Monitored information holding function

If [ ] switch is depressed while monitoring,
all the monitored information are put on hold.
If [ ] switch is depressed in this condition,
information holding is released.
5) Machine setting mode switching function

If it becomes necessary to change settings of
working mode, select mode, travel speed
and auto-decel while monitoring, depress the
corresponding switch, then the mode confir-
mation display is shown.
An illustration at right shows the display in A
mode and E mode. Symbol marks are partial-
ly different in B mode.
When a specific setting is confirmed, depress
[ ] switch, then the display returns to that of
monitoring.
In case a specific setting has been changed
while monitoring, the new setting is still main-
tained when returning from Service Menu to
Operator's Menu after the monitoring is fin-
ished.
20-154 PC160LC-7
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Table for Monitoring Items

Code Unit (Default: ISO)
Item to be monitored Remark
No. ISO Meter Inch
000 Return (Not displayed) Return menu
Execute
999 To Display Screen (Not displayed)
Command menu
002 Controller Model Select Figure
003 Controller Model Select Figure
010 Engine Speed r/min rpm rpm
011 F Pump Pressure MPa 2 psi
kg/cm
012 R Pump Pressure MPa kg/cm2 psi
013 PC-EPC Sol. Curr. mA mA mA
015 LS-EPC Sol. Curr. mA mA mA (Not used)
016 2nd Eng. Speed Command r/min rpm rpm
017 Service Sol. Curr. mA mA mA
Swing ON/OFF
Travel ON/OFF
Pressure Boom Lower ON/OFF
019
Switch 1 Boom Raise ON/OFF
Arm In ON/OFF
Arm Out ON/OFF
Bucket Curl ON/OFF
Bucket Dump ON/OFF
Pressure
021 Offset ON/OFF (Not used)
Switch 2
Service ON/OFF
Travel differential Pressure ON/OFF
Knob Sw. ON/OFF
022 Switch Input 1 Swing Release Sw. ON/OFF
Swing holding Brake Sw. ON/OFF
Travel Junction ON/OFF
Swing holding Brake ON/OFF
023 Solenoid valve 1 Merge-divider ON/OFF
2-stage Relief ON/OFF
Travel Speed ON/OFF
024 Solenoid valve 2 ATT Return ON/OFF
Model Select 1 ON/OFF
027 Switch Input 2
Low-viscosity fuel mode ON/OFF
030 Fuel Dial Vol. V V V
031 Gov. Motor Potentio Vol. V V V
032 Battery Voltage V V V
033 Gov. Motor Phase A Curr. mA mA mA
034 Gov. Motor Phase B Curr. mA mA mA
035 Battery Relay O/P Vol. V V V
036 Switch Input 3 Key Switch ON/OFF
037 Controller Output Batt. Relay Dr. ON/OFF
041 Engine Water Temperature ºC ºC ºF
PC160LC-7 20-155
(1)
Code Unit (Default: ISO)

Item to be monitored Remark
No. ISO Meter Inch
042 Fuel Lever Sensor Vol. V V V
043 Battery Charge Vol. V V V
044 Hydr. Oil Temperature ºC ºC ºF
Key Switch ON/OFF
Start ON/OFF
045 Monitor Input 1 Preheat ON/OFF
Light ON/OFF
Radiator water Level ON/OFF
Aircleaner ON/OFF
Engine Oil Pressure ON/OFF
046 Monitor Input 2 Engine Oil Level ON/OFF
Spare ON/OFF
Battery Charge ABN•NOR
Swing Holding Brake Switch ON/OFF
Buzzer cancel Switch ON/OFF
049 Monitor Input 3 Window Limit Switch ON/OFF
W Limit Switch ON/OFF
P Limit Switch ON/OFF
159 Boom bottom Pressure MPa {kg/cm2} PSI (Not used)
200 Monitor Prog. Version Figure
201 Controller Prog. Version Figure
Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When
changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu.
Abbreviations, ABN and NOR, stand for the following conditions.
ABN: Abnormal, NOR: Normal
20-156 PC160LC-7
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17. Function for Abnormality Record [02]

The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical System
02 Mechanical Systems
3) Information shown in display of Abnormality

Record in the electrical system
[1]: The numerator expresses sequence of
failure occurrence, counting from the lat-
est one. The denominator expresses the
t o ta l n u m b e r o f a s p e c i f i c f a i l u r e
recorded.
[2]: Error Code
[3]: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
[4]: Time elapsed since the occurrence of
the first failure
[5]: Contents of failure
Refer to "Table for Error Code and Ab-
normality Code" in Operator's Menu.
4) Information shown in display of Failure His-

tory in the mechanical systems
[1]: Record No.
[2]: Contents of Abnormality
[3]: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
[4]: Total number of occurrence
[5]: Service meter reading at the initial
occurrence
Refer to "Table for Error Code and Ab-
normality Code" in Operator's Menu.
PC160LC-7 20-157
(1)
5) Resetting Electrical Systems

Resetting Electrical Systems (deletion) is
possible only with the electrical system.
The failure history in the mechanical sys-
tem cannot be reset.
For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,
call the resetting display in the display of
Electrical Systems.
• Switch operation: [ ]+[1] [2] [3]
This is the same switch operation in
changing the display to Service
Menu.
ii) Operate the switch, following the instruc-
tions shown in the resetting display.
When resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
When resetting all the information, a
display of any information will do.
20-158 PC160LC-7
(1)
18. Function for Maintenance Record [03]

The monitor panel records information on the
maintenance of filters and oils. The stored infor-
mation can be displayed through the following
switch operation.
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
• Name of oils and filters
• Times of replacement to date
• Service meter reading at the latest re-
placement
PC160LC-7 20-159
(1)
19. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance dis-
play function can be changed in the following
manner.
• Turn the function effectual or ineffectual.
• Change the set interval for replacement.
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No. Maintenance mode change item
00 Return
01 Maintenance Mode On/Off
02 Engine Oil Exch. Int.
03 Engine Oil Filter Exch. Int.
04 Fuel Filter Exch. Int.
05 Hydr. Oil Filter Exch. Int.
06 H/Tank Breather Exch. Int.
07 Corro. Resis. Exch. Int.
08 Damper Case Oil Service Int.
09 Final Drive Oil Exch. Int.
10 S/Machinery Oil Exch. Int.
11 Hydraulic Oil Exch. Int.
12 Use Default Values
01 and 12 menus are provided for setting the

whole maintenance mode, while those from
02 through 11 are for setting individual items.
3) Contents of Maintenance Mode On/Off

• Use: The maintenance display function
of all oil and filter-related items are
turned effectual. (Irrespective of whether
"On" or "Off" set for individual items, this
setting prevails)
• Do not use: The maintenance display
function of all oil and filter-related items
are turned ineffectual. (Irrespective of
whether "On" or "Off" set for individual
items, this setting prevails)
20-160 PC160LC-7
(1)
4) Set contents of individual items

(1): Default: The maintenance time set in the
monitor (recommended by the manufac-
turer and cannot be changed).
(2): Set: Maintenance time that can be freely
set. The maintenance mode program
functions based on this maintenance
time. (The maintenance time can be
increased or decreased by 50 hours with
[ ] or [ ] switch)
(3): Off: Maintenance display with this
instruction becomes ineffectual.
(4): On: Maintenance display function with
this instruction becomes effectual.
The lowest maintenance time is 50 h.
5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings are
reduced to the initial settings.
PC160LC-7 20-161
(1)
20. Function for Phone Number Entry [05]

In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the follow-
ing manner.
If there is no Phone number registered, the
display for Phone numbers does not appear.
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
Even if a Phone number is already input-
ted, it is deleted, upon switching to the
Phone Number Entry display.
3) Entry and setting Phone number

Following the method explained below, Entry
a Phone number in the Phone Number Entry
display. (Entry automatically begins with a
cursor at the left end)
(1) Enter a number into a cursor at the left
end with a ten-key.
Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
When entering a wrong number, depress
[B] switch, then the cursor goes back by
one digit.
(2) Depress [ ] switch when all the num-
bers have been entered.
When input is finished, the display
changes to Entry display shown above. If
the inputted Phone number is shown in
this display, the input is normal.
20-162 PC160LC-7
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21. Function for AAAAA/Default [06]

It is possible to change the following settings for
the monitor panel as well as the machine. Make
a change as is required.
• Working mode when the engine starting
switch is in the ON position.
• Display language in Service Menu
• Display unit in the monitoring function
• With/Without Service Cir.
Select 06 "AAAAA/Default menu" in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
No. AAAAA/Default submenu
00 Return (termination of AAAAA/Default)
01 Key-on Mode
02 AA/Language
03 Unit
04 With/Without Service Cir.
3) Function for Key-on Mode

When the engine starting switch is turned
ON, a working mode can be set that is
shown in the monitor panel.
• A, E, L and B Modes: If any of them is
set, the machine always ramps up with
that working mode, when turning the en-
gine starting switch ON.
• Mode at Previous Key-off: If this mode is
set, the machine ramps up with the work-
ing mode that was last used in the previ-
ous machine operation.
• Default Value: If this mode is set, the ma-
chine ramps up with the default mode (A
mode) that was originally set at the time
of delivery from the factory.
Irrespective of this setting mode, a ma-
chine "With attachment" always ramps
up with B mode, when the engine start-
ing switch is turned ON at the subse-
quent operation, if that was the working
mode used in the last machine work.
PC160LC-7 20-163
(1)
4) Function for AA/Language

In Service Menu, the language in use can be
changed between Japanese and English.
English is used as the language for de-
fault setting in the monitor panel.
If the monitor panel for spare parts is to
be used in a Japanese-speaking region
or organization, change the language
from English to Japanese, using this
function.
5) Function for unit selection

As the unit to be used in the monitoring func-
tion display of Service Menu, three kinds of
unit are provided.
Unit used for default setting in the moni-
tor panel is SI, i.e. International System
of Units.
6) Function for selecting distinction of With/

Without Service Cir.
It is possible in this function to set a distinc-
tion between with or without attachment.
• With Service Circuit: When an attach-
ment is installed.
• Without Service Circuit: When no attach-
ment is installed.
If "With Service Circuit" setting is not
made in this display, while it is actually
installed on a specific machine, SELECT
function in Operator's Mode (attachment
oil flow rate adjustment) cannot be uti-
lized.
20-164 PC160LC-7
(1)
22. Function for Adjustment [07]

The monitor panel has a function of making vari-
ous adjustments of the machine.
Select 07 adjustment in the initial display of
Service Menu, and depress [ ] switch.
2) Selection of submenu
Select an item to change from the submenu
No. Adjustment submenu
00 Return (termination of adjustment)
01 Governor lever stroke adjustment
02 Pump Absorption Torque
03 Low Idle Speed
04 Service Current Adjustment
3) Function of adjusting governor lever stroke

After the governor actuator, the fuel in-
jection pump, or governor spring is re-
moved and installed or when the engine
speed does not rise to high idling or is not
stable, adjust the governor lever stroke
(1) Select Adjustment on the Governor lever
stroke adjustment screen and set the
fuel control dial to the MAX position.
Under this condition, the governor
actuator lever moves to the FULL
position. Keep this screen while you
are adjusting the governor lever
stroke.
The engine speed is displayed in 10
rpm on the center of the screen.
The rotation direction of the governor
spring when you see the governor
actuator side from the fuel injection
pump side is indicated.
To adjust the governor spring, turn
the square part on the governor mo-
tor side with a spanner, etc.
PC160LC-7 20-165
(1)
(2) Loosen locknut (2) on the governor actu-

ator side of governor spring (1).
(3) Turn governor spring (1) clockwise to de-
crease installed length (a) and return
governor lever (3) of the fuel injection
pump to a position where it will not touch
the full stopper.
(4) Turn governor spring (1) counterclock-
wise to increase installed length (a) and
stop it when governor lever (3) of the fuel
injection pump touches the full stopper.
• Standard installed length (a) (Refer-
ence): 259.9 mm
(5) Turn governor spring (1) counterclock-
wise further by 2.5 turns to shorten the
internal spring of governor spring (1).
Since the internal spring is short-
ened, only the outer cylinder of gov-
ernor spring (1) moves about 3.1 mm
toward the fuel injection pump (The
installed length does not change).
(6) With governor spring (1) fixed, tighten
locknut (2) on the governor actuator side.
Before fixing the locknut, check that
the water drain hole of the governor
spring is directed down. If the water
drain hole is not directed down, loos-
en locknut (4) on the fuel injection
pump side and turn the whole gover-
nor spring (Take care that the adjust-
ment length of the governor spring
will not change).
Locknut:
11.8 – 19.6 Nm {1.2 – 2.0 kgm}
(7) Return the fuel control dial to the MIN po-
sition, and then turn it again gradually to-
ward the MAX position. At this time,
check that the governor spring is short-
ened about 3.1 mm after governor lever
(3) touches the full stopper.
4) Function for Pump Absorption Torque adjust-

ment
The pump absorption torque can be adjusted
within the range shown in the table below.
Adjustment value Torque adjustment value
220 +4.0 kgm
221 +3.0 kgm
222 +2.0 kgm
223 +1.0 kgm
224 0.0 kgm
225 –1.0 kgm
226 –2.0 kgm
227 –3.0 kgm
228 –4.0 kgm
20-166 PC160LC-7
(1)
5) Function for Low Idle Speed adjustment

The engine rotation at low idling can be ad-
justed within the range shown in the table be-
low.
Adjustment value Low idling rotation
320 1,030 ± 50 rpm
321 1,100 rpm
322 1,200 rpm
323 1,300 rpm
6) Function for Service Current Adjustment

When a machine is used for a compound op-
eration, distribution of hydraulic pump oil flow
can be adjusted within the range shown in
the table below.
Distribution of oil flow
Adjustment value
to attachment
370 0.5 Time
371 0.7 Time
372 1.0 Time
373 0.4 Time
PC160LC-7 20-167
(1)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Section to display Section to operate special Section to operate special function 2

special functions function 1 (Basic operation) (Selecting operation and special operation)
1. Display section 3. Caution buzzer stop switch 7. Working mode selector (UP) switch
2. Service meter 4. Auto-decelerator switch 8. Working mode selector (DOWN) switch
section 5. Setting switch (Black switch)
6. Travel speed shifting switch
PC160LC-7 20-169
(3)
Ordinary functions and special functions of monitor panel

The monitor panel has the ordinary functions and special functions and displays various pieces of information
on display section (1) and service meter section (2).
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu

The items in this menu are displayed normally or displayed automatically when a trouble occurs.
2. Special functions: Service menu

The items in this menu are not displayed normally. Each serviceman can display them by operating special
switches. These functions are used for special setting, testing, adjusting, or troubleshooting.
Flow of each function
Ordinary functions (Operator menu) Special functions (Service menu)
1 Function of displaying service meter <Operation of switch> O 3 Function of displaying service code [01]
O <Automatic> 4 Monitoring function [02]
2 Function of displaying user code 5 Function of adjusting governor [03]
6 Function of selecting maintenance period [04]

7 Function of selecting default working mode [05]
8 Function of setting installation of attachment [16]
Special function of monitoring replacement

9
of engine oil
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
20-170 PC160LC-7
(3)
Display of operator menu
a Only outline of the operator menu is described in

this section. For details of each menu, see OP-
ERATION MANUAL or the volume of STRUC-
TURE AND FUNCTION.
1. Function of displaying service meter

While the machine is used normally, the monitor
panel displays the following information.
• Display section (1): Nothing is displayed
• Service meter section (2): Service meter
2. Function of displaying user code

If the machine has any trouble, the correspond-
ing user code is displayed automatically in dis-
play section (1) and the caution buzzer is turned
ON to urge the operator to take a proper remedy,
depending on the degree of the trouble.
a Service meter section (2) continues display-
ing the service meter.
a For displayed user codes and the remedies
shown to the operator, see "User codes and
remedies shown to operator".
a Each user code simply shows occurrence of
a trouble to the operator. To find out the
cause of the trouble, a serviceman must
check the service code with the "Function of
displaying service code [01]" in the service
menu.
<Reference>
A user code is displayed only when a serious
trouble occurs.
Even if a user code is not displayed, a trouble
may have occurred. If you feel any abnormality,
be sure to check for a service code with the
"Function of displaying service code [01]" in the
service menu.
a User codes and remedies shown to operator
User Caution
Error mode Remedy (shown to operator)
code buzzer
If the emergency pump drive switch is set in the upper position, the
Error in pump
E02 machine can operate normally. Have the machine inspected immediately, q
control system
however.
Set the swing holding brake release switch in the upper position to release
Error in swing the brake. When applying the swing brake, operate the swing lock switch
E03 q
brake system manually. The brake may not be released, depending on the cause of the
failure. In this case, have the machine inspected immediately.
Error in governor
E05 Have the machine inspected immediately. q
system
PC160LC-7 20-171
(3)
Operation and display of service menu
How to select service menu

a When using the general functions in the service
menu, perform the following switch operation to
change the screen of the monitor panel.
3. Function of displaying service code [01]
4. Monitoring function [02]
5. Function of adjusting governor [03]
6. Function of selecting maintenance period
[04]
7. Function of selecting default working
mode [05]
8. Function of setting installation of attach-
ment [16]
1) Operating switches
While holding caution buzzer stop switch (3),
hold auto decelerator switch (4) for 2.5 seconds.
2) Displaying display section and service meter

section
If the switches are operated as shown above,
the first menu No. [01] (Monitoring function) is
displayed in service meter section (2).
a Nothing is displayed in display section (1).
3) Selecting menu
operate working mode selector switches (7) and
(8) to select a menu you will use.
• UP switch (7): Increase Menu No.
• DOWN switch (8): Decrease Menu No.
Menu Service menu

No. (Excluding special functions)
01 Function of displaying error code
02 Monitoring function
03 Function of adjusting governor
04 Function of selecting maintenance period
05 Function of selecting default working mode
16 Function of setting installation of attachment
4) Executing menu
Select a menu you will use and press set switch
(5), and the menu is executed.
5) Finishing service menu

hold auto decelerator switch (4) for 2.5 seconds
(similarly to the selecting operation).
a The service menu is finished and the ordi-
nary screen appears.
a The service menu can be also finished by
turning the starting switch OFF while the
service menu is selected. (In this case, the
ordinary screen appears when the starting
switch is turned ON again.)
20-172 PC160LC-7
(3)
a To use the following special function, you must

operate the switches differently from the above.
See details of this function "9. Special function
of monitoring replacement of engine oil".
3. Function of displaying service code [01]

With this function, you can check the service
code of a trouble which is occurring at present or
has occurred in the past.
1) Selecting and executing function

i) Select menu No. [01] in the menu selec-
tion mode.
ii) Press set switch (5) to execute this func-
tion.
2) Information displayed in display section and

service meter section 1 (When service code
is recorded)
If a service code is recorded, the following
information is displayed in display section
(1) and service meter section (2).
(a): Service code
(b): Service meter reading increased after
trouble occurred
(c): Mark [E] to indicate that trouble is occur-
ring at present
a Mark [E] to indicate that a trouble is oc-
curring at present indicates that the serv-
ice code is being detected now. It is not
displayed if the trouble has been re-
paired or the service code is not detect-
ed.
a For the service codes which the monitor
panel and engine throttle and pump con-
troller can detect, see the "Service codes
table".

service meter section 2 (When service code
is not recorded)
If a service code is not recorded, display
section (1) and service meter section (2) dis-
play as shown in the figure.
4) Number of recorded service codes and dis-

play order of them
This function can record up to 20 service
codes, which are displayed in order from the
latest one.
a If a new trouble occurs while 20 service
codes are recorded, the oldest service
code is deleted and the service code of
the new trouble is recorded.
PC160LC-7 20-173
(3)
1) Change of displayed service codes

operate working mode selector switches (7)
and (8) to change the displayed service
codes.
• UP switch (7):
Next service code appears.
• DOWN switch (8):
Previous service code appears.
2) How to delete service code

i) While holding caution buzzer stop
switch (3), turn the starting switch OFF
and keep holding caution buzzer stop
switch (3).
ii) Under the above condition, turn the
starting switch ON again and hold cau-
tion buzzer stop switch (3) for 5 sec-
onds.
a A service code having the mark [E] is not
deleted.
20-174 PC160LC-7
(3)
Service codes table

User code Service code Trouble
— E101 Abnormality in error history data
— E104 Clogging of air cleaner (Equivalent to error code [AA10NX])
— E108 Overheating of engine coolant (Equivalent to error code [B@BCNS])
— E112 Short circuit in wiper motor drive forward system
— E113 Short circuit in wiper motor drive reverse system
— E114 Short circuit in windshield washer drive system
— E115 Trouble in operation of windshield wiper
— E116 Trouble in storage of windshield wiper
— E201 Short circuit in travel junction solenoid
E03 E203 Short circuit in swing holding brake solenoid
— E204 Short circuit in merge-divider solenoid
— E205 Short circuit in 2-stage relief solenoid
— E206 Short circuit in travel speed shifting solenoid
— E211 Disconnection in travel junction solenoid
E03 E213 Disconnection in swing holding brake solenoid
— E214 Disconnection in merge-divider solenoid
— E215 Disconnection in 2-stage relief solenoid
— E216 Disconnection in travel speed shifting solenoid
— E217 Abnormality in input model code
— E218 Disconnection in S-NET signal line
— E222 Short circuit in LS-EPC solenoid
— E223 Disconnection in LS-EPC solenoid
— E224 Abnormality in F pump pressure sensor
— E225 Abnormality in R pump pressure sensor
— E226 Abnormality in pressure sensor power supply
— E227 Abnormality in engine speed sensor
— E228 Short circuit in ATT return selector relay
E02 E232 Short circuit in PC-EPC solenoid
E02 E233 Disconnection in PC-EPC solenoid
— E238 Disconnection in ATT return selector relay
— E256 Illegal non-volatile memory data
— E304 Short circuit in engine stop solenoid relay
— E306 Abnormality in governor potentiometer
E05 E308 Abnormality in fuel control dials
— E313 Abnormality in auto grease system (Equivalent to error code [DA80MA])
— E314 Disconnection in engine stop solenoid relay
— E315 Short circuit in battery relay output line
— E316 Abnormality in step-out of governor motor
E05 E317 Disconnection in phases A and B of governor motor
E05 E318 Short circuit in phases A and B of governor motor
a For troubleshooting for a service code having the description of (Equivalent to error code [******]), see the
section of the corresponding "Error code of mechanical system".
a "E" at the head of each service code indicates the following condition.
• With E: The trouble has not been repaired.
• Without E: The trouble has been repaired.
PC160LC-7 20-175
(3)
4. Monitoring function [02]

With this function, you can monitor the revolution
speed, oil pressure, current, voltage, input condi-
tion, output condition, etc. in real time by the sig-
nals from the sensors, switches, and solenoids
installed to various parts of the machine.

tion mode.
tion.
2) Selecting and executing monitoring code

operate working mode selector switches (7)
and (8) to select a monitoring code dis-
played in service meter section (1).
• UP switch (7): Increase code No.
• DOWN switch (8): Decrease code No.
a This function displays monitoring code
[001] and its information first.
a For the items and code Nos. which you
can monitor, see the "Monitoring codes
table".

service meter section 1 (When numeral
code is displayed)
If a numeral monitoring code is selected, the
following information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (Value is dis-
played)

service meter section 2 (When 6-bit code is
displayed)
If a 6-bit monitoring code is selected, the fol-
lowing information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (6 pieces of infor-
mation are displayed in bits)
a In the 6-bit display mode, only the top
and bottom of the 7-segments mark are
used to display. "Solid black" indicates
the ON state, and "white on black back-
ground" indicates the OFF state.
a For the No. of each bit, see the "Monitor-
ing codes table" and the drawing at-
tached to it.
20-176 PC160LC-7
(3)
Monitoring codes table

Code Monitoring item Unit Remarks
002 Engine throttle and pump controller model code Numeral
003 Engine throttle and pump controller model code Numeral
010 Engine speed 10 rpm
011 F pump discharge pressure kg/cm2
012 R pump discharge pressure kg/cm2
013 PC-EPC solenoid output current 10 mA
015 LS-EPC solenoid output current 10 mA
016 2nd throttle speed 10 rpm
017 (Unused) —
a Swing oil pressure switch (ON) (6 bit)
b Travel oil pressure switch (ON) (6 bit)
c Boom LOWER oil pressure switch (ON) (6 bit)
019 Input condition 1 of switch
d Boom RAISE oil pressure switch (ON) (6 bit)
e Arm IN oil pressure switch (ON) (6 bit)
f Arm OUT oil pressure switch (ON) (6 bit)
a Bucket CURL oil pressure switch (ON) (6 bit)
b Bucket DUMP oil pressure switch (ON) (6 bit)
c (Unused) (6 bit)
d Service oil pressure switch (ON) (6 bit)
e Travel differential pressure switch (6 bit)
f (Unused) (6 bit)
a (Unused) (6 bit)
b (Unused) (6 bit)
c One-touch power maximizing switch (ON) (6 bit)
d Swing holding brake release switch (RELEASE) (6 bit)
e Swing lock switch (LOCK) (6 bit)
f (Unused) (6 bit)
a (Unused) (6 bit)
b Travel junction solenoid (ON) (6 bit)
Drive condition of solenoid c Swing holding brake solenoid (ON) (6 bit)
023
valve 1 d Merge-divider solenoid (ON) (6 bit)
e 2-stage relief solenoid (ON) (6 bit)
f Travel speed shifting solenoid (ON) (6 bit)
a (Unused) (6 bit)
b (Unused) (6 bit)
Drive condition of solenoid c (Unused) (6 bit)
024
valve 2 d ATT return selector relay (ON) (6 bit)
e (Unused) (6 bit)
f (Unused) (6 bit)
PC160LC-7 20-177
(3)

a Model selection 1 (Connected to ground) (6 bit)
b Model selection 2 (Connected to ground) (6 bit)
Input condition of model c Model selection 3 (Connected to ground) (6 bit)
027
selection signal d Model selection 4 (Connected to ground) (6 bit)
e Model selection 5 (Connected to ground) (6 bit)
f Kerosene mode (Connected to ground) (6 bit)
030 Fuel control dial input voltage 10 mV
031 Governor potentiometer input voltage 10 mV
032 Controller power source voltage 100 mV
033 Governor motor phase A output current 10 mA
034 Governor motor phase B output current 10 mA
035 Battery relay BR output voltage 100 mV
a (Unused) (6 bit)
b (Unused) (6 bit)
c (Unused) (6 bit)
036 Input condition of signal
d (Unused) (6 bit)
e Starting switch signal C (START) (6 bit)
f (Unused) (6 bit)
a Battery relay (DRIVEN) (6 bit)
b (Unused) (6 bit)
c Engine stop solenoid relay (DRIVEN) (6 bit)
037 Output condition of signal
d (Unused) (6 bit)
e (Unused) (6 bit)
f (Unused) (6 bit)
041 Engine coolant sensor input voltage 10 mV
042 Fuel level sensor input voltage 10 mV
043 Alternator input voltage 100 mV
044 Hydraulic oil temperature sensor input voltage 10 mV
a Starting switch signal ACC (ON) (6 bit)
b Starting switch signal C (START) (6 bit)
c Starting switch signal R1 (HEAT) (6 bit)
045 Input condition of switch 4
d Lamp switch (ON) (6 bit)
e Radiator coolant level switch (OPEN) (6 bit)
f (Unused) (6 bit)
a Air cleaner clogging switch (OPEN) (6 bit)
b (Unused) (6 bit)
c Engine oil pressure switch (OPEN) (6 bit)
046 Input condition of sensor
d Engine oil level switch (OPEN) (6 bit)
e (Unused) (6 bit)
f Alternator (Normal generation) (6 bit)
20-178 PC160LC-7
(3)

a Swing lock switch (LOCK) (6 bit)
b Caution buzzer stop switch (ON) (6 bit)
c Windows limit switch (ON) (6 bit)
049 Input condition of switch 5
d Wiper contact W (ON) (6 bit)
e Wiper contact P (ON) (6 bit)
f (Unused) (6 bit)
200 Monitor panel program version Numeral
201 Engine throttle and pump controller program version Numeral
a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or
(d) and (e) light up.
Display of numeral code Display of 6-bit code
PC160LC-7 20-179
(3)
5. Function of adjusting governor [03]

This function is used to adjust the governor lever
stroke after the governor actuator, fuel injection
pump, or governor spring is removed and
installed or replaced, or when the high idling
speed is low or engine speed is not stabilized.

tion mode.
tion.
2) Condition of governor motor

If this function is executed, all the governor
control functions are cancelled, and then the
operating angle of the governor actuator fol-
lows up only the operation signal of the fuel
control dial.
a While this function is executed, [GOV] is
displayed in display section (1) and
[gSET] is displayed in service meter sec-
tion (2).
3) Adjusting governor lever stroke

i) Keep the fuel control dial to the MAX
position.
ii) Loosen nuts (2) and (3) of governor
spring (1).
a Nut (2) is left-handed.
iii) Turn and adjust rod (5) so that governor
lever (4) of the fuel injection pump will
touch the full stopper.
iv) Tighten rod (5) a little less than 1 turn to
compress governor spring (1) by 2.0
mm.
a At this time, distance (a) between the
pins does not change but the spring
in the go ver nor spr in g is c om-
pressed.
3 Nut:
v) Tighten nuts (2) and (3).
11.8 – 19.6 Nm {1.2 – 2.0 kgm}

vi) Return the fuel control dial to the MIN
position, and then turn it again slowly
toward the MAX position. At this time,
check that governor spring (1) expands
by about 2.0 mm after it reaches the full
stopper.
20-180 PC160LC-7
(3)
6. Function of selecting maintenance period [04]

With this function, you can adjust the mainte-
nance period of the engine oil for the function of
the engine oil replacement monitor.

tion mode.
tion.
2) Selecting maintenance period

The current display mode or maintenance
period is displayed in service meter section
(2). Press set switch (5) to select a mainte-
nance period.
a Nothing is displayed in display section
(1).
a Each time the set switch is pressed, the
display mode or maintenance period
changes in the following order.
Display mode/
Display
Maintenance period
0 Maintenance function is reset.
125 125-hour interval
d Demonstration mode
3) Settling maintenance period

The display or maintenance period becomes
effective when it is selected. Accordingly,
perform the ordinary finishing operation.
<Special functions of engine oil replacement

monitor>
a For the method of displaying the engine oil
replacement monitor, method of checking
the elapsed time after replacement of engine
oil, method of clearing the elapsed time, and
method of displaying demonstration mode,
see "9. Special functions of engine oil re-
placement monitor".
PC160LC-7 20-181
(3)
7. Function of selecting default working mode [05]

With this function, you can freely select the work-
ing mode which is set automatically when the
starting switch is turned ON (When the machine
is delivered, mode A is set).

tion mode.
tion.
2) Selecting default working mode

The currently set working mode is displayed
in service meter section (2). Press working
mode selector switches (7) and (8) to select
a working mode.
• UP switch (7): Next mode is displayed.
• DOWN switch (8): Previous mode is dis-
played.
a Nothing is displayed in display section
(1).
a The working mode changes in the follow-
ing order: A o E o B
3) Settling default working mode

Press set switch (5) to settle the selected
working mode.
20-182 PC160LC-7
(3)
8. Function of setting installation of attachment [16]

With this function, you can set installation of
attachment.
a When an attachment is installed, if IN-
STALLED is not set with this function, the B-
mode function (automatic single/double op-
eration selecting function) cannot be used.

tion mode.
tion.
a While this function is executed, [16SET]
is displayed in the service meter section
(2) and [0] or [1] is displayed in display
section (1).
2) Selecting installation of attachment

i) The current setting is displayed in serv-
ice meter section (1). Check the actual
installation of attachment and setting.
• [0]: Attachment is not installed.
• [1]: Attachment is installed.
ii) While holding caution buzzer stop
switch (3), operate working mode selec-
tor switches (7) and (8) to select [0] or
[1].
• UP switch (7): [1] is selected.
• DOWN switch (8): [0] is selected.
3) Settling installation of attachment

Press set switch (5) to settle the selected
setting of installation of attachment.
PC160LC-7 20-183
(3)
9. Special functions of engine oil replacement monitor

1) Ordinary display of engine oil replacement
monitor
If the rest of time before the set engine oil
replacement time is 10 hours or shorter,
engine oil replacement monitor (10) lights up
and display the elapsed time in service
meter section (2) for 20 seconds each time
the starting switch is turned ON.
2) Checking elapsed time

To check the elapsed time while engine oil
replacement monitor (10) is OFF, turn the
starting switch OFF and press set switch (5)
and then turn the starting switch ON and
keep holding set switch (5).
3) Clearing elapsed time

To clear the elapsed time after replacing the
engine oil, hold set switch (5) for 3 seconds
while the elapsed time is displayed in serv-
ice meter section (2).
a If the above operation is performed, the
elapsed time in the monitor panel is set
to 0 hours.
4) Function of demonstration mode

If the demonstration mode is selected, you
can perform demonstration of the oil mainte-
nance function when teaching the operation
to a customer.
The functions and display of the demonstra-
tion mode are as follows.
i) The internally set interval is recognized
as 250 hours and the elapsed time is
recognized as 240 hours.
ii) When the starting switch is turned ON
after the demonstration mode is set, the
ordinary display is repeated up to 3
times (number of the times of turning the
starting switch ON).
iii) After the demonstration is finished,
resetting of maintenance setting [0] is
recognized.
a When the demonstration is repeated 3
times, resetting of maintenance setting is
recognized. If setting is necessary at this
time, see "Function of selecting mainte-
nance period".
20-184 PC160LC-7
(3)
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL

SYSTEM
Serial No.: 10001 – 11000 2. Governor pump controller
The governor pump controller is installed un-
When diagnosing electric circuits related to the der a cover behind the operator's seat.
monitor panel and governor pump controller, first 1) Remove three caps (3) and then three
open up the connector portions in the following securing bolts.
manner. When removing the caps, use of a thin
flat-head screw driver is recommended.
1. Monitor panel 2) Take off cover (4).
1) Take off cover (1).
The cover is fixed with two upper and
lower clips. Pull it up for the removal.
If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.
3) Insert or connect a T-adapter for diagnosis

with C01, C02 and C03 connectors of gover-
nor pump controller (5).
The connectors are fixed with screws.
Loosen the screws and detach the con-
nectors.
2) Remove three securing screws and take When putting the connectors back into
monitor panel (2) off the mount. position, tighten them to the specified
Be careful not to let fall the securing torque.
screws inside the console. Screw: 2.82 Nm {0.288 kgm}
3) Insert or connect a T-adaptor for diagnosis
with P01, P02 and P70 (multi-monitor only)
connectors.
20-186 PC160LC-7
(4)
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
Serial No.: 11001 and up 2. Governor pump controller

a The governor pump controller is installed un-
a When diagnosing electric circuits related to the der a cover behind the operator's seat.
monitor panel and governor pump controller, first 1) Remove three bolts and then cover (5).
open up the connector portions in the following
manner.
1. Monitor panel
1) Take off cover (1).
a The cover is fixed with two upper and
lower clips. Pull it up for the removal.
a If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.
2) Insert or connect a T-adapter for diagnosis

with C01, C02 and C03 connectors of gover-
nor pump controller (6).
a The connectors are fixed with screws.
Loosen the screws and detach the con-
nectors.
a When putting the connectors back into
position, tighten them to the specified
3 Screw: 2.82 Nm {0.288 kgm}

torque.
2) Remove three securing screws and take

monitor panel (2) off the mount.
a Be careful not to let fall the securing
screws inside the console.
3) Insert or connect a T-adaptor for diagnosis
with P01, P02 and P70 (multi-monitor only)
connectors.
PC160LC-7 20-186-1
(4)
PC160LC-7 20-187
(3)
20-188 PC160LC-7
(3)
PC160LC-7 20-189
(3)
20-190 PC160LC-7
(3)
PC160LC-7 20-191
(3)
TROUBLESHOOTING
Points to remember when troubleshooting.................................................................................................. 20-202

Sequence of events in troubleshooting ....................................................................................................... 20-203
Points to remember when carrying out maintenance.................................................................................. 20-204
Checks before troubleshooting ................................................................................................................... 20-212
Classification and steps for troubleshooting................................................................................................ 20-213
Connector location chart and electrical circuit diagram by system ............................................................. 20-218
Connection table for connector pin numbers .............................................................................................. 20-236
T-adapter - boxes and T-adapter table........................................................................................................ 20-258
Troubleshooting error code "electrical system" and failure code "mechanical system" are indicated......... 20-301
Troubleshooting of electrical system (E-mode)........................................................................................... 20-401
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................................ 20-501
PC160LC-7 20-201
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 PC160LC-7
(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC160LC-7 20-203
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or oxi-
dization of the contact surfaces.
(2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC160LC-7
(1)
(3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering
may be damaged, or the wiring may be bro-
ken.
(4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the connec-
tor, depending on the direction of the water
jet.
As already said, the connector is designed to
prevent water from entering, but at the same
time, if water does enter, it is difficult for it to
be drained. Therefore, if water should get
into the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take other
appropriate action before passing electricity
through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector and
an oil film is formed on the mating surface be-
tween the male and female pins, the oil will
not let the electricity pass, so there will be de-
fective contact.
If there is oil or grease stuck to the connector,
wipe it off with a dry cloth or blow it dry with
compressed air and spray it with a contact re-
storer.
When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
PC160LC-7 20-205
(1)
2) Removing, installing, and drying connectors

and wiring harnesses
(1) Disconnecting connectors

• Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors
held by a screw, loosen the screw fully, then
hold the male and female connectors in each
hand and pull apart. For connectors which
have a lock stopper, press down the stopper
with your thumb and pull the connectors
apart.
Never pull with one hand.
• When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
If the connector is twisted up and down
or to the left or right, the housing may
break.
• Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or wa-
ter from getting in the connector portion.
If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC160LC-7
(1)
(2) Connecting connectors

• Check the connector visually.
Check that there is no oil, dirt, or water stuck
to the connector pins (mating portion).
Check that there is no deformation, defective
contact, corrosion, or damage to the connec-
tor pins.
Check that there is no damage or breakage
to the outside of the connector.
If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connector,
warm the inside of the wiring with a dryer,
but be careful not to make it too hot as
this will cause short circuits.
If there is any damage or breakage, re-
place the connector.
• Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in the
connector until the stopper clicks into posi-
tion.
• Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is out
of position, adjust it to its correct position.
If the connector cannot be corrected eas-
ily, remove the clamp and adjust the po-
sition.
• If the connector clamp has been removed, be

sure to return it to its original position. Check
also that there are no loose clamps.
(3) Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
PC160LC-7 20-207
(1)
(4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows.
• Disconnect the connector and wipe off the
water with a dry cloth.
If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
• Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
• Carry out a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and carry out a continuity test to
check for any short circuits between pins
caused by water.
After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC160LC-7
(1)
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box un-
less necessary.
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
(5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
(6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand).
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
If there is any change, there is probably defective contact in that circuit.
PC160LC-7 20-209
(1)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling or
assembling hydraulic equipment, it is necessary to
be particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
20-210 PC160LC-7
(1)
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC160LC-7 20-211
(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check for clogging of fuel filter cartridge — Replace
4. Check engine oil level in oil pan, type of oil — Add oil
Lubricating oil,
5. Check for clogging of engine oil filter — Replace

coolant
6. Check coolant level — Add water

7. Check for clogging of air cleaner — Clean or replace
8. Check hydraulic oil level, type of oil — Add oil
9. Check for clogging of hydraulic oil strainer — Clean, drain
10. Check for clogging of hydraulic oil filter — Replace
11. Check swing machinery oil level, type of oil — Add oil
12. Check final drive oil level, type of oil — Add oil
mechanical equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Hydraulic, Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention to Disconnect
—
water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
After
running for
7. Check alternator voltage (engine running at 1/2 throttle or above) several Replace
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay
— Replace
(when switch is turned ON/OFF)
20-212 PC160LC-7
(1)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
Code display
displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine assembly
Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Service
Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is
recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system
Failure Code, using the failure history function of the monitor panel.
If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
PC160LC-7 20-213
(4)
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No. Failure-looking phenomenon
Code
E mode H mode S mode
display
Action to be taken concerning Error Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
ing to dis-
2 Display Error Code in electrical system after checking failure history
played
3 Display Failure Code in mechanical system after checking failure history code
Engine-related failure
4 Starting performance is poor (Starting always takes time) S-1
5 Engine does not turn E-1 (1) S-2 (1)
Engine turns but no exhaust smoke comes out
6 S-2 (2)
(Fuel is not being injected)
Engine does not start Exhaust smoke comes out but engine does not
7 S-2 (3)
start (Fuel is being injected)
Engine does not start easily or at all low temper-
8 E-1 (2)
ature
9 Engine does not pick-up smoothly (Follow-up is poor) S-3
10 Engine stops while in operation E-2 S-4
11 Engine rotations unstably hunting E-3 S-5
12 Engine lacks output (or lacks power) S-6
13 Exhaust gas is black S-7
14 Oil consumption is excessive (or exhaust gas is blue) S-8
15 Oil becomes contaminated quickly S-9
16 Fuel consumption is excessive S-10
17 Oil is in cooling water, or water spurts back, or water level goes down S-11
18 Oil level rises (Water, fuel in oil) S-13
19 Abnormal noise is made S-15
20 Vibrations is excessive S-16
21 Engine does not stop E-4
22 Auto-decelerator does not work E-5 H-5
23 Auto engine warm-up device does not work E-6
24 Preheater does not operate E-7
Failure related to work equipment, swing and travel
25 Speed or power of all work equipment, swing, and travel are low H-1
26 Engine speed sharply drops or engine stalls H-2 S-4
27 No work equipment, travel and swing move E-8 H-3
28 Abnormal noise is heard from around hydraulic pump H-4
29 Fine control mode does not function H-6
20-214 PC160LC-7
(4)
Troubleshooting
Code
display
Work equipment-related failure

30 Speed or power of boom is low E-22, 23 H-7
31 Speed or power of arm is low E-24, 25 H-8
32 Speed or power of bucket is low E-26, 27 H-9
33 Work equipment does not move in its single operation H-10
34 Hydraulic drift of work equipment is large H-11
35 Time lag of work equipment is large H-12
36 One-touch power max system does not operate E-9 H-13
37 Attachment circuit does not change E-10 H-28
38 Flow rate in attachment circuit cannot be adjusted H-29
Compound operation-related failure
39 Work equipment loaded more is slower during compound operation H-14
40 Boom RAISE speed is low in compound operation of swing + boom RAISE H-15
Travel speed lowers largely during compound operation of work equip-
41 H-16
ment/swing + travel
Travel-related failure
42 Machine deviates during travel H-17
43 Travel speed is low E-29 H-18
44 Machine cannot be steered easily or steering power is low E-29, 30 H-19
45 Travel speed does not change or it is kept low or high E-29 H-20
46 Track does not move (only either side) H-21
Swing-related failure
47 Machine does not swing H-22
48 Swing acceleration or swing speed is low E-28 H-23
49 Excessive overrun when stopping swing H-24
50 When upper structure stops swinging, it makes large shock H-25
51 When upper structure stops swinging, it makes large sound H-26
52 Hydraulic drift of swing is large H-27
Monitor panel-related failure (Operator's Menu: ordinary display)
53 No display in monitor panel at all E-11
54 Monitor panel does not display partially E-12
55 Contents of monitor panel are different from mounted model E-13
56 Abnormally lowered radiator water level B@BCZK
57 Abnormally lowered engine oil pressure B@BAZK
PC160LC-7 20-215
(4)
Troubleshooting
Code
display
58 In startup inspection, maintenance hour monitor lamp lights up red Refer to Operation and Maintenance Manual
59 Abnormally lowered charging voltage AB00KE
60 Fuel level monitor lights up in red while engine is running E-14
61 Air cleaner clogging AA10NX
62 Engine cooling water overheating B@BCNS
63 Hydraulic oil overheating B@HANS
64 Engine cooling water temperature gauge does not indicate correctly E-15
65 Hydraulic oil temperature gauge does not display correctly E-16
66 Fuel gauge does not display correctly E-17
67 Swing lock monitor does not display correctly E-18
68 When monitor switch is operated, nothing is displayed E-19
69 Windshield wiper and window washer does not work E-20
70 Alarming buzzer cannot be cancelled E-21
Monitor panel-related failure (Service Menu: Special Function Display)
71 "Boom RAISE" is not correctly displayed in monitor function E-22
72 "Boom LOWER" is not correctly displayed in monitor function E-23
73 "Arm IN" is not correctly displayed in monitor function E-24
74 "Arm OUT" is not correctly displayed in monitor function E-25
75 "Bucket CURL" is not correctly displayed in monitor function E-26
76 "Bucket DUMP" is not correctly displayed in monitor function E-27
77 "SWING" is not correctly displayed in monitor function E-28
78 "TRAVEL" is not correctly displayed in monitor function E-29
79 "Travel differential pressure" is not correctly displayed in monitor function E-30
80 "Service" is not correctly displayed in monitor function E-31
Other failure
81 Air Conditioner does not work E-32
82 Travel alarm does not sound or does not stop sounding E-33
20-216 PC160LC-7
(4)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT

DIAGRAM BY SYSTEM
Connector table
Serial No.: 10001 – 11000
Address
Connector No. of
Type Name of device Stereo- M G P
No. pin
gram circuit circuit circuit
A01 X 4 Intermediate connector T-1 H-6 I-5 I-8

A02 X 4 Intermediate connector T-1 H-6 I-4 H-6
A03 SWP 12 Intermediate connector N-1 H-6 I-2 I-8
A04 SWP 12 Intermediate connector O-1 I-7
A05 SWP 14 Intermediate connector T-1 H-5 I-7 I-7
A06 SWP 14 Intermediate connector N-1 H-5 I-6 I-5
A07 SWP 16 Intermediate connector S-1 H-4 I-5 I-4
A08 SWP 12 Intermediate connector N-2
A09 SWP 8 Intermediate connector N-2 I-4
A10 Terminal 1 Revolving frame grounding H-1 H-1 I-5 J-4
A11 Terminal 1 Revolving frame grounding H-1 I-1
A13 Terminal 1 Revolving frame grounding H-1 I-1 I-4 J-8
A14 Terminal 1 Revolving frame grounding K-1 I-1 J-4
A15 Terminal 1 Revolving frame grounding H-2 I-1 J-4
A16 Terminal 1 Revolving frame grounding I-2 I-1 J-1
A20 Terminal 1 Battery relay (E terminal) L-2 I-2 J-4
A21 Terminal 1 Battery relay (BR terminal) L-2 I-1 J-4
A22 Terminal 1 Battery relay (M terminal) J-2 J-2 K-4
A23 Terminal 1 Battery relay (B terminal) J-2 J-1 K-4
A25 Terminal 1 Heater relay (coil) L-1 K-6
A26 Terminal 1 Heater relay (contact) K-1 K-2 L-6
A27 X 2 Starter safety relay (S and R terminals) K-3 J-2 K-3
A29 Terminal 1 Starter safety relay (C terminal) J-1 L-3
A30 YAZAKI 2 Air conditioner outside air temperature sensor L-6
A31 D 2 Air cleaner clogging sensor L-4 K-4
A33 X 2 Radiator water level sensor L-6 K-5
A34 L 2 Fusible link (65A) L-5 K-6 K-5
A35 M 2 Fusible link (30A) K-3 K-6 K-4
A40 Y090 1 Alarm horn (low tone) G-1
A41 Y090 1 Alarm horn (high tone) G-1
A42 X 1 Intermediate connector G-9 J-8
A43 X 2 Travel alarm G-9 K-4
A44 M 1 Front right lamp D-9 K-7
A50 KES0 2 Window washer monitor (tank) E-9 K-5
20-218 PC160LC-7
(4)
Address
Connector No. of
No. pin
A51 D 3 F pump hydraulic oil pressure sensor I-9 K-5
A52 D 3 R pump hydraulic oil pressure sensor L-5 K-5 K-5
A60 X 1 Fuel level sensor F-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
C01 DRC 24 Governor pump controller V-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller W-9 A-3 A-7 A-7
C09 S 8 Model selection connector W-6 C-9
D01 SWP 8 Assembled type diode W-7 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
D03 SWP 8 Assembled type diode P-1 H-1
D04 SWP 8 Assembled type diode Q-1 A-8 I-1
Suction type air heater
E01 Terminal 1 K-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine oil pressure switch L-8 K-6
E03 D 2 Engine oil level switch L-7 K-5
E04 D 2 Engine rotation sensor L-8 K-8 K-8
Engine cooling water temperature sensor
E05 D 2 J-9 K-4
(for high temperature)
E06 M 3 Fuel dial O-8 F-1
E06 X 1 Air conditioner compressor electromagnetic switch K-9
E08 X 1 Intermediate connector L-6 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-2
E11 D 4 Governor motor L-9 K-2
E12 – 3 Alternator L-7 K-3 K-5
E12 D 3 L-7 K-3
(for low temperature)
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box W-5 I-9 B-2 F-9
H08 M 8 Intermediate connector W-4 K-8
H09 S 8 Intermediate connector W-5 J-8
H10 S 16 Intermediate connector T-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
J01 J 20 Junction connector (black) W-8 C-9 D-9 C-9
J02 J 20 Junction connector (black) W-8 D-9 D-9 D-9
J03 J 20 Junction connector (green) W-8 D-9 E-9 D-9
J04 J 20 Junction connector (green) W-7 E-9 E-9 E-9
J05 J 20 Junction connector (pink) W-6 E-9 E-9 E-9
J06 J 20 Junction connector (orange) W-6 F-9 H-9
J07 J 20 Junction connector (orange) U-9 F-9 F-9 H-9
J08 J 20 Junction connector (pink) U-9 I-9
PC160LC-7 20-219
(4)
Address
Connector No. of
No. pin
K19 M 2 Pump resistor (for driving emergency pump) U-2

K30 DT 3 CAN terminating resistor T-9 A-2 C-1
K31 DT 3 CAN terminating resistor N-4 A-4 K-7
M07 M 3 Lamp switch P-8 C-1
M09 M 1 Working lamp (boom) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch N-7
M23 Y090 2 One-touch power max. switch T-1 A-9
M26 S 12 Air conditioner unit W-5
M27 SWP 16 Air conditioner unit W-5
M29 040 20 Air control panel W-3
M30 040 16 Air control panel W-3
M31 M 2 Option power source (2) U-2
M32 M 2 Option power source (1) S-9
M33 M 2 Option power source (3) –
M34 YAZAKI 2 Air conditioner inside air sensor W-8
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector H-9 J-7
M43 M 1 Working lamp (rear) I-9 K-7
M45 D 12 Intermediate connector U-2
M46 S090 4 RS232C relaying connector U-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter U-2
M73 KES0 2 Speaker (left) AD-8
M79 M 2 12V electrical equipment socket V-9
P01 070 12 Monitor panel N-6 A-7
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Alarm buzzer stop switch P-9 D-1
P05 M 2 Revolving warning lamp switch W-3
P15 Y050 2 Air conditioner sun light sensor N-6
P70 040 16 Monitor panel N-4 A-5 K-8
20-220 PC160LC-7
(4)
Address
Connector No. of
No. pin
R10 R 5 Lamp relay O-8 E-1

R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1 B-9
R13 R 5 Engine starting motor cutting relay (personal code) Q-9 F-1
R20 R 5 Attachment return switching relay W-6 C-9
R21 R 5 Additional relay connector W-7
R22 R 5 Cold starting solenoid relay W-5 F-9
S01 X 2 Bucket CURL oil pressure switch J-3 K-3
S02 X 2 Boom LOWER oil pressure switch K-3 K-3
S03 X 2 Swing oil pressure switch, left K-4 K-2
S04 X 2 Arm IN oil pressure switch K-3 K-3
S05 X 2 Bucket DUMP oil pressure switch L-5 K-2
S06 X 2 Boom RAISE oil pressure switch K-4 K-3
S07 X 2 Swing oil pressure switch, right K-3 K-2
S08 X 2 Arm OUT oil pressure switch K-4 K-3
S09 X 2 Service oil pressure switch (intermediate connector) J-3 K-2
S10 X 2 Service oil pressure switch, front J-3 K-2
S11 X 2 Service oil pressure switch, rear J-3 K-1
S14 M 3 Safety lever lock switch S-1 K-8 E-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
S22 Terminal 6 Swing holding brake releasing switch R-9 E-2
S25 S090 16 Intermediate connector Q-9 E-3
S30 X 2 Travel oil pressure switch O-1 A-1
S31 X 2 Travel steering oil pressure switch P-1 A-1
SC Terminal 1 Engine starting motor (C terminal) I-9
SSW Terminal 5 Engine starting switch N-7
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding –
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Operator's cab grounding AD-3
T13 D 1 Intermediate connector L-6 J-3 J-6
V01 D 2 PPC oil pressure lock solenoid valve I-2 K-1
V02 D 2 Travel junction solenoid valve I-2 K-6
V03 D 2 Merge/divide valve solenoid valve I-2 K-7
V04 D 2 Travel speed solenoid valve J-3 K-5
V05 D 2 Swing holding brake solenoid valve I-2 K-6
V06 D 2 2-stage relief solenoid valve I-2 K-6
V07 1 Cold starting solenoid L-8 K-7
PC160LC-7 20-221
(4)
Address
Connector No. of
No. pin
V12 D 2 Attachment return switching solenoid valve G-9 K-4

V21 D 2 PC-EPC solenoid valve H-9 K-7
V22 D 2 EPC solenoid connector (spare) K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9
W04 M 6 Windshield wiper motor Y-4 B-9
X05 M 4 Swing lock switch Q-9 D-2 C-1
20-222 PC160LC-7
(4)
Connector No. Detailed information
D or DT Japanese and German makes DT type connector (08192-XXXXX)

L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
040 Product of Japan AMP 040 type connector
Y050 Product of Yazaki 050 type connector
S090 Product of Sumitomo 090 type connector
YAZAKI Yazaki-made connector
KES0 KESO type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
*An affiliated company of Mitsubishi Cable Industries, Ltd.
PC160LC-7 20-223
(1)
Connector table
Serial No.: 11001 and up
Address
Connector No. of
Type Name of device
No. pin Stereo- M G P
A01 X 4 Intermediate connector M-8 H-6 I-5 I-8

A02 X 4 Intermediate connector M-9 H-6 I-4 H-6
A03 SWP 12 Intermediate connector M-9 H-6 I-2 I-8
A04 SWP 6 Intermediate connector O-8 L-7 I-7
A06 SWP 14 Intermediate connector O-9 H-5 I-6 I-5
A08 SWP 12 Intermediate connector O-9
A09 SWP 8 Intermediate connector O-9 I-4 I-4
A10 Terminal 1 Revolving frame grounding H-1 H-1 I-5 J-4
A13 Terminal 1 Revolving frame grounding H-1 I-1 I-4 J-8
A14 Terminal 1 Revolving frame grounding K-1 I-1 J-4
A15 Terminal 1 Revolving frame grounding H-2 I-1 J-4
A16 Terminal 1 Revolving frame grounding I-2 I-1 J-1
A20 Terminal 1 Battery relay (E terminal) L-2 I-2 J-4
A21 Terminal 1 Battery relay (BR terminal) L-2 I-1 J-4
A22 Terminal 1 Battery relay (M terminal) J-2 J-2 K-4
A23 Terminal 1 Battery relay (B terminal) J-2 J-1 K-4
A25 Terminal 1 Heater relay (coil) L-1 K-6
A26 Terminal 1 Heater relay (contact) K-1 K-2 L-6
A27 X 2 Starter safety relay (S and R terminals) K-3 J-2 K-3
A29 Terminal 1 Starter safety relay (C terminal) J-1 K-2 L-3
A31 D 2 Air cleaner clogging sensor L-4 K-4
A33 X 2 Radiator water level sensor L-6 K-5
A34 L 2 Fusible link (65A) L-6 K-6 K-5
A35 M 2 Fusible link (30A) K-3 K-6 K-4
A40 Y090 1 Alarm horn (low tone) G-1
A41 Y090 1 Alarm horn (high tone) G-1
A42 X 1 Intermediate connector G-9 J-7
A43 D 2 Travel alarm G-9 K-4
A44 M 1 Front right lamp D-9 K-7
A50 KES0 2 Window washer monitor (tank) E-9 K-5
A51 D 3 F pump hydraulic oil pressure sensor I-9
A52 D 3 R pump hydraulic oil pressure sensor L-5 K-5 K-5
20-223-1 PC160LC-7
(4)
Address
Connector No. of
No. pin
A60 X 1 Fuel level sensor F-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
C01 DRC 24 Governor pump controller U-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller V-9 A-3 A-7 A-7
C09 S 8 Model selection connector U-9 C-9
D01 SWP 8 Assembled type diode W-9 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
Suction type air heater
E01 Terminal 1 K-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine oil pressure switch L-8 K-6
E03 D 2 Engine oil level switch L-7 K-6
E04 D 2 Engine rotation sensor L-8 K-8 K-8
E05 D 2 J-9 K-4
(for high temperature)
E06 M 3 Fuel dial O-8 F-1
E06 X 1 Air conditioner compressor electromagnetic switch K-9
E08 X 1 Intermediate connector L-6 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-2
E11 D 4 Governor motor L-9 K-2
E12 – 3 Alternator L-7 K-5
E12 D 3 L-7 K-3
(for low temperature)
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box U-2 H-9 B-2 F-9
H08 M 8 Intermediate connector W-6 K-8
H09 S 8 Intermediate connector W-6 J-8
H11 S 16 Intermediate connector S-9 D-6 I-8 B-9
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
J01 J 20 Junction connector (black) T-1 C-9 D-9 C-9
J02 J 20 Junction connector (black) V-2 D-9 D-9 D-9
J03 J 20 Junction connector (green) V-2 D-9 E-9 D-9
J04 J 20 Junction connector (green) V-3 E-9 E-9 E-9
J05 J 20 Junction connector (pink) V-3 E-9 E-9 E-9
J06 J 20 Junction connector (orange) V-3 F-9
J07 J 20 Junction connector (orange) W-3 F-9 F-9 H-9
K19 M 2 Pump resistor (for driving emergency pump) W-3
K30 DT 3 CAN terminating resistor S-9 A-2 C-1
K31 DT 3 CAN terminating resistor N-4 A-4 K-7
PC160LC-7 20-223-2
(4)
Address
Connector No. of
No. pin
M07 M 3 Lamp switch P-8 C-1

M09 M 1 Working lamp (boom) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3 E-3
M21 PA 9 Radio T-1
M22 Y090 2 Horn switch N-7
M23 Y090 2 One-touch power max. switch S-1 A-9
M26 S 12 Air conditioner unit W-3
M27 Y090 18 Air conditioner unit W-5
M29 040 20 Air control panel T-2
M30 040 16 Air control panel U-2
M31 M 2 Option power source (2) W-6
M33 SUMITOMO 8 Air conditioner unit W-5
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector H-9 J-7
M43 M 1 Working lamp (rear) I-9 K-7
M45 D 12 Intermediate connector W-7
M46 S090 4 RS232C relaying connector V-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter W-7
M73 KES0 2 Speaker (left) AD-8
M79 M 2 12V electrical equipment socket W-8
P01 070 12 Monitor panel N-6 A-7
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Alarm buzzer stop switch P-9 D-1
P05 M 2 Revolving warning lamp switch U-2
P15 Y050 2 Air conditioner sun light sensor N-6
P17 090 2 Air conditioner high/low pressure switch
P70 040 16 Monitor panel N-4 A-5 K-8
R10 R 5 Lamp relay O-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1 B-9
R13 R 5 Engine starting motor cutting relay (personal code) Q-9 F-1
R20 R 5 Attachment return switching relay U-9 C-9
R22 R 5 Cold starting solenoid relay T-9 F-9
R30 SUMITOMO 5 Air conditioner blower relay W-4
R31 AMP 4 Air conditioner compressor relay W-3
20-223-3 PC160LC-7
(4)
Address
Connector No. of
No. pin
S01 X 2 Bucket CURL oil pressure switch J-3 K-3

S02 X 2 Boom LOWER oil pressure switch K-3 K-3
S03 X 2 Swing oil pressure switch, left K-4 K-2
S04 X 2 Arm IN oil pressure switch K-3 K-3
S05 X 2 Bucket DUMP oil pressure switch L-5 K-2
S06 X 2 Boom RAISE oil pressure switch K-4 K-3
S07 X 2 Swing oil pressure switch, right K-3 K-2
S08 X 2 Arm OUT oil pressure switch K-4 K-3
S09 X 2 Service oil pressure switch (intermediate connector) J-3 K-2
S10 X 2 Service oil pressure switch, front J-3 K-2
S11 X 2 Service oil pressure switch, rear J-3 K-1
S14 M 3 Safety lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
S22 Terminal 6 Swing holding brake releasing switch R-9 F-2
S25 S090 16 Intermediate connector Q-9 E-3
S30 X 2 Travel oil pressure switch O-1 A-1
S31 X 2 Travel steering oil pressure switch P-1 A-1
SC Terminal 1 Engine starting motor (C terminal) I-9
SSW Terminal 5 Engine starting switch N-7
T05 Terminal 1 Floor frame grounding U-2 J-8
T06 Terminal 1 Radio body grounding T-1
T06A M 1 Intermediate connector T-1
T11 Terminal 1 Operator's cab grounding AD-3
T13 D 1 Intermediate connector L-6 J-3 J-6
V01 D 2 PPC oil pressure lock solenoid valve I-2
V02 D 2 Travel junction solenoid valve I-2 K-6
V03 D 2 Merge/divide valve solenoid valve I-2 K-7
V04 D 2 Travel speed solenoid valve J-3 K-5
V05 D 2 Swing holding brake solenoid valve I-2 K-6
V06 D 2 2-stage relief solenoid valve I-2 K-6
V07 1 Cold starting solenoid L-8 K-7
V12 D 2 Attachment return switching solenoid valve G-9 K-4
V21 D 2 PC-EPC solenoid valve H-9 K-7
V22 D 2 EPC solenoid connector (spare) K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9
W04 M 6 Windshield wiper motor Y-3 B-9
X05 M 4 Swing lock switch Q-9 D-1 C-1
PC160LC-7 20-223-4
(4)
Connector No. Detailed information
D or DT Japanese and German makes DT type connector (08192-XXXXX)

L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
AMP Japan AMP-mode connector
S090 Product of Sumitomo 090 type connector
Y090 Product of Yazaki Y090 type connector
YAZAKI Yazaki-made connector
KES0 KESO type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
*An affiliated company of Mitsubishi Cable Industries, Ltd.
20-223-5 PC160LC-7
(4)
CONNECTOR LOCATION STEREOGRAM

Serial No.: 10001 – 11000
20-224 PC160LC-7
(4)
PC160LC-7 20-225
(1)
20-226 PC160LC-7
(1)
PC160LC-7 20-227
(4)
20-228 PC160LC-7
(1)
20-229-1 PC160LC-7
(4)
PC160LC-7 20-229-2
(4)
20-229-3 PC160LC-7
(4)
PC160LC-7 20-229-4
(4)
20-229-5 PC160LC-7
(4)
Monitor Panel System Circuit Diagram (M Circuit)

Serial No.: 10001 – 11000
20-230 PC160LC-7
(4)
This circuit diagram is made of the monitor panel system, engine preheating and starting system, and night
lighting system extracted from the general electric circuit diagram.
PC160LC-7 20-231
(1)
20-231-1 PC160LC-7
(4)
This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.
PC160LC-7 20-231-2
(4)
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controlle

Serial No.: 10001 – 11000
20-232 PC160LC-7
(4)
This circuit diagram has been compiled by extracting the governor•pump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC160LC-7 20-233
(1)
20-233-1 PC160LC-7
(4)
This circuit diagram has been compiled by extracting the governor•pump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC160LC-7 20-233-2
(4)
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller

Serial No.: 10001 – 11000
20-234 PC160LC-7
(4)
This circuit diagram has been compiled by extracting the governor•pump controller system (pump control),
PPC lock system and backup alarm system from the overall electrical circuit diagram.
PC160LC-7 20-235
(1)
20-235-1 PC160LC-7
(4)
This circuit diagram has been compiled by extracting the governor•pump controller system (pump control),
PPC lock system and backup alarm system from the overall electrical circuit diagram.
PC160LC-7 20-235-2
(4)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-236 PC160LC-7
(1)
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
PC160LC-7 20-237
(1)
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-238 PC160LC-7
(1)
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7390
Part No.: 08056-00871 Part No.: 08056-00881
PC160LC-7 20-239
(1)
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-240 PC160LC-7
(1)
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
PC160LC-7 20-241
(1)
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-242 PC160LC-7
(1)
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
PC160LC-7 20-243
(1)
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
! Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-244 PC160LC-7
(1)
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
PC160LC-7 20-245
(1)
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
20-246 PC160LC-7
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
PC160LC-7 20-247
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
20-248 PC160LC-7
(1)
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
PC160LC-7 20-249
(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-250 PC160LC-7
(1)

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
PC160LC-7 20-251
(1)

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-252 PC160LC-7
(1)

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC160LC-7 20-253
(1)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-254 PC160LC-7
(1)
DT Series connector
No.of
pins T-adapter
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC160LC-7 20-255
(1)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820T (normal type) Part No.: 08192-1810T (normal type)
08192-2820T (fine wire type) 08192-2810T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920T (normal type) Part No.: 08192-1910T (normal type)
08192-2920T (fine wire type) 08192-2910T (fine wire type)
20-256 PC160LC-7
(1)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC160LC-7 20-257
(1)
DRC26 Series connector

No.of
pins T-adapter
Part No.
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
20-257-1 PC160LC-7
(4)
TROUBLESHOOTING T-ADAPTER - BOXES AND T-ADAPTER TABLE
T-ADAPTER - BOXES AND T-ADAPTER TABLE

The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring har-
ness checker assemblies are shown in the lines.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Part No. Type of connector No. of pins
799-601-2600 Box for measurement Econo-21P Q Q Q Q Q Q

799-601-3100 Box for measurement MS-37P Q
799-601-3200 Box for measurement MS-37P Q
799-601-3300 Box for measurement Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 Case Q
799-601-7000 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
20-258 PC160LC-7
(1)
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD24 24-9 Q Q
PC160LC-7 20-259
(1)
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Box for measurement For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
For fuel, boost
799-601-9420 3P Q
pressure
799-601-9430 PVC socket 2P Q
20-260 PC160LC-7
(4)
TROUBLESHOOTING ERROR CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE ....................................................................... 20-304

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-310
Error Code in Electrical System E101 (Abnormal data in error history) ..................................................... 20-312
Error Code in Electrical System E112 (Short-circuiting in normal rotation system of
windshield wiper motor drive)............................................................................................................... 20-314
Error Code in Electrical System E113 (Short-circuiting in reverse rotation system of
windshield wiper motor drive)............................................................................................................... 20-316
Error Code in Electrical System E114 (Short-circuiting in window washer drive system) .......................... 20-318
Error Code in Electrical System E115 (Abnormal operation of windshield wiper) ...................................... 20-320
Error Code in Electrical System E116 (Abnormality operation of retracting windshield wiper) .................. 20-322
Error Code in Electrical System E201 (Short-circuiting in travel junction solenoid) ................................... 20-324
Error Code in Electrical System E203 (Short-circuiting in swing holding brake solenoid).......................... 20-326
Error Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)..................................... 20-328
Error Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)..................................... 20-330
Error Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) ......................... 20-332
Error Code in Electrical System E211 (Disconnection in travel junction solenoid)..................................... 20-334
Error Code in Electrical System E213 (Disconnection in swing holding brake solenoid) ........................... 20-336
Error Code in Electrical System E214 (Disconnection of merge/divide solenoid) ...................................... 20-338
Error Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) ...................................... 20-340
Error Code in Electrical System E216 (Disconnection in travel speed shifting solenoid) ........................... 20-342
Error Code in Electrical System E217 (Abnormality in inputting model code)............................................ 20-344
Error Code in Electrical System E218 Disconnection of S-NET signal) ..................................................... 20-346
Error Code in Electrical System E224 (Abnormality in F pump pressure sensor) ...................................... 20-348
Error Code in Electrical System E225 (Abnormality in R pump pressure sensor) ..................................... 20-350
Error Code in Electrical System E226 (Abnormality in pressure sensor power source) ............................ 20-352
Error Code in Electrical System E227 (Abnormality in engine rotation sensor) ......................................... 20-354
Error Code in Electrical System E228 (Short-circuiting in attachment return switching relay) ................... 20-356
Error Code in Electrical System E232 (Short-circuiting in PC-EPC solenoid) ............................................ 20-358
Error Code in Electrical System E233 (Disconnection in PC-EPC solenoid) ............................................. 20-360
Error Code in Electrical System E238 (Disconnection in attachment return switching relay) .................... 20-362
Error Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate
adjusting EPC solenoid) ....................................................................................................................... 20-364
Error Code in Electrical System E246 (Disconnection in attachment oil flow rate
adjusting EPC solenoid) ....................................................................................................................... 20-365
Error Code in Electrical System E306 (Abnormality in governor potentiometer)........................................ 20-366
Error Code in Electrical System E308 (Abnormality in fuel dial) ................................................................ 20-368
Error Code in Electrical System E311 (Short-circuiting in cold starting solenoid relay) ............................. 20-370
Error Code in Electrical System E312 (Disconnection in cold starting solenoid relay)............................... 20-372
Error Code in Electrical System E315 (Short-circuiting in battery relay) .................................................... 20-374
Error Code in Electrical System E316 (Step-out in governor motor) .......................................................... 20-376
Error Code in Electrical System E317 (Disconnection in governor motor Phase A and B)........................ 20-377
Error Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) ........... 20-380
PC160LC-7 20-301
(1)
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling) .......................... 20-382
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)............................ 20-382
Failure Code in Mechanical System AA10NX (Air cleaner clogging) ......................................................... 20-383
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage).............................. 20-384
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ........................ 20-386
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)............................... 20-387
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating).................................. 20-388
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level) ........................ 20-389
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-390
20-302 PC160LC-7
(1)
–
–
–
–
–
–
–
–
–
code
Error
E113
E211
E116
E115
E114
E112
E311
E246
E245
E233
E232
E227
E225
E224
E218
E217
E318
E317
E316
E315
E312
E308
E306
E238
E228
E226
E216
E215
E214
E213
E206
E205
E204
E203
E201
E101
(4)
20-304
code
A000N2
A000N1
Failure
D110KB
DY10K4
D199KA
D199KB
D196KA
D196KB
AB00KE
DK10KZ
DK54KZ
AA10NX
DY20KA
DY10KB
DY10KA
DA25KP
DAF0KT
DXE4KA
DXE4KB
DXA0KA
DXA0KB
DA2SKA
DY2EKB
DLE2MA
DY2CKB
DY2DKB
DY20MA
DA2SKQ
DWJ0KA
DWJ0KB
DW91KA
DW43KA
DW45KA
DW43KB
DW45KB
DW91KB
DHPAMA
DWK0KA
DWK0KB
DHPBMA
B@BAZK
B@BCZK
B@BAZG
B@HANS
B@BCNS
q
Defective battery relay
q
q
q
Defective fuse or fusible link
TROUBLESHOOTING
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Defective monitor panel
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Governor pump controller
q
q
q
q
Defective sensor power supply (5 V)
q
q
q
q
Defective wiper motor
q
Defective windshield washer motor
q
Defective swing lock switch
q
q
Defective emergency pump driving switch
q
Model selector connector
q
q
q
Defective fuel control dial
q
q
q
Defective governor motor
q
q
q
Defective governor potentiometer
Possible causes
Defective engine speed sensor
q
(including adjustment)
Error codes and failure codes and possible causes of them
q
q
Defective cold starting solenoid relay
q
Defective engine oil pressure switch
q
Defective engine oil level switch
Defective engine water temperature sensor
q
(for monitor)
q
Defective radiator water level switch
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
q
Defective air cleaner clogging switch
q
Defective alternator
q
q
Defective mechanical system of engine
q
Defective adjustment of governor lever
PC160LC-7
q
Defective fuel control of engine
q
Low engine oil pressure
q
Low engine oil level
PC160LC-7
q
Overheating of engine
q
Low water level in radiator sub tank
TROUBLESHOOTING
q
Clogged air cleaner
q
q
Defective PC-EPC solenoid
q
q
Defective travel junction solenoid
q
q
Defective swing holding brake solenoid
q
q
Defective pump merge-divider solenoid
q
q
Defective 2-stage relief solenoid
q
q
Defective travel speed shifting solenoid
Possible causes
q
q
Defective attachment return switching relay
Defective attachment flow rate adjustment
q
q
EPC solenoid
q
q
Defective F pump pressure sensor
q
q
Defective R pump pressure sensor
q
Defective hydraulic oil temperature sensor
q
Overheating of hydraulic oil
q
q
q
q
q
q
Defective diode block
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Disconnection in wiring harness
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Grounding fault in wiring harness

Short-circuiting with power source in wiring
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
harness
(4)
20-305
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Connection table of fuse box

This connection table shows the devices to which each power supply of the fuse box (FB1) supplies power
directly (A switch power supply is a device which supplies power while the starting switch is at the ON posi-
tion and a constant power supply is a device which supplies power while the starting switch is at the OFF
position).
When carrying out troubleshooting for an electric system, you should check its fuse box and fusible link to
see if the power is supplied normally.
Type of power
Fuse No. Fuse capacity Destination of power
supply
Governor pump controller (Controller power supply)
1 10A Emergency pump drive resistor
Swing holding brake release switch
Governor pump controller (Solenoid power supply)
Switch power supply 2 20A Cold starting solenoid relay (Coil side and contact side)
(Fusible link: A34) Attachment return switching relay (Coil side and contact side)
3 10A Safety lock switch
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn switch
6 10A (Spare)
Rotary lamp switch

7 10A
Additional relay (Coil side and contact side)
Switch power supply
8 10A Light relay (Contact side)
(Fusible link: A34)
One-touch power maximizing switch
9 10A
Radio
10 10A (Spare)
11 20A Air conditioner unit
Starting motor cut-out (Personal code) relay (Coil side)

12 20A
Monitor panel
Switch power supply
13 20A Light switch
(Fusible link: A34)
14 10A Service power supply (M32 connector)
Travel alarm
15 10A
DC/DC converter
16 10A Radio
17 20A (Spare)
Constant power Starting switch / Monitor panel
supply 18 10A
(Fusible link: A35) —
19 10A Room lamp
20 10A (Spare)
20-306 PC160LC-7
(4)
Problems which occur when controller power supply of governor pump controller is
defective
The controller power supply (FB1-1) of the governor pump controller drives the controller system.
Accordingly, if the controller power supply is turned off, the controller cannot control the governor motor and
battery relay and the following problems occur.
1) The engine can be started but cannot be started.
2) The engine speed cannot be controlled with the fuel control dial.
If the above problems occur, check the related fuse (FB1-1) and "green LED" of the governor pump control-
ler to see if the power is supplied normally.
• Lighting: The controller power is supplied (There is not an error and the power supply is normal).
• Flashing: The controller power is supplied (There is an error).
• Put out: The controller power is not supplied.
Green LED of governor pump controller (GREEN)
PC160LC-7 20-307
(1)
Problems which occur when solenoid power supply of governor pump controller is
defective
The solenoid power supply (FB1-2) of the governor pump controller is used by the controller to drive the
solenoids and relays.
Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the sole-
noids or relays, the power is not supplied to any of the solenoids and relays and all or some of the following
error codes are displayed simultaneously.
• [E212]: Disconnection in travel junction solenoid
• [E213]: Disconnection in swing holding brake solenoid
• [E214]: Disconnection in pump merge-divider solenoid
• [E215]: Disconnection in 2-stage relief solenoid
• [E216]: Disconnection in travel speed shifting solenoid
• [E233]: Disconnection in PC-EPC solenoid
• [E248]: Disconnection in attachment flow rate adjustment EPC solenoid (when attachment is installed)
If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the governor pump control-
ler.
1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33).
• Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins.
• If the voltage is 20 – 30 V, it is normal.
Power supply connector (C03) of governor pump controller
20-308 PC160LC-7
(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

The troubleshooting table and the related circuit diagrams contain the following information. Grasp their
contents fully before proceeding to actual troubleshooting work.
User Code Error Code Failure Code

Failure
Display in Display in Display in Title of failure phenomenon shown in failure history
phenomenon
monitor panel monitor panel monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
monitor panel
detect some failure.
or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
occurring on
controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting

<Content Included>
• Standard value in normalcy by which to pass "Good" or "No good" judgement over the
presumed cause
1
• Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>

Presumed cause and standard value in normalcy
• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness occurred.
• Defective grounding
2 A wiring harness that is not connected with a grounding circuit has a contact with the
grounding circuit.
• Short-circuiting
Cause that presumably A wiring harness that is not connected with a 24 V electric circuit has a contact with the
triggered failure in ques- electric circuit.
tion
3 (The assigned No. is for <Precaution for Troubleshooting>
filing purpose only. It 1) Connector No. display method and handling of T-adapter
does not stand for any Insert or connect T-adapters in the following manner before starting troubleshooting
priority) unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., disconnect
the connector and insert the T-adapter into both male and female sides.
4 • If there is an indication of "male" or "female" in a specific connector No., disconnect
the connector and connect the T-adepter with only one side of either "male" or "fe-
male".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the fol-
lowing manner unless otherwise instructed.
• Connect the positive (+) lead with the pin No. indicated at the front or the wiring har-
5
ness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring har-
ness.
20-310 PC160LC-7
(1)
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
PC160LC-7 20-311
(1)
TROUBLESHOOTING E101
Error Code in Electrical System E101 (Abnormal data in error history)
User Code Error Code Failure Code Failure Abnormal data in error history
— E101 DAF0KT phenomenon (in Monitor Panel system)
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
• None in particular
Monitor Panel
Phenomenon
occurring on • A display for information on the failure history (in the electrical system) cannot be called.
machine

If the fuse No. 17 is blown, there is a big possibility that the circuit has a grounding fault.
1 Fuse No. 17 defective
(cause 4 reference)
Fusible link No. A35 If the fusible link No. A35 is blown, there is a big possibility that the circuit has a ground-
2
defective ing fault. (cause 4 reference)
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Disconnection of wiring Between wiring harness from P01 (female) (8) to J07 to Resistance
Below 1 Ω
harness FB1-17 outlet value
3
(Disconnection or Resistance
connector contact fault) Wiring harness between FB1-17 inlet and A35 (male) (2) Below 1 Ω
value
Wiring harness between A35 (male) (1) and A23 (B termi- Resistance
Below 1 Ω
nal) value
Grounding fault of wiring Between wiring harness between P01 (female) (8) to J07 Resistance Above
harness and FB1-17 outlet and grounding value 1 MΩ
4
(Contact with grounding Between wiring harness between FB1-17 inlet and A35 Resistance Above
circuit) (male) (2) and grounding value 1 MΩ
Between wiring harness between A35 (male) (1) and A23 Resistance Above
(B terminal) and grounding value 1 MΩ
5 Monitor Panel defective
P01 Voltage
Between (8) and (6) (7) 20 – 30 V
20-312 PC160LC-7
(1)
Related circuit diagram

Serial No.: 10001 – 11000
PC160LC-7 20-313
(4)
Error Code in Electrical System E112

(Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code Error Code Failure Code Failure Short-circuiting in normal rotation system of wind-
— E112 DY2DKB phenomenon shield wiper motor drive (in monitor panel system)
Failure content • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stops moving.
machine

Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between (3) and (1) Continued
Between (3) and grounding Above 1 MΩ
Grounding fault of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) (9) and Resistance
circuit) Above 1 MΩ
W04 (male) (3) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between (9) and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)
20-314 PC160LC-7
(1)
PC160LC-7 20-315
(1)

(Short-circuiting in reverse rotation system of windshield wiper motor drive)
User Code Error Code Failure Code Failure Short-circuiting in reverse rotation system of wind-
— E113 DY2EKB phenomenon shield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
Failure content
windshield wiper was set in motion.
Response from
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stopped moving.
machine

Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
or grounding fault) Between (1) and (3) Continued
harness for the troubleshooting.
2
W04 (male) (1) and grounding value
P01 Windshield wiper switch Voltage
OFF Below 3 V
Between (10) and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)
20-316 PC160LC-7
(1)
PC160LC-7 20-317
(1)

(Short-circuiting in window washer drive system)
Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
Window washer drive for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z
aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring har-
circuit) Voltage Below 1 V
ness between P01 (female) (3) and D04 (female) (8) and
grounding
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
20-318 PC160LC-7
(4)
PC160LC-7 20-319
(1)
User Code Error Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine

Window washer drive for the troubleshooting.
1 motor defective
A50 (male) Resistance value
Between (1) and (2) 5 – 20 z
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring har-
ness between P01 (female) (3) and D02 (female) (7) and
grounding
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
ON Below 1 V
20-319-1 PC160LC-7
(4)
PC160LC-7 20-319-2
(4)
Error Code in Electrical System E115 (Abnormal operation of windshield wiper)
User Code Error Code Failure Code Failure Abnormal operation of windshield wiper
— E115 DY20KA phenomenon (in Monitor Panel system)
Failure content • W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)

Windshield wiper motor W04 (female) Windshield wiper blade Resistance value
1 defective At upper end of operation
(Internal disconnection) Below 1 Ω
range
Between (6) and (5)
Outside upper end of
Above 1 MΩ
operation range
Disconnection of wiring for the troubleshooting.
harness Wiring harness between P01 (female) (5) and W04 (male) Resistance
2 Below 1 Ω
(Disconnection or faulty (6) value
contact with connector) Resistance
Wiring harness between W04 (male) (5) and grounding Below 1 Ω
value
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of operation
Below 1 V
range
Outside upper end of
20 – 30 V
operation range
20-320 PC160LC-7
(1)
PC160LC-7 20-321
(1)

(Abnormality operation of retracting windshield wiper)
User Code Error Code Failure Code Failure Abnormal operation of retracting windshield wiper
— E116 DY20MA phenomenon (in Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No. 049: Monitor Input 3)


Windshield wiper motor
1 defective W04 (female) Windshield wiper blade Resistance value
(Internal disconnection) Retraction range Below 1 Ω
Between (4) and (5)
Operation range Above 1 MΩ
Disconnection of wiring during the troubleshooting.
harness
Wiring harness between P01 (female) (12) and W04 Resistance
2 (Disconnection or defec- Below 1 Ω
(male) (4) value
tive contact with connec-
tor) Resistance
Between wiring harness W04 (male) (5) and grounding Below 1 Ω
value
during the troubleshooting.
3 Monitor panel defective P01 Windshield wiper blade Voltage
Retraction range Below 1V
Operation range 20 – 30 V
20-322 PC160LC-7
(1)
PC160LC-7 20-323
(1)

(Short-circuiting in travel junction solenoid)
Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Short-circuiting in travel junction solenoid
— E201 DW91KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel junction circuit, when power was supplied to the circuit.
• Power supply to the travel junction circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on • It is difficult to steer the machine at turns. (Both travel circuits are not separated)
machine
Relative • Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code
information No. 023: Solenoid 1)

Travel junction solenoid during the troubleshooting.
defective V02 (male) Resistance value
1
or grounding fault) Between (1) and (2) 20 – 60 z

Between (1) and grounding Above 1 Mz
Assembled-type diode during the troubleshooting.
2 D03 defective
D03 (male) Resistance value (Continuity)
Between (3) and (7) Above 1 Mz (No continuity)
Grounding fault of wiring during the troubleshooting.
harness Between wiring harness from C03 (female) (7) to J06 to
3
(Contact with grounding V02 (female) (1) and grounding, or between wiring har- Resistance
circuit) Above 1 Mz
ness between C03 (female) (7) and D03 (female) (3) and value
grounding
aTurn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump Left and right travel
4 C03 Voltage
controller defective control lever
NEUTRAL Below 1 V
Steering 20 – 30 V
20-324 PC160LC-7
(4)
PC160LC-7 20-325
(1)
User Code Error Code Failure Code Failure Short-circuiting in travel junction solenoid
Failure content • Abnormal current flew to the travel junction circuit, when power was supplied to the circuit.
• Power supply to the travel junction circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
Phenomenon
occurring on • It is difficult to steer the machine at turns. (Both travel circuits are not separated)
machine
Relative • Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code
information No. 023: Solenoid 1)

Travel junction solenoid during the troubleshooting.
1
Grounding fault of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) (7) to V02 Resistance
circuit) Above 1 Mz
(female) (1) and grounding value
troubleshooting.
Governor • pump Left and right travel
3 C03 Voltage
NEUTRAL Below 1 V
Steering 20 – 30 V
20-325-1 PC160LC-7
(4)
PC160LC-7 20-325-2
(4)

(Short-circuiting in swing holding brake solenoid)
Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Short-circuiting in swing holding brake solenoid
E03 E203 DW45KB phenomenon (in governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing and steering brake does not return to normal-
controller
cy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the swing holding brake releasing switch to the FREE position.
(In this case, however, the holding brake does not work, when stopping the machine)

Swing holding brake during the troubleshooting.
solenoid defective V05 (male) Resistance value
1

2 D03 defective
Grounding fault of wiring
harness Wiring harness from C03 (female) (37) to D01 to J02 to
3 X05 to J06 to V05 (female) (1), or between wiring harness
(Contact with grounding Resistance
circuit) between C03 (female) (37) and D03 (female) (4), or Above 1 Mz
value
between wiring harness between C03 (female) (37) and
S25 (female) (8) and grounding
troubleshooting.
C03 Swing control lever Voltage
Governor • pump
4 Below 1 V (5 sec after
controller defective NEUTRAL
the lever is set in neutral)
Swing 20 – 30 V
20-326 PC160LC-7
(4)
PC160LC-7 20-327
(1)
User Code Error Code Failure Code Failure Short-circuiting in swing holding brake solenoid
E03 E203 DW45KB phenomenon (in governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing and steering brake does not return to normal-
controller
cy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the swing holding brake releasing switch to the FREE position.
(In this case, however, the holding brake does not work, when stopping the machine)

Swing holding brake during the troubleshooting.
1

2 D03 defective
harness Wiring harness from C03 (female) (37) to D01 to J02 to
3 X05 to J06 to V05 (female) (1), or between wiring harness
circuit) between C03 (female) (37) and D03 (female) (4), or Above 1 Mz
value
between wiring harness between C03 (female) (37) and
troubleshooting.
C03 Swing control lever Voltage
Governor • pump
4 Below 1 V (5 sec after
controller defective NEUTRAL
the lever is set in neutral)
Swing 20 – 30 V
20-327-1 PC160LC-7
(4)
PC160LC-7 20-327-2
(4)
Error Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)

Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(The F and R pumps are not separated)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)

Merge/divide solenoid during the troubleshooting.
1

2 D03 defective
D03 (male) Resistance value
Between (1) and (5) Above 1 Mz
harness
3 Wiring harness from C03 (female) (17) to J06 to V03
circuit) (female) (1), or between wiring harness between C03 Above 1 Mz
value
(female) (17) and D03 (female) (1) and grounding
troubleshooting.
Left and right travel
Governor • pump C03 Voltage
4 control lever
controller defective
NEUTRAL Below 1 V
Between (17) and grounding When operated for straight
20 – 30 V
travel
20-328 PC160LC-7
(4)
PC160LC-7 20-329
(1)
User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(Front and rear pumps are not separated)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.

1
2
circuit) Above 1 Mz
troubleshooting.
Governor • pump C03 Travel control lever Voltage
3
controller defective NEUTRAL Below 1 V
Between (17) and grounding When operating one side
20 – 30 V
only
20-329-1 PC160LC-7
(4)
Electrical Circuit Diagram for Merge/Divide Solenoid
PC160LC-7 20-329-2
(4)
Error Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)

Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

2-stage relief solenoid during the troubleshooting.
defective
1 V06 (male) Resistance value

2 D03 defective
harness
value
Governor • pump C03 Working mode Voltage
4
Other than L mode Below 1 V
L mode 20 – 30 V
20-330 PC160LC-7
(4)
PC160LC-7 20-331
(1)
User Code Error Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
controller
Phenomenon
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

1
2
circuit) Above 1 Mz
3
Other than L mode Below 1 V
L mode 20 – 30 V
20-331-1 PC160LC-7
(4)
PC160LC-7 20-331-2
(4)

(Short-circuiting in travel speed shifting solenoid)
Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.

Travel speed shifting during the troubleshooting.
1
2 D04 defective
harness
value
troubleshooting.
Governor • pump Travel speed +
4 C03 Voltage
controller defective Travel control lever
Lo + Neutral Below 1 V
Hi + Travel operation 20 – 30 V
20-332 PC160LC-7
(4)
PC160LC-7 20-333
(1)
User Code Error Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.

1
2
circuit) Above 1 Mz
troubleshooting.
Governor • pump Travel speed +
3 C03 Voltage
controller defective Travel control lever
Lo + Neutral Below 1 V
Hi + Travel operation 20 – 30 V
20-333-1 PC160LC-7
(4)
PC160LC-7 20-333-2
(4)
Error Code in Electrical System E211 (Disconnection in travel junction solenoid)

Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Disconnection in travel junction solenoid
— E211 DW91KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the travel junction solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • It is difficult to steer the machine while traveling. (Both travel circuits are not separated)
machine
• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code
No. 023: Solenoid 1)
Relative
aSince the controller detects disconnection when the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking for reproduction of the failure after repair. (For how to turn power ON
or OFF, refer to the troubleshooting under Error Code [E201].)

Travel junction during the troubleshooting.
1 solenoid defective
V02 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
harness
Wiring harness from C03 (female) (7) to J06 to V02 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tor) Resistance
Wiring harness between V02 (female) (2) and grounding Below 1 z
value
Short-circuiting of wiring during the troubleshooting.
harness
(Contact with 24 V cir-
cuit) (female) (1), or between wiring harness C03 (female) (7) Voltage Below 1 V
and D03 (female) (3) and grounding
Governor • pump during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (7) and grounding 20 – 60 z
20-334 PC160LC-7
(4)
PC160LC-7 20-335
(1)
User Code Error Code Failure Code Failure Disconnection in travel junction solenoid
Failure content • No current flows to the travel junction solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
Phenomenon
occurring on • It is difficult to steer the machine while traveling. (Both travel circuits are not separated)
machine
• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function. (Code
No. 023: Solenoid 1)
Relative
information

Travel junction during the troubleshooting.
Between (1) and (2) 20 – 60 z
harness
(female) (1) value
tor) Wiring harness from C03 (female) (3), (13), (23) to V02 Resistance
Below 1 z
(female) (2) value
Short-circuiting of wiring aTurn the engine starting switch OFF for the preparations, and hold it in the ON position
3
(Contact with 24 V cir- Between wiring harness from C03 (female) (7) to V02
cuit) Voltage Below 1 V
(female) (1) and grounding
4
20-335-1 PC160LC-7
(4)
PC160LC-7 20-335-2
(4)

(Disconnection in swing holding brake solenoid)
Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake is not released)
machine
• If the solenoid and wiring harness are free from abnormality, the machine can swing by setting the swing
holding brake release switch in the RELEASE position (The parking brake does not work when the ma-
Relative chine stops, however).
information • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the RE-
LEASE position.

Swing holding brake
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion)
Between (1) and (2) 20 – 60 z
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Below 1 z
Between (3) and (4)

ON Above 1 Mz
Assembled-type
diode D01 defective
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion)
Between (7) and (3) Diode mode Continued
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
defective contact value
with connector) Resistance
Wiring harness from X05 (male) (4) to J06 to V05 (female) (1) Below 1 z
value
Resistance
value
Short-circuiting of aTurn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
Governor • pump
6 C03 (female) Disconnect D01 and con- Resistance value
nect pins (3) and (7) of the
Between (37) and grounding male side. 20 – 60 z
20-336 PC160LC-7
(4)
Electrical Circuit Diagram for Swing and Parking Brake Solenoid
PC160LC-7 20-337
(1)
User Code Error Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake is not released)
machine
• If the solenoid and wiring harness are free from abnormality, the machine can swing by setting the swing
holding brake release switch in the RELEASE position (The parking brake does not work when the ma-
Relative chine stops, however).
information • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the RE-
LEASE position.
Swing holding brake aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 – 60 z
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
tion) OFF Below 1 z
Between (3) and (4)
ON Above 1 Mz
Assembled-type aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 defective during the troubleshooting.
3
tion) Between (7) and (3) Diode mode Continued
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
value
defective contact
Wiring harness from X05 (male) (4) to V05 (female) (1) Below 1 z
value
Wiring harness from C03 (female) (3), (13), (23) to V05 Resistance
Below 1 z
(female) (2) value
Short-circuiting of aTurn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
Governor • pump
6 C03 (female) Disconnect D01 and con- Resistance value
nect pins (3) and (7) of the
Between (37) and grounding male side. 20 – 60 z
20-337-1 PC160LC-7
(4)
Electrical Circuit Diagram for Swing and Parking Brake Solenoid
PC160LC-7 20-337-2
(4)
Error Code in Electrical System E214 (Disconnection of merge/divide solenoid)

Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

1 defective
Between (1) and (2) 20 – 60 z
harness
(female) (1) value
tor) Resistance
value
harness
cuit) (female) (1), or between wiring harness between C03 Voltage Below 1 V
4
20-338 PC160LC-7
(4)
PC160LC-7 20-339
(1)
User Code Error Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

1 defective
Between (1) and (2) 20 – 60 z
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (17) to V03 (female) (1) Below 1 z
value
Below 1 z
(female) (2) value
3
4
20-339-1 PC160LC-7
(4)
PC160LC-7 20-339-2
(4)
Error Code in Electrical System E215 (Disconnection in 2-stage relief solenoid)

Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Phenomenon
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

1 defective
Between (1) and (2) 20 – 60 z
harness
(female) (1) value
tor) Resistance
value
harness
4
20-340 PC160LC-7
(4)
PC160LC-7 20-341
(1)
User Code Error Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Phenomenon
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

1 defective
Between (1) and (2) 20 – 60 z
harness
Resistance
value
Below 1 z
(female) (2) value
3
4
20-341-1 PC160LC-7
(4)
PC160LC-7 20-341-2
(4)

(Disconnection in travel speed shifting solenoid)
Serial No.: 10001 – 11000
User Code Error Code Failure Code Failure Disconnection in travel speed shifting solenoid
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on • The travel speed does not shift to Hi. (The swash plate angle of the travel motor is not minimized)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

Between (1) and (2) 20 – 60 z
harness
(female) (1) value
tor) Resistance
value
harness
4
20-342 PC160LC-7
(4)
PC160LC-7 20-343
(1)
User Code Error Code Failure Code Failure Disconnection in travel speed shifting solenoid
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on • The travel speed does not shift to Hi. (The swash plate angle of the travel motor is not minimized)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information

Between (1) and (2) 20 – 60 z
harness
Resistance
value
Below 1 z
(female) (2) value
harness
4
20-343-1 PC160LC-7
(4)
PC160LC-7 20-343-2
(4)
Error Code in Electrical System E217 (Abnormality in inputting model code)
User Code Error Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in governor • pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC200-7).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • The engine does not output sufficient power or it stalls.
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002: Controller Model Code: No. 003)
information !Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)

Model selecting connec- during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection
or short-circuiting) Between (2), (4) and (8) Below 1 Ω
Between (1), (3), (7) and (8) Above 1 MΩ
Disconnection of wiring Wiring harness between C02 (female) (7) and C09 Resistance
harness Below 1 Ω
(male) (4) value
2 (Disconnection or defec-
Wiring harness between C02 (female) (27) and C09 Resistance
tive contact with connec- Below 1 Ω
tor) (male) (2) value
Between wiring harness between C09 (male) (8) and Resistance
Below 1 Ω
grounding value
Grounding fault of wiring Between wiring harness between C02 (female) (13) and Resistance
Above 1 MΩ
harness C09 (male) (7) and grounding value
3
(Contact with grounding Between wiring harness between C02 (female) (17) and Resistance
C09 (male) (3) and grounding value
Between wiring harness between C02 (female) (37) and Resistance
Above 1 MΩ
C09 (male) (1) and grounding value
4
Between (13), (17), (37) and grounding 20 – 30 V
Between (7), (27) and grounding Below 1 V
20-344 PC160LC-7
(1)
PC160LC-7 20-345
(1)
Error Code in Electrical System E218 Disconnection of S-NET signal)
User Code Error Code Failure Code Failure Disconnection in S-NET signal
— E218 DA2SKA phenomenon (in governor • pump controller system)
• A failure occurred in S-NET communication between the monitor panel and controller in the past.
Failure content
(The machine operation returned to normalcy, when the display was resumed)
• While the failure is still continuing, the machine operation is controlled by the following default setting.
1) Working mode: E mode
Response from 2) Travel speed: Lo
controller 3) Auto-decelerator: ON
4) Attachment oil flow rate: Minimum (When an attachment is installed)
• When the failure cause disappears of itself, the machine operation returns to normalcy.
• The working mode cannot be changed. (The display changes normally in the monitor panel)
Phenomenon
• The travel speed cannot be shifted. (The display changes normally in the monitor panel)
occurring on
• The auto-decelerator cannot be released. (The display changes normally in the monitor panel)
machine
• The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel)
• This Error Code No. is displayed to inform that there was a failure occurred in the past, when S-NET
communication between the monitor panel and the governor • pump controller is returned to normalcy.
Relative
• The communication has already returned to normalcy by the time this Error Code No. is displayed. But
information
thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a failure
in order to prevent recurrence of failures.

harness
Wiring harness between P02 (female) (9) (10) and C02 Resistance
(female) (21) value

tor) Wiring harness between P02 (female) (20) and C02 Resistance
Below 1 Ω
(female) (31) value
2
(Contact with grounding Between wiring harness between P02 (female) (9) (10) Resistance
and C02 (female) (21) and grounding value
Short-circuiting of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the ON position
3
(Contact with 24 V cir- Between wiring harness between P02 (female) (9) (10)
and C02 (female) (21) and grounding
P02 (male) Voltage
Between (9) (10) and (20) 6–9V
5
controller defective C02 (male) Voltage
Between (21) and (31) 6–9V
20-346 PC160LC-7
(1)
PC160LC-7 20-347
(1)
Error Code in Electrical System E224 (Abnormality in F pump pressure sensor)
User Code Error Code Failure Code Failure Abnormality in F pump pressure sensor
— E224 DHPAMA phenomenon (in governor • pump controller system)
Failure content • Signal voltage from the F pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.
Response from • The controller controls the F pump pressure at 0 MPa{0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
!If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected reversely, the pressure
Relative sensor will be broken. Accordingly, take care extremely when checking.
information • Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function.
(Code No. 011: F pump pressure)

Sensor power source
1 If the Service Code No. [E226] is displayed, troubleshoot the failure first.
fault
!Turn the engine starting switch OFF for the preparations, and keep the engine running
A51 Voltage
F pump pressure sensor Between (B) and (A) Power source 4.5 – 5.5 V
2 defective Between (C) and (A) Signal 0.5 – 4.5 V
(Internal failure)
The voltage of the pressure sensor is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller to con-
firm that there is not another cause of the failure before judging the troubleshooting
result.
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to A51 Resistance
harness Below 1 Ω
(female) (B) value
Wiring harness between C01 (female) (10) and A51 Resistance
tor) (female) (A) value
Below 1 Ω
(female) (C) value
4
A51 (female) (C) and grounding value
harness Between wiring harness between C01 (female) (22) to
5 Voltage Below 1 V
(Contact with 24 V cir- J07 and A51 (female) (B) and grounding
cuit) Between wiring harness between C01 (female) (8) and
Voltage Below 1 V
A51 (female) (C) ang grounding
6
Between (22) and (10) Power source 4.5 – 5.5 V
Between (8) and (10) Signal 0.5 – 4.5 V
20-348 PC160LC-7
(1)
PC160LC-7 20-349
(1)
Error Code in Electrical System E225 (Abnormality in R pump pressure sensor)
User Code Error Code Failure Code Failure Abnormality in R pump pressure sensor
— E225 DHPBMA phenomenon (in governor • pump controller system)
Failure content • Signal voltage from the R pump pressure sensor dropped below 0.3 V or exceeded 4.42 V.
Response from • The controller controls the R pump pressure as 0 MPa {0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
!If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected reversely, the pressure
Relative sensor will be broken. Accordingly, take care extremely when checking.
information • Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function.
(Code No. 012: R pump pressure)

Sensor power source
1 If the Service Code No. [E226] is displayed, troubleshoot the failure first.
fault
A52 Voltage
R pump pressure sen- Between (B) and (A) Power source 4.5 – 5.5 V
2 sor defective Between (C) and (A) Signal 0.5 – 4.5 V
(Internal failure)
The voltage of the pressure sensor is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller to con-
firm that there is not another cause of the failure before judging the troubleshooting
result.
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 and A52 Resistance
harness Below 1 Ω
(female) (B) value
tor) (female) (A) value
Below 1 Ω
(female) (C) value
4
A52 (female) (C) and grounding value
harness Between wiring harness between C01 (female) (22) to
5 Voltage Below 1 V
(Contact with 24 V cir- J07 and A52 (female) (B) and grounding
Voltage Below 1 V
A52 (female) (C) and grounding
6
Between (22) and (10) Power source 4.5 – 5.5 V
20-350 PC160LC-7
(1)
PC160LC-7 20-351
(1)
Error Code in Electrical System E226 (Abnormality in pressure sensor power source)
User Code Error Code Failure Code Failure Abnormality in pressure sensor power source
— E226 DA25KP phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.
• The controller turns OFF power supply to the power source circuit (5 V).
Response from
• Even when the failure cause disappears of itself, the current does not return to normalcy, unless the en-
controller
gine starting switch is once turned OFF.
Phenomenon • Signals from the pressure sensors and potentiometer are not inputted correctly.
occurring on • The Error Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at
machine the same time.

Disconnect the following equipment one by one. Equipment that shows no error code is
defective, having an internal failure.
Pressure sensor or during the troubleshooting.
1 potentiometer defective Fuel dial E06 Connector
(Internal short-circuit)
Governor potentiometer E10 Connector
F pump pressure sensor A51 Connector

R pump pressure sensor A52 Connector
Between wiring harness from C01 (female) (22) to J07 to Resistance
Above 1 MΩ
E06 (female) (1) and grounding [Fuel dial system] value
Between wiring harness from C01 (female) (22) to J07 to
Resistance
E10 (female) (A) and grounding Above 1 MΩ
value
Grounding fault of wiring [Governor potentiometer system]
2 Resistance
(Contact with grounding A51 (female) (B) and grounding Above 1 MΩ
circuit) value
[F pump pressure sensor system]
Resistance
A52 (female) (B) and grounding Above 1 MΩ
value
[R pump pressure sensor system]
Resistance
A08 (male) (7) and grounding Above 1 MΩ
value
[Attachment system]
3
controller defective C01 Voltage
Between (22) and (10) 4.5 – 5.5 V
20-352 PC160LC-7
(1)
PC160LC-7 20-353
(1)

(Abnormality in engine rotation sensor)
User Code Error Code Failure Code Failure Abnormality in engine rotation sensor
— E227 DLE2MA phenomenon (in governor • pump controller system)
Failure content • A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from • The controller exercises a control equivalent to E mode.
controller • If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on • The machine lacks power a bit. (The engine speed cannot be sensed)
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine RPM)

Engine rotation sensor during the troubleshooting.
fault E04 (male) Resistance value
1
500 – 1,000 Ω
or disconnection) Between (1) and (2)

Engine rotation sensor For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation
2
adjustment improper Sensor" in this manual.
harness
Wiring harness between C02 (female) (40) and E04 Resistance
(female) (1) value
tor) Wiring harness between C02 (female) (29) (39) and E04 Resistance
Below 1 Ω
(female) (2) value
4
(Contact with 24 V cir- Between wiring harness between C02 (female) (40) and
E04 (female) (1) and grounding
Governor • pump C02 (female) Resistance value
5
Between (40) and (29) (39) 500 – 1,000 Ω
20-354 PC160LC-7
(1)
PC160LC-7 20-355
(1)

(Short-circuiting in attachment return switching relay)
User Code Error Code Failure Code Failure Short-circuiting in attachment return switching relay
— E228 D196KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from • The controller turned OFF power to the attachment return switching relay circuit.
controller • Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
• The hydraulic circuit for attachments is not switched to the single operation circuit.
occurring on
(The selector valve is not switched to the tank circuit)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No. 024:Solenoid 2)
information • This error code detects abnormality on the primary side (coil side) of the attachment return switching
relay but does not detect abnormality on the secondary side (contact side).

Attachment return !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
switching relay defective during the troubleshooting.
1
(Internal short-circuiting R20 (male) Resistance value
or grounding fault) Between (1) and (2) 100 – 500 Ω
2
R20 (female) (2) and grounding
3
controller defective Other than B mode 20 – 30 V
B mode Below 1 V
20-356 PC160LC-7
(1)
PC160LC-7 20-357
(1)
Error Code in Electrical System E232 (Short-circuiting in PC-EPC solenoid)
User Code Error Code Failure Code Failure Short-circuiting in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the PC-EPC solenoid circuit.
• The controller reduces the output to the PC-EPC solenoid circuit to OFF.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative • If the solenoid and wiring harness are free from abnormality, the machine can be operated with the out-
information put equivalent to E-mode by setting the emergency pump driving switch in the emergency position (Error
code [E233] is displayed at this time, but it does not indicate abnormality).
• Keep the emergency pump driving switch in the normal position during troubleshooting.

PC-EPC solenoid defec- during the troubleshooting.
tive V21 (male) Resistance value
1
Between (1) and (2) 7 – 14 Ω
or grounding fault)
Defective emergency
pump driving switch Emergency pump
2 S25 (male) Resistance value
(Internal short-circuiting driving switch
or grounding fault) Between (3) and (4) Above 1 MΩ
Normal
harness Between wiring harness from C03 (female) (16) to S25 Resistance
3 Above 1 MΩ
(Contact with grounding (female) (3) and grounding value
circuit) Between wiring harness from S25 (female) (2) to V21 Resistance
Above 1 MΩ
4
Between (16) and (3) (13) (23) 7 – 14 Ω
20-358 PC160LC-7
(1)
PC160LC-7 20-359
(1)
Error Code in Electrical System E233 (Disconnection in PC-EPC solenoid)
User Code Error Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the PC-EPC solenoid circuit.
controller • When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative
• If the solenoid and wiring harness are free from abnormality, the machine can be operated with the out-
information
put equivalent to E-mode by setting the emergency pump driving switch in the emergency position.
• Keep the emergency pump driving switch in the normal position during troubleshooting.

PC-EPC solenoid during the troubleshooting.
1 defective
Between (1) and (2) 7 – 14 Ω
Emergency pump
S25 (male) Resistance value
Emergency pump driving driving switch
2 switch defective Below 1 Ω
Normal
(Internal disconnection) Between (2) and (3)
Emergency Above 1 MΩ
Normal Below 1 Ω
Between (5) and (6)
Emergency Above 1 MΩ
Resistance
Disconnection of wiring Wiring harness between C03 (female) (16) and S21 (3) Below 1 Ω
value
harness
Resistance
3 (Disconnection or defec- Wiring harness between S21 (2) and V21 (female) (1) Below 1 Ω
value
tor) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Below 1 Ω
S25 (female) (6) value
Wiring harness between S25 (female) (5) and V21 Resistance
Below 1 Ω
(female) (2) value
harness Between wiring harness between C03 (female) (16) and
4 Voltage Below 1 V
(Contact with 24 V cir- S25 (female) (3) and grounding
cuit) Between wiring harness between S25 (female) (2) and
Voltage Below 1 V
V21 (female) (1) and grounding
5
Between (16) and (3) (13) (23) 7 – 14 Ω
20-360 PC160LC-7
(1)
PC160LC-7 20-361
(1)

(Disconnection in attachment return switching relay)
User Code Error Code Failure Code Failure Disconnection in attachment return switching relay
— E238 D196KA phenomenon (in governor • pump controller system)
• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24 V
Failure content
voltage is not generated.
Response from • None in particular
controller • If the failure cause disappears, the governor returns to normalcy.
Phenomenon
• The hydraulic circuit for attachments cannot be switched to the single operation
occurring on
(The selector valve is not switched to the tank circuit)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No. 024:Solenoid 2)
information • This error code detects abnormality on the primary side (coil side) of the attachment return switching
relay but does not detect abnormality on the secondary side (contact side).

If the fuse No. 2 has been blown, there is a big possibility that grounding fault occurred
1 Fuse No. 2 fault
in the relay circuit. (Cause 4 reference)
Attachment return during the troubleshooting.
2 switching relay defective

R20 (male) Resistance value
Between (1) and (2) 100 – 500 Ω
harness
Wiring harness between C02 (female) (8) and R20 Resistance
(female) (2) value
tor) Wiring harness from R20 (female) (1) to J03 to FB1-2 Resistance
Below 1 Ω
outlet value
harness Between wiring harness between C02 (female) (8) and Resistance
4 Above 1 MΩ
(Contact with grounding R20 (female) (2) and grounding value
circuit) Between wiring harness from R20 (female) (1) to J03 to Resistance
Above 1 MΩ
FB1-2 outlet and grounding value
5
Other than B mode 20 – 30 V
B mode Below 1 V
20-362 PC160LC-7
(1)
PC160LC-7 20-363
(1)
Error Code in Electrical Equipment E245

(Short-circuiting in attachment oil flow rate adjusting EPC solenoid)
User Code Error Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
— E245 DXE4KB phenomenon EPC solenoid (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
• The controller turns OFF power to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • The attachments do not move. (The PPC basic pressure is not supplied to the service PPC valve)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Attachment oil flow rate
adjusting EPC solenoid
1 defective V30 (male) Resistance value
(Internal short-circuiting Between (1) and (2) 7 – 14 Ω
or grounding fault)
2
V30 (female) (1) and grounding value
3
Between (26) and (3) (13) (23) 7 – 14 Ω
20-364 PC160LC-7
(1)

(Disconnection in attachment oil flow rate adjusting EPC solenoid)
User Code Error Code Failure Code Failure Disconnection in attachment oil flow rate adjusting
— E246 DXE4KA phenomenon EPC solenoid (in governor • pump controller system)
Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from • None in particular (The solenoid does not work, as there is no current flowing to it)
controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
occurring on • The attachments do not move. (The PPC basic pressure is not supplied to the service PPC valve)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Attachment oil flow rate !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
adjusting EPC solenoid during the troubleshooting.

harness
V30 (male) (1) and grounding value
tor) Between wiring harness between C03 (female) (3) (13) (23) Resistance
Below 1 Ω
and V30 (male) (2) and grounding value
3
V30 (female) (1) and grounding
4
Between (26) and (3) (13) (23) 7 – 14 Ω
PC160LC-7 20-365
(1)
Error Code in Electrical System E306 (Abnormality in governor potentiometer)
User Code Error Code Failure Code Failure Abnormality in governor potentiometer
— E306 DK54KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
• The controller exercises control by computing the motor position through voltage right before a failure
Response from occurred.
controller • Even if the failure cause disappears of itself, the governor potentiometer does not return to normalcy,
• The engine cannot attain the specified rotation at high idling. (A bit lower)
• The engine cannot attain the specified rotation at low idling (A bit higher)
Phenomenon
• The auto-decelerator or automatic warming-up function does not work.
occurring on
• There is hunting while the engine is running.
machine
• The engine stalls.
• The engine does not stop.
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: Governor potentiometer voltage)

Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
Governor potentiometer E10 (male) Resistance value
2 defective
Between (A) and (C) 4.0 – 6.0 kΩ
(Internal failure)
Between (B) and (A) 0.25 – 5.0 kΩ
Between (B) and (C) 0.25 – 5.0 kΩ
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to E10 Resistance
harness Below 1 Ω
(female) (A) value
tor) (female) (C) value
Below 1 Ω
(female) (B) value
4
E10 (female) (B) and grounding value
5 Voltage Below 1 V
(Contact with 24 V cir- E10 (female) (A) and grounding
Voltage Below 1 V
E10 (female) (B) and grounding
Governor • pump C01 Resistance value
6
Between (22) and (21) Power sourse 4.5 – 5.5 V
20-366 PC160LC-7
(1)
PC160LC-7 20-367
(1)
Error Code in Electrical System E308 (Abnormality in fuel dial)
User Code Error Code Failure Code Failure Abnormality in fuel dial
E05 E308 DK10KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
• The controller exercises control by computing the fuel dial position through voltage right before a failure
Response from
occurred.
controller
• If the failure cause disappears, the fuel dial returns to normalcy.
• If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL.
Phenomenon
• If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL.
occurring on
• There is hunting while the engine is running.
machine
• The engine cannot attain the specified rotation at high idling and lacks power.
Relative • Input from the fuel dial (voltage) can be confirmed in the monitor function.
information (Code No. 030: Fuel dial voltage)

Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
Fuel dial defective E06 (male) Resistance value

2
(Internal failure) Between (1) and (3) 4.0 – 6.0 kΩ
Between (2) and (1) 0.25 – 5.0 kΩ
Between (2) and (3) 0.25 – 5.0 kΩ
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to E06 Resistance
harness Below 1 Ω
(female) (1) value
tor) (female) (3) value
Below 1 Ω
(female) (2) value
4
E06 (female) (2) and grounding value
5 Voltage Below 1 V
(Contact with 24 V cir- E06 (female) (1) and grounding
Voltage Below 1 V
E06 (female) (2) and grounding
Governor • pump C01 Resistance value
6
Between (22) and (21) Power sourse 4.5 – 5.5 V
20-368 PC160LC-7
(1)
PC160LC-7 20-369
(1)
Error Code in Electrical System E311 (Short-circuiting in cold starting solenoid relay)
User Code Error Code Failure Code Failure Short-circuiting in cold starting solenoid relay
— E311 D199KB phenomenon (in governor•pump controller system)
Failure content • Abnormal current flowed when the cold starting solenoid relay circuit was grounded (power ON).
• The controller turns OFF power to the cold starting solenoid relay circuit.
Response from
• Even when the failure cause disappears, the current does not return to normalcy, unless the engine
controller
starting switch is once turned OFF.
Phenomenon
• The engine does not start easily or at all when temperature is low.
occurring on
(The fuel injection pump rack does not move in the increasing direction.)
machine
Relative • This error code detects abnormality on the primary side (coil side) of the cold starting solenoid relay but
information does not detect abnormality on the secondary side (contact side).

Cold starting solenoid !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
relay defective during the troubleshooting.
1
(Internal short-circuiting R22 (male) Resistance value
2
R22 (female) (2) and grounding
!Turn the engine starting switch OFF for the preparations, and perform troubleshooting
when turning it ON.
C02 Engine water temperature Voltage
Governor • pump
3 20 – 30 V
controller defective Below 0°C
(for 3 sec at max)
0°C or higher Below 1 V
20-370 PC160LC-7
(1)

Serial No.: 10001 – 11000
PC160LC-7 20-371
(4)
Error Code in Electrical System E312 (Disconnection in cold starting solenoid relay)
User Code Error Code Failure Code Failure Disconnection in cold starting solenoid relay
— E312 D199KA phenomenon (in governor • pump controller system)
• When the cold starting solenoid relay is disconnected from grounding (power OFF), 24 V voltage is not
Failure content
generated.
Response from • None in particular.
controller • If the failure cause disappears, the voltage returns to normalcy.
Phenomenon
• The engine does not start easily or at all when temperature is low.
occurring on
(The fuel injection pump rack does not move in the increasing direction.)
machine
Relative • This error code detects abnormality on the primary side (coil side) of the cold starting solenoid relay but
information does not detect abnormality on the secondary side (contact side).

1 Fuse No. 2 defective If fuse No. 2 is broken, the circuit probably has grounding fault (See cause 4).
Cold starting solenoid during the troubleshooting.
2 relay defective
R22 (male) Resistance value
(Disconnection)
Between (1) and (2) 100 – 500 Ω

harness
Wiring harness between C02 (female) (9) and R22 Resistance
(female) (2) value
tor) Wiring harness between R22 (female) (1), J03, and FB1-2 Resistance
Below 1 Ω
outlet value
4 Above 1 MΩ
(Contact with grounding R22 (female) (2) and grounding value
circuit) Between wiring harness between R22 (female) (1), J03, Resistance
Above 1 MΩ
and FB1-2 outlet and grounding value
!Turn the engine starting switch OFF for the preparations, and perform troubleshooting
when turning it ON.
Governor • pump
5 20 – 30 V
controller defective Below 0°C
(for 3 sec at max)
0°C or higher Below 1 V
20-372 PC160LC-7
(1)

Serial No.: 10001 – 11000
PC160LC-7 20-373
(4)
Error Code in Electrical System E315 (Short-circuiting in battery relay)
User Code Error Code Failure Code Failure Short-circuiting in battery relay
— E315 D110KB phenomenon (in governor • pump controller)
Failure content • Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.
• The controller turns OFF power to the battery drive circuit.
Response from
• Even when the failure cause disappears, the relay does not return to normalcy, unless the engine start-
controller
ing switch is once turned OFF.
Phenomenon
occurring on • The engine does not stop. (The controller power cannot be maintained until the engine stops)
machine
Relative • It can be confirmed in the monitor function how the battery relay works (ON or OFF).
information (Code No. 037: Controller output)

Battery relay defective Battery relay (Unit) Resistance value
1
(Internal failure) Between A21 (BR terminal) and A20 (E
Approx. 100 Ω
terminal)
Between A21 (BR terminal) and grounding Above 1 MΩ
2
(Contact with grounding Between wiring harness from C03 (female) (4) to D01 to Resistance
J01 to A21 (BR terminal) and grounding value
Governor • pump
3 C03 (female) Engine starting switch Voltage
20 – 30 V
Between (4) and grounding ON → OFF
(for 4 to 7 seconds)
20-374 PC160LC-7
(1)
PC160LC-7 20-375
(1)
Error Code in Electrical System E316 (Step-out in governor motor)
User Code Error Code Failure Code Failure Step-out in governor motor
— E316 DY10K4 phenomenon (in governor • pump controller)
Failure content • There is a big difference between signals from the potentiometer and the set values in the controller.
• The controller repeats the same controlling motions (step-out).
Response from
• Even when the failure cause disappears, the governor motor does not return to normalcy, unless the
controller
Phenomenon • The engine rotation cannot be controlled.
occurring on • There is hunting in the rotation.
machine • The engine does not stop.

1 Fuel dial defective If Service Code [E308] is displayed, troubleshoot that failure first.
Presumed cause and standard
2 Governor potentiometer system defective If Service Code [E306] is displayed, troubleshoot that failure first.
Governor motor system defective
value in normalcy
3 If Service Code [E317] is displayed, troubleshoot that failure first.

(disconnection)
Governor motor system defective
4 If Service Code [E318] is displayed, troubleshoot that failure first.
(short-circuiting)
Refer to the section of "Inspection and Adjustment - Special Func-
5 Governor lever adjustment improper
tion of Monitor Panel" in this manual.
6 Engine fuel control system defective Refer to 102 series Engine Shop Manual.
As this is an internal failure, no troubleshooting can be carried out.
7 Governor • pump controller defective (If there is none of the failures listed above, the controller is judged
as defective)
20-376 PC160LC-7
(1)
Error Code in Electrical System E317 (Disconnection in governor motor Phase A and B)
User Code Error Code Failure Code Failure Disconnection in governor motor Phase A and B
E05 E317 DY10KA phenomenon (in governor • pump controller)
Failure content • No current flew to the governor motor, when power was supplied to the motor.
Response from • None in particular.
controller • If the failure cause disappears, the governor returns to normalcy.
• The engine rotation drops to low idling.
Phenomenon
• There is hunting in the rotation
occurring on
machine
• The governor motor steps out.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Governor motor defec-
E11 (male) Resistance value
1 tive
(Internal disconnection) Between (1) and (2) 2.5 – 7.5 Ω
Between (3) and (4) 2.5 – 7.5 Ω
Disconnection of wiring Below 1 Ω
(female) (1) value
harness
(female) (2) value
tor) Wiring harness between C03 (female) (25) and E11 Resistance
Below 1 Ω
(female) (3) value
Below 1 Ω
(female) (4) value
3
Between (5) and (15) 2.5 – 7.5 Ω
Between (25) and (35) 2.5 – 7.5 Ω
PC160LC-7 20-377
(1)
20-378 PC160LC-7
(1)

(Short-circuiting in governor motor Phase A and Phase B)
User Code Error Code Failure Code Failure Short-circuiting in governor motor Phase A and
E05 E318 DY10KB phenomenon Phase B (in governor • pump controller system)
Failure content • Abnormal current flew to the governor motor, when power is supplied to the motor.
controller • If the failure cause disappears, the governor motor returns to normalcy.
• The engine rotation cannot be controlled.
Phenomenon
• The engine rotation drops to low idling.
occurring on
• There is hunting in the rotation.
machine
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Governor motor defec- E11 (male) Resistance value
tive Between (1) and (2) 2.5 – 7.5 Ω
1
or grounding fault) Between (3) and (4) 2.5 – 7.5 Ω

Above 1 MΩ
Grounding fault of wiring E11 (female) (1) and grounding value
2 Above 1 MΩ
(Contact with grounding E11 (female) (2) and grounding value
circuit) Between wiring harness between C03 (female) (25) and Resistance
Above 1 MΩ
Above 1 MΩ
C03 (female) Resistance value
Between (5) and (15) 2.5 – 7.5 Ω
Governor • pump Between (25) and (35) 2.5 – 7.5 Ω
3
20-380 PC160LC-7
(1)
PC160LC-7 20-381
(1)
TROUBLESHOOTING A000N1 / A000N2
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling)
User Code Error Code Failure Code Failure Out-of-rate engine rotation at high idling
— — A000N1 phenomenon (in mechanical system)
Failure content • Engine rotation above 2,650 rpm was detected for more than 10 seconds, while the engine was running.
controller • If the failure cause disappears of itself, the engine rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if is used continuously without adjustment.
machine
information (Code No. 010: Engine rotation)

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idling, and troubleshoot the mechanical
cause and ical system
system of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (Unless there is any visible trouble found in the machine, use of the con-
troller may be continued as it is)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)
User Code Error Code Failure Code Failure Out-of-rate engine rotation at low idling
— — A000N2 phenomenon (in mechanical system)
Failure content • Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
controller • If the failure cause disappears of itself, the rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without adjustment.
machine
information (Code No. 010: Engine rotation)

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idling, and troubleshoot the mechanical
cause and ical system
system of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (Unless there is any visible trouble found in the machine, use of the con-
troller may be continued as it is)
20-382 PC160LC-7
(1)
TROUBLESHOOTING AA10NX
Failure Code in Mechanical System AA10NX (Air cleaner clogging)
User Code Error Code Failure Code Failure Air cleaner clogged
— — AA10NX phenomenon (in mechanical system)
• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
controller
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
• This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative panel while the engine is running.
information • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)

Air cleaner clogged
1 (when the system is in !Check the air cleaner for clogging. If it is clogged, clean or replace it with new one.
normal condition)
Air cleaner clogging
2 switch defective A31 (male) Air cleaner Resistance value
(Internal disconnection) When in normal condition Below 1 Ω
Between (1) and (2)
When clogged Above 1 MΩ
!Turn the engine starting switch OFF for the preparations, and hold it running during the
Disconnection of wiring troubleshooting.
harness
Wiring harness between P02 (female) (5) and A31 Resistance
(female) (1) value
tor) Resistance
Between wiring harness A31 (female) (2) and grounding Below 1 Ω
value
4 Monitor panel defective P02 Air cleaner Voltage
When in normal condition Below 1 V
When clogged 20 – 30 V
PC160LC-7 20-383
(1)
TROUBLESHOOTING AB00KE
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)
User Code Error Code Failure Code Failure Abnormally lowered charging voltage
— — AB00KE phenomenon (in mechanical system)
Failure content • Generation signal from the alternator is not inputted, while the engine is running.
Response from
controller
Phenomenon
• There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
• If the charge monitor of the monitor panel lights up in red while the engine is running, this failure code
Relative is recorded.
information • Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)

!Turn the engine starting switch OFF for the preparations, and hold it running during the
Alternator defective troubleshooting.
1
(short generating output) E12 (male) Engine rotation Voltage
Between (1) and grounding Above medium speed 27.5 – 29.5 V
Disconnection of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Wiring harness from P02 (female) (11) to J02 to E12 Resistance
tor) (female) (1) value
harness Between each wiring harness between C02 (female) (11),
3 J02, and E12 (female) (1), between C02 (female) (11) and
circuit) A27 (female) (2), between C02 (female) (11) and D01 Above 1 MΩ
value
(female) (6), and between C02 (female) (11) and other
related circuits and grounding
P02 Engine rotation Voltage
Between (11) and grounding Above medium speed 27.5 – 29.5 V
20-384 PC160LC-7
(1)
TROUBLESHOOTING AB00KE
PC160LC-7 20-385
(1)
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)
User Code Error Code Failure Code Failure Abnormally lowered engine oil pressure
— — B@BAZG phenomenon (in mechanical system)
• The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
Failure content
engine was running.
Response from
controller
Phenomenon
occurring on • There is a possibility that the engine may seize, if the engine is kept running without corrective action.
machine
• If the engine oil pressure monitor of the monitor panel lights up in red while the engine is running, this
Relative failure code is recorded.
information • Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.

Engine oil pressure low-
Check the engine oil pressure. If it is abnormal, inspect failure cause and damage of the
1 ered (the system in nor-

engine, and then repair.
mal condition)
Engine oil pressure
2 switch defective E02 (Unit) Engine oil pressure Resistance value
(Internal short-circuiting) Between terminal and When in normal condition Above 1 MΩ
grounding When lowered Below 1 Ω
3
(Contact with grounding Between wiring harness between P02 (female) (7) and E02 Resistance
(terminal) and grounding value
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition 20 – 30 V
When lowered Below 1 V
20-386 PC160LC-7
(1)
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code Error Code Failure Code Failure Abnormally lowered engine oil level
— — B@BAZK phenomenon (in mechanical system)
• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
Failure content
engine is stopped (with the starting switch in the ON position).
Response from
controller
Phenomenon
occurring on • There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
• If the engine oil level monitor of the monitor panel lights up in red while the engine is stopped (with the
Relative starting switch in ON position), this failure code is recorded.
information • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)

Engine oil level lowered
!Check the oil level in the engine oil pan. If it is low, add oil.
1 (System in normal condi-

(If the phenomenon occurs frequently, check the cause)
tion)
Engine oil level switch
2 defective E03 (male) Engine oil level Resistance value
When lowered Above 1 MΩ
Disconnection of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Wiring harness between P02 (female) (8) and E03 (female) Resistance
tor) (1) value
4 Monitor panel defective P02 Engine oil level Voltage
When lowered 20 – 30 V
PC160LC-7 20-387
(1)
TROUBLESHOOTING B@BCNS
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating)
User Code Error Code Failure Code Failure Engine cooling water overheated
— — B@BCNS phenomenon (in mechanical system)
Failure content • The engine cooling water sensor inputted a signal of 102°C, while the engine was running.
Response from
• Response from controller
controller
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• If the engine water temperature monitor of the monitor panel lights up in red while the engine is running,
Relative this failure code is recorded.
information • Input from the engine cooling water temperature sensor (temperature) can be confirmed in the monitor
function. (Code No. 041: Engine cooling water temperature)

Engine Overheating
!The engine may have overheated. Inspect failure cause and damage of the engine,
1 (system in normal condi-
and then repair.

tion)
Engine cooling water
temperature sensor Engine cooling water tem-
2 E05 (male) Resistance value
defective perature
(Internal short-circuiting) Between (1) and (2) 90 – 3.5kΩ
10 – 100 °C
3
4 Monitor panel defective P02 (female) Engine water temperature Resistance value
Between (1) and (13) 90 – 3.5kΩ
10 – 100 °C
20-388 PC160LC-7
(1)
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level)
User Code Error Code Failure Code Failure Abnormally lowered radiator water level
— — B@BCZK phenomenon (in mechanical system)
Failure content • The signal circuit in the radiator water level switch was opened (i.e. disconnected from grounding).
Response from
controller
Phenomenon
machine
• If the radiator water level monitor of the monitor panel lights up in red while the engine is stopped (with
Relative the starting switch in ON position), this failure code is recorded.
information • Input from the radiator water level switch (ON or OFF) can be confirmed in the monitor function.

Radiator sub-tank water
!Check the water level in the radiator sub-tank. If it is low, add water.
1 level lowered (system in
(If this phenomenon occurs frequently, check the cause)
normal condition)
Radiator water level
2 switch defective A33 (male) Sub-tank water level Resistance value
Between (1) and (2)
When lowered Above 1 MΩ
harness
Wiring harness between P02 (female) (3) and A33 (female) Resistance
(1) value
tor) Resistance
Wiring harness between A33 (female) (2) and grounding Below 1 Ω
value
4 Monitor panel defective P02 Sub-tank water level Resistance value
When lowered 20 – 30 V
Electrical Circuit Diagram for Radiator Water Level Switch in Monitor Panel
PC160LC-7 20-389
(1)
TROUBLESHOOTING B@HANS
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)

(Multi-monitor only)
User Code Error Code Failure Code Failure Hydraulic oil overheated
— — B@HANS phenomenon (in mechanical system)
Failure content • The hydraulic oil temperature sensor inputted a signal of 102°C, while the engine was running.
Response from
controller
Phenomenon
machine
• If the hydraulic oil temperature monitor of the monitor panel lights up in red while the engine is running,
Relative this failure code is recorded.
information • Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function.
(Code No. 044: Hydraulic oil temperature)

Hydraulic oil overheat-
!The hydraulic oil may have overheated. Inspect failure cause and damage of the hy-
1 ing (system in normal

draulic equipment, and then repair.
condition)
Hydraulic oil temperature
2 sensor defective A61 (male) Hydraulic oil temperature Resistance value
(Internal short-circuiting) Between (1) and (2) 90 – 3.5kΩ
10 – 100 °C
3
A61 (female) (2) and grounding value
4 Monitor panel defective P02 (female) Hydraulic oil temperature Resistance value
Between (12) and (13) 90 – 3.5kΩ
10 – 100 °C
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
20-390 PC160LC-7
(1)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
BEFORE CONDUCTING E-MODE TROUBLESHOOTING ....................................................................... 20-402

E- 1 Engine does not start ........................................................................................................................ 20-404
E- 2 Engine stops while in operation ........................................................................................................ 20-409
E- 3 Engine rotates unstably or hunting ................................................................................................... 20-410
E- 4 Engine does not stop ........................................................................................................................ 20-412
E- 5 Auto-decelerator does not work ........................................................................................................ 20-414
E- 6 Auto engine warm-up device does not work ..................................................................................... 20-415
E- 7 Preheater does not operate .............................................................................................................. 20-416
E- 8 All work equipment, swing and travel do not move........................................................................... 20-418
E- 9 One-touch power max switch does not work .................................................................................... 20-420
E-10 Attachment circuit does not change.................................................................................................. 20-421
E-11 No display in monitor panel at all ...................................................................................................... 20-422
E-12 Monitor panel does not display partially............................................................................................ 20-423
E-13 Contents of monitor panel are different from mounted model........................................................... 20-423
E-14 Fuel level monitor lights up in red while engine is running................................................................ 20-424
E-15 Engine cooling water temperature gauge does not indicate correctly .............................................. 20-425
E-16 Hydraulic oil temperature gauge does not display correctly ............................................................. 20-426
E-17 Fuel gauge does not display correctly .............................................................................................. 20-427
E-18 Swing lock monitor does not display correctly .................................................................................. 20-428
E-19 When monitor switch is operated, nothing is displayed .................................................................... 20-430
E-20 Windshield wiper and window washer does not work....................................................................... 20-432
E-21 Alarming buzzer cannot be cancelled ............................................................................................... 20-436
E-22 "Boom RAISE" is not correctly displayed in monitor function ........................................................... 20-437
E-23 "Boom LOWER" is not correctly displayed in monitor function ......................................................... 20-438
E-24 "Arm IN" is not correctly displayed in monitor function ..................................................................... 20-439
E-25 "Arm OUT" is not correctly displayed in monitor function ................................................................. 20-440
E-26 "Bucket CURL" is not correctly displayed in monitor function........................................................... 20-441
E-27 "Bucket DUMP" is not correctly displayed in monitor function .......................................................... 20-442
E-28 "SWING" is not correctly displayed in monitor function .................................................................... 20-443
E-29 "TRAVEL" is not correctly displayed in monitor function................................................................... 20-446
E-30 "Travel differential pressure" is not correctly displayed in monitor function ...................................... 20-448
E-31 "Service" is not correctly displayed in monitor function..................................................................... 20-450
E-32 Troubleshooting for air conditioner system ....................................................................................... 20-452
E-33 Travel alarm does not sound or does not stop sounding .................................................................. 20-454
PC160LC-7 20-401
(4)
TROUBLESHOOTING BEFORE CONDUCTING E-MODE TROUBLESHOOTING
BEFORE CONDUCTING E-MODE TROUBLESHOOTING

Connection table of fuse box
This connection table shows the devices to which each power supply of the fuse box (FB1) supplies power
directly (A switch power supply is a device which supplies power while the engine starting switch is at the
ON position and a constant power supply is a device which supplies power while the engine starting switch
is at the OFF position).
When conducting troubleshooting for an electric system, you should check its fuse box and fusible link to
see if the power is supplied normally.
Type of power
Fuse No. Fuse capacity Destination of power
supply
Governor pump controller (Controller power supply)
1 10A Emergency pump drive resistor
Swing holding brake release switch
Governor pump controller (Solenoid power supply)
Switch power supply 2 20A Cold starting solenoid relay (Coil side and contact side)
(Fusible link: A34) Attachment return switching relay (Coil side and contact side)
3 10A Safety lock switch
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn switch
6 10A (Spare)
Rotary lamp switch

7 10A
Additional relay (Coil side and contact side)
Switch power supply
8 10A Light relay (Contact side)
(Fusible link: A34)
One-touch power maximizing switch
9 10A
Radio
10 10A (Spare)
11 20A Air conditioner unit
Starting motor cut-out (Personal code) relay (Coil side)

12 20A
Monitor panel
Switch power supply
13 20A Light switch
(Fusible link: A34)
14 10A Service power supply (M32 connector)
Travel alarm
15 10A
DC/DC converter
16 10A Radio
17 20A (Spare)
Constant power Engine starting switch / Monitor panel
supply 18 10A
(Fusible link: A35) —
19 10A Room lamp
20 10A (Spare)
20-402 PC160LC-7
(4)

! The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
with it.
Cause for presumed • Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V) is
(The attached No. for in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
• If there is no indication of (male) or (female) in the connector No., pull off a connec-
4
tor and insert a T-adapter into both sides of male and female.
• If there is an indication of (male9 and (female) in the connection No., pull off a con-
nector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead (–) for troubleshooting in the follow-
5 ing manner unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
PC160LC-7 20-403
(1)
TROUBLESHOOTING E-1
E-1 Engine does not start
Failure
• Engine does not start. (1) Engine does not turn.
information
• The engine starting circuit has the following 2 starting lock mechanisms.
Relative
1) Starting lock by password of monitor panel
information
2) Starting lock by safety lock lever

Insufficient battery Battery voltage Specific gravity of battery fluid
1
capacity Above 24 V Above 1.26
If fuse No. 3 or 18 is broken, the circuit probably has grounding fault, etc. (See cause 10.)
Fuses No. 3 or 18
2 If the fuse is not broken but the monitor panel does not light up, check the power supply cir-
defective
cuit between the battery and fuse box.
aTurn the engine starting switch OFF for the preparations.
Engine starting
switch defective H15 (male) Engine starting switch Resistance value
3
(Internal disconnec- OFF Above 1 Mz
tion) Between (1) and (4)
START Below 1 z
Lock switch defec- during the troubleshooting.
tive S14 (female) Lock lever Resistance value
4
tion) Reset Above 1 Mz
Between (1) and (3)
Lock Below 1 z
Starting motor cut-off during the troubleshooting.
relay R11 or R13 R11 (female), R13 (female) Resistance value
5 defective
Between (1) and (2) 100 – 500 z
tion or short-circuit) Between (3) and (5) Above 1 Mz
Between (3) and (6) Below 1 z
aTurn the engine starting switch OFF for the preparations (and disconnect only terminal C),
and hold it in the START position during the troubleshooting.
Engine
Relay terminal A27 Voltage/Resistance value
starting switch
Power
Between B and grounding 20 – 30 V
source
Starting motor safety Between E and grounding GND Below 1 z
6 relay defective Between A27 (2) and ground- Generation
(Internal failure) Below 1 V
ing signal START
Between A27 (1) and ground- Starting
20 – 30 V
ing input
Starting out-
Between C and grounding 20 – 30 V
put
If the power source, grounding, generation signal, and starting input are normal but the
starting output is abnormal, the starting motor safety relay is defective.
aTurn the engine starting switch OFF for the preparations, and hold it in the START position
Engine
Starting motor Voltage
starting switch
Starting motor
Power
7 defective Between B and grounding 20 – 30 V
source
(Internal failure) START
Starting
Between C and grounding 20 – 30 V
signal
If the power source and starting signal are normal but the starting motor does not rotate, the
starting motor is defective.
20-404 PC160LC-7
(4)
TROUBLESHOOTING E-1

!Turn the engine starting switch OFF for the preparations, and hold it in the ON or START
Alternator defective position during the troubleshooting.
8
(Internal failure) E12 (male) Voltage
Between (1) and grounding Below 1 V
Resistance
Wiring harness between FB1-18 outlet and H15 (female) (1) Below 1 Ω
value
Wiring harness from H15 (female) (4) to J01 and R11 (female) Resistance
Below 1 Ω
(5) value
Resistance
Disconnection of Wiring harness between R11 (female) (3) and A27 (female) (1) Below 1 Ω
value
wiring harness
Wiring harness between starting safety relay C and starting Resistance
9 (Disconnection or Below 1 Ω
motor C value
defective contact
Wiring harness between FB1-3 outlet and S14 (male) (1) Below 1 Ω
value
Resistance
Wiring harness between S14 (male) (3) and R11 (female) (1) Below 1 Ω
value
Resistance
Wiring harness between R11 (female) (2) and R13 (female) (6) Below 1 Ω
value
Wiring harness between R13 (female) (3) and J04 and Resistance
Below 1 Ω
grounding value
Between wiring harness between FB1-18 outlet and H15 Resistance
Above 1 MΩ
Between wiring harness from H15 (female) (4) to J01 and
R11 (female) (5), or H15 (female) (4) and P01 (female) (4), or Resistance
Above 1 MΩ
H15 (female) (4) and C01 (female) (17), or H15 (female) (4) value
to other relative circuits and grounding
Grounding fault of
wiring harness Between wiring harness between R11 (female) (3) and A27 Resistance
10 Above 1 MΩ
(Contact with (female) (1) and grounding value
grounding circuit) Between wiring harness between starting motor safety relay Resistance
Above 1 MΩ
C and starting motor C and grounding value
Between wiring harness between FB1-3 outlet and S14 (male) Resistance
Above 1 MΩ
(1) and grounding value
Between wiring harness between S14 (male) (3) and R11 Resistance
Above 1 MΩ
Between wiring harness from P02 (female) (14) to J05 and Resistance
Above 1 MΩ
R13 (female) (2) and grounding value
!Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuit of wiring ing the troubleshooting.
harness Between wiring harness from A27 (female) (2) and E12
11
(Contact with 24 V (female) (1), or A27 (female) (2) to J02 and D01 (female) (6),
or A27 (female) (2) and P02 (female) (11), or A27 (female) (2)
to other relative circuits and grounding
PC160LC-7 20-405
(1)
TROUBLESHOOTING E-1
20-406 PC160LC-7
(1)
TROUBLESHOOTING E-1
Failure (2) Engine does not start easily or at all at low tem-
• Engine does not start.
information perature.
• If the engine starting switch is turned ON when temperature is low (Engine water temperature: Below
Relative 0°C), the cold start solenoid is turned ON to increase the fuel injection rate.
information • If the primary side (coil side) of the cold start solenoid relay has a fault (short-circuit or disconnection),
an error code is displayed. A fault on the secondary side (contact side) cannot be detected, however.

1 Fuse No. 2 defective If fuse No. 2 is broken, the circuit probably has grounding fault, etc. (See cause 6.)
Engine water tem- during the troubleshooting.
perature sensor (for E12 (male) Engine water temperature Resistance value
2 controller) defective
- 30 – 0°C 57 k – 10 kΩ
(Internal short-cir- Between (A) and (B)
cuit) 5 – 100°C 10 k – 0.3 kΩ
Between (B) and grounding - 30 – 100°C Above 1 MΩ
Cold start solenoid
relay R22 defective When relay R22 is replaced with another relay, if the condition becomes normal, relay R22
3
(Internal disconnec- is defective.
tion)
Cold start solenoid !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
defective
4
(Internal disconnec- V07 (Unit) Resistance value
tion or short-circuit) Between terminal and solenoid body 7.7 ± 0.3 Ω
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
5 (Disconnection or Wiring harness from FB1-2 outlet to J03 and R22 (female) (3) Below 1 Ω
value
defective contact
Wiring harness between R22 (female) (5) and V07 Below 1 Ω
value
Grounding fault of Between wiring harness between C01 (female) (20) and E12 Resistance
Above 1 MΩ
wiring harness (female) (B) and grounding value
6
(Contact with Between wiring harness from FB1-2 outlet to J03, to R22 Resistance
grounding circuit) Above 1 MΩ
(female) (3), and to other relative circuits and grounding value
Between wiring harness between R22 (female) (5) and V07 Resistance
Above 1 MΩ
and grounding value
during the troubleshooting (Troubleshooting on the input side).
C01 (female)
Engine water temperature Resistance value
P02 (female)
Between C01 (20) and P02 - 30 – 0°C 57 k – 10 kΩ
(13) 5 – 100°C 10 k – 0.3 kΩ
Between C01 (20) and
- 30 – 100°C 57 k – 0.3 kΩ
grounding
Governor • pump
7 !Turn the engine starting switch OFF for the preparations, and conduct troubleshooting
when it is turned from the OFF position to the ON position (Troubleshooting on the output
side).
Below 0°C 20 – 30 V
Between (9) and grounding (or disconnect E12) (Max. 3 sec)
Above 0°C Below 1V
If the troubleshooting result on the input side is normal but that on the output side is abnor-
mal, the controller is defective.
PC160LC-7 20-407
(1)
TROUBLESHOOTING E-1

Serial No.: 10001 – 11000
20-408 PC160LC-7
(4)
TROUBLESHOOTING E-2
E-2 Engine stops while in operation
Failure
• Engine stops while in operation. Engine stops while in operation.
information
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: governor potentiometer voltage)

Governor potentiom-
E10 (male) Resistance value

1 eter fault
Between (A) and (C) 4.0 – 6.0 kΩ
(Internal failure)
Between (B) and (A) 0.25 – 5.0 kΩ
Between (B) and (C) 0.25 – 5.0 kΩ
Disconnection of wir- !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
2 (Disconnection or
Wiring harness between C01 (female) (13) and E10 (female) Resistance
defective contact Below 1 Ω
with connector) (B) value
Grounding fault of !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3
(Contact with Between wiring harness between C01 (female) (13) and E10 Resistance
(female) (B) and grounding value
ing the troubleshooting.
4
Between (22) and (21) 4.5 – 5.5 V
Between (13) and (21) 0.5 – 4.5 V
PC160LC-7 20-409
(1)
TROUBLESHOOTING E-3
E-3 Engine rotates unstably or hunting
(1) Engine rotates unstably at low idling.

Failure
• Engine rotates unstably or hunting (2) Engine hunting.
information
(3) High idling speed is low.
• The governor • pump controller carries out the following controls normally. Consequently, the set open-
ing angle of the fuel control dial and the control angle of the governor motor may not precisely conform
to each other.
1) Control of governor by selection of working mode
2) Control of governor by setting of auto deceleration function
3) Control of governor by operating condition of control lever
Relative
4) Control of governor by automatic warm-up function in cold state
information
5) Control of governor by turbocharger protection function at starting of engine
Accordingly, be sure to select the "Governor lever stroke adjustment mode" when checking the opera-
tion of the fuel control dial and governor motor (Since the governor control function does not work in this
mode, the set opening angle of the fuel control dial always conforms to the control angle of the governor
motor).
• The engine speed can be confirmed in the monitor function. (Code No. 010: Engine speed)

!Turn the engine starting switch ON for the troubleshooting (Monitoring).
Monitoring code Item Normal display
Model code signal
1 002
fault Controller model code 150
003
If the monitoring display is abnormal, conduct troubleshooting for error code [E217].
Defective adjustment
2 See TESTING AND ADJUSTING "Special function of monitor panel".
of governor lever
!Turn the engine starting switch ON or start the engine for the troubleshooting.
Malfunction of gover- When the following operation is conducted, if the governor motor lever moves smoothly, gov-
3 ernor motor is normal.
nor motor
• Operate the fuel control dial between low idling and high idling.
• Stop the engine by turning the starting switch OFF.
Engine fuel control
4 See Shop Manual for 102 Series Engine.
system defective
5 (Disconnection or
Wiring harness from C01 (female) (23) to J07 and H15 Resistance
with connector) (female) (5) value
6
(Contact with Between wiring harness from C01 (female) (23) to J07 and Resistance
H15 (female) (5) and to other relative circuits and grounding value
Governor • pump As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
7
controller defective causes listed in Item 1 through 6, the controller is judged as defective.)
20-410 PC160LC-7
(1)
TROUBLESHOOTING E-3
PC160LC-7 20-411
(1)
TROUBLESHOOTING E-4
E-4 Engine does not stop
Failure
• Engine does not stop.
information
• The governor • pump controller holds the battery relay for 4 seconds at shortest and 7 seconds at longest
to secure the drive power for the governor motor after the starting switch is turned to the OFF position
Relative
until the engine stops.
information
• It can be confirmed in the monitor function how the battery relay works (ON or OFF)
(Code No. 037: Controller output)

!Operate the starting switch for the troubleshooting.
Battery relay fault When the starting switch is operated as follows, if the battery relay contacts make operating
1
(Internal failure) sounds, the battery relay is normal.
• Starting switch OFF→ON→OFF
Assembled-type !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 fault during the troubleshooting.
2
tion) Between (5) and (1) Diode mode Continued
Disconnection of wir- Resistance
ing harness Wiring harness between C03 (female) (4) and D01 (female) (5) Below 1 Ω
value
3 (Disconnection or
Resistance
defective contact Wiring harness from D01 (female) (1) to J01 and A21 (BR) Below 1 Ω
with connector) value
Resistance
Wiring harness between A20 (E1) and grounding Below 1 Ω
value
Governor • pump
4 C03 Engine starting switch Voltage
20 – 30 V
Between (4) and grounding ON→OFF
(for 4 to 7 seconds)
20-412 PC160LC-7
(1)
TROUBLESHOOTING E-4
PC160LC-7 20-413
(1)
TROUBLESHOOTING E-5
E-5 Auto-decelerator does not work
Failure
• Auto-decelerator does not work.
information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
Relative
auto-decelerator does not work.
information
• Confirm the display on the monitor panel, when the engine is running.

Boom RAISE signal Lever operation: ON
1 019 Boom RAISE
fault Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-22 Troubleshooting.
Boom LOWER sig- Lever operation: ON
2 019 Boom LOWER
nal fault Lever NEUTRAL: OFF
Lever operation: ON
3 Arm IN signal fault 019 Arm IN
Lever NEUTRAL: OFF

Arm OUT Lever operation: ON
4 019 Arm OUT
signal fault Lever NEUTRAL: OFF
Bucket CURL signal Lever operation: ON
5 021 Bucket CURL
fault Lever NEUTRAL: OFF
Bucket DUMP sig- Lever operation: ON
6 021 Bucket DUMP
nal fault Lever NEUTRAL: OFF
Lever operation: ON
7 Swing signal fault 019 Swing
Lever NEUTRAL: OFF
Lever operation: ON
8 Travel signal fault 019 Travel
Lever NEUTRAL: OFF
Attachment signal Monitoring code Item Normal display

fault Lever operation: ON
9 021 Service
(When attachments Lever NEUTRAL: OFF
is installed) If the display on the monitor panel is not normal, proceed to No. E-31 Troubleshooting.
Governor • pump As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
10
controller defective causes listed in Item 1 through 9, the controller is judged as defective.
20-414 PC160LC-7
(1)
TROUBLESHOOTING E-6
E-6 Auto engine warm-up device does not work
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C,
Relative and raise the engine rotation up to 1,200 rpm.
information • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.


value in normalcy
Engine cooling water Compare with the actual

1 temperature signal Engine cooling water tem-
041 engine cooling water tem-
fault perature
perature.
If the display on the monitor panel is not normal, proceed to No. E-15
Troubleshooting.
As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (If the fault mentioned in the above item is not found, the Governor • pump controller is
judged as defective)
PC160LC-7 20-415
(1)
TROUBLESHOOTING E-7
E-7 Preheater does not operate
Failure (1) When starting switch is turned to HEAT position,

• Preheater does not operate.
information preheater monitor does not light up.
• The preheater monitor lights up when the starting switch is turned to the HEAT position and starts flash-
ing about 30 seconds later to notify the operator of completion of preheating (It stops flashing about 10
Relative
seconds after).
information
• Input state (ON • OFF) of the preheating signal can be confirmed in the monitor function.

Starting switch sys- If the preheater does not operate (If the heating unit does not become hot), conduct
1
tem defective troubleshooting (2).
Disconnection of wir- !Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
value in normalcy
ing harness tion during the troubleshooting.

2 (Disconnection or
Wiring harness between P02 (female) (18) and J02 (male) Resistance
with connector) (7) value
!Turn the engine starting switch OFF for the preparation.

Monitor panel defec- P02 Starting switch Voltage
3
tive OFF Below 1 V
HEAT 20 – 30 V
Failure (2) When starting switch is turned to HEAT position,

• Preheater does not operate.
information preheater unit does not become hot.
Relative • When the temperature is low (When the water temperature is below 30°C), the governor • pump control-
information ler drives the heater relay for 100 seconds after the engine is started to heat the engine automatically.

Starting switch
defective H15 (male) Starting switch Resistance value
1
(Internal disconnec- OFF Above 1 MΩ
tion) Between (1) and (3)
HEAT Below 1 Ω
Heater relay defec-
Continuity • Resistance
tive Heater relay Starting switch
2 value
value in normalcy
tion) Between A25 and grounding OFF There is continuity

Between contact terminals HEAT Below 1 Ω
Intake air heater !Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
defective tion during the troubleshooting.
3
(Internal disconnec- Intake air heater Continuity
tion) Between E01 and grounding There is continuity
!Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
ing harness Wiring harness from H15 (female) (3) to J02 and A25 Below 1 Ω
value
4 (Disconnection or
Resistance
defective contact Wiring harness between A22 and heater relay Below 1 Ω
Resistance
Between A26 and E01 Below 1 Ω
value
20-416 PC160LC-7
(1)
TROUBLESHOOTING E-7
PC160LC-7 20-417
(1)
TROUBLESHOOTING E-8
E-8 All work equipment, swing and travel do not move
Failure
• All work equipment, swing and travel do not move.
information
Relative
—
information

If the fuse No. 3 is blown, there is a big possibility that grounding fault occurred in the cir-
1 Fuse No. 3 fault
cuit. (cause 6 reference)
Lock switch defec- during the troubleshooting.
tive S14 (female) Lock lever Resistance value
2
tion) Lock Above 1 Mz
Between (1) and (2)
Release Below 1 z
PPC lock solenoid

fault
3 (Internal disconnec- V01 (male) Resistance value
tion or short-circuit- Between (1) and (2) 20 – 60 z
ing)
Assembled-type aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 fault during the troubleshooting.
4
(Internal short-cir- D01 (male) Resistance value
cuiting) Between (4) and (8) Above 1 Mz (no continuity)
ing harness Wiring harness between FB1-3 outlet and S14 (male) (1) Below 1 z
value
5 (Disconnection or
defective contact Resistance
Wiring harness from S14 (male) (2) to J02 and V01 (female) (1) Below 1 z
Resistance
value
Grounding fault of during the troubleshooting.
wiring harness Between wiring harness between FB1-3 outlet and S14 Resistance
Above 1 Mz
6 (Contact with (male) (1) and grounding value
grounding (GND) Wiring harness from S14 (male) (2) to J02 and V01 (female)
circuit) Resistance
(1), or between wiring harness between S14 (male) (2) and Above 1 Mz
value
D01 (female) (4) and grounding
20-418 PC160LC-7
(4)
TROUBLESHOOTING E-8
PC160LC-7 20-419
(4)
TROUBLESHOOTING E-9
E-9 One-touch power max switch does not work
Failure
• One-touch power max. switch does not work.
information
• If the one-touch power max switch is pressed while the engine is running in mode A or E, the one-touch
Relative power max monitor is displayed on the monitor panel.
information • Input from the one-touch power max. switch (left knob switch) can be confirmed in the monitor function.
(Code No. 022: Switch input 1)

1 Fuse No. 9 fault
One-touch power during the troubleshooting.
max. switch fault M23 (male) One-touch power max. switch Resistance value
2
tion) Release Above 1 MΩ
Between (1) and (2)
Depress Below 1 Ω
ing harness
Resistance
3 (Disconnection or Wiring harness between FB1-9 outlet and M23 (female) (1) Below 1 Ω
value
defective contact
Wiring harness between M23 (female) (2) and C01 (female) (11) Below 1 Ω
value
Grounding fault of during the troubleshooting.
wiring harness
Between wiring harness between FB1-9 outlet and M23 Resistance
4 (Contact with Above 1 MΩ
grounding (GND)
circuit) Between wiring harness between M23 (female) (2) and C01 Resistance
Above 1 MΩ
Governor • pump C01 One-touch power max. switch Voltage
5
Release Below 1 V
Depress 20 – 30 V
20-420 PC160LC-7
(1)
TROUBLESHOOTING E-10
E-10 Attachment circuit does not change
(1) When working mode A or E is selected, attach-

ment circuit is not switched to crusher circuit
Failure (reciprocation circuit).
• Attachment circuit does not change.
information (2) When working mode B is selected, attachment
circuit is not switched to breaker circuit (one-way
circuit).
• If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or discon-
Relative
nection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected,
information
however.

selector solenoid
(Internal disconnec- 20 – 60 Ω
Between (1) and (2)

tion or short-circuit)
selector relay defec-
2 tive R20 (male) Resistance value
(Internal disconnec- Between (3) and (5) Below 1 Ω
tion or short-circuit)
Between (3) and (6) Above 1 MΩ
ing harness Wiring harness between J03 (male) (8) and R20 (female) (3) Below 1 Ω
value
3 (Disconnection or
Resistance
defective contact Wiring harness between R20 (female) (5) and V12 (female) (1) Below 1 Ω
Resistance
Wiring harness between V12 (female) (2) and grounding Below 1 Ω
value
Short-circuit of wiring !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness and R20 (female) (5) and V12
PC160LC-7 20-421
(1)
E-11 No display in monitor panel at all
Failure • No display in monitor panel at all • When the engine starting switch is turned ON,
information there appears no display at all in the monitor panel.
Relative
—
information

1 Fuse No. 12 fault
ing harness
Resistance
2 (Disconnection or Wiring harness from P01 (female) (1) (2) to J07 to FB1-12 Below 1 z
value
defect contact with
connector) Resistance
Wiring harness between P01 (female) (6) (7) and grounding Below 1 z
value
Grounding fault of aTurn the engine starting switch OFF for the preparations, and hold it in the OFF position
3 (Contact with
grounding (GND) Between wiring harness from P01 (female) (1) (2) to J07 to Resistance
Above 1 Mz
circuit) FB1-12 outlet and grounding value
aTurn the engine starting switch OFF for the preparations.

Engine Voltage and resistance
P01 (female)
Monitor panel starting switch value
4
defective Between (1) (2) and grounding ON Voltage: 20 – 30 V
Resistance value:
Between (6) (7) and grounding OFF
Below 1 z
20-422 PC160LC-7
(4)

Serial No.: 10001 – 11000
PC160LC-7 20-422-1
(4)
TROUBLESHOOTING E-12, E-13
E-12 Monitor panel does not display partially
Failure When starting switch is turned ON, monitor panel

• Monitor panel does not display partially.
information does not display partially.
Relative
—
information

standard value in normalcy
!Turn the engine starting switch ON for the troubleshooting.

Presumed cause and
Monitor panel LCD When the switch is operated as follows, if the all panel LCD goes off (if the all screen
1
defective becomes white), the monitor panel LCD is normal.
• Press switches [ ] + [ A ] simultaneously.
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is none of
2
defective the causes listed above, the monitor panel is judged as defective.)
E-13 Contents of monitor panel are different from mounted model
Failure
• Contents of monitor panel are different from mounted model.
information
Relative
—
information

standard value in normalcy

Presumed cause and

Model code signal 002
1 Controller model code 150
fault 003
If the display of the monitor is abnormal, conduct the troubleshooting for error code
[E217].
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is none of
2
defective the causes listed above, the monitor panel is judged as defective.)
PC160LC-7 20-423
(1)
E-14 Fuel level monitor lights up in red while engine is running
Failure
• Fuel level monitor lights up in red while engine is running.
information
• If the fuel level gauge of the monitor panel enters the red range, the fuel level monitor lights up in red.
Relative
• Input (Voltage) from the fuel level sensor can be confirmed in the monitor function.
information
(Code No. 042: Fuel level sensor voltage)

Fuel level low
1 Check the fuel level in the fuel tank and add fuel, if necessary.
(System is normal)
Fuel level sensor during the troubleshooting.
defective A60 (male) Fuel level Resistance value
2
tion) FULL (Upper limit) Approx. 12 Ω
EMPTY (Lower limit) 85 – 110 Ω
Disconnection of !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
3 (Disconnection or
Wiring harness between P02 (female) (2) and A60 (female) Resistance
with connector) (1) value
Monitor panel P02 (female) Fuel level Resistance value
4
defective
FULL (Upper limit) Approx. 12 Ω
20-424 PC160LC-7
(1)
E-15 Engine cooling water temperature gauge does not indicate correctly
(1) The engine cooling water rises normally, but the

Failure • Engine cooling water temperature gauge does display does not exceed the white range (C).
information not indicate correctly. (2) The engine cooling water temperature remains
stable, but the display rises to the red range (H).
Relative • Input from the engine cooling water temperature sensor can be confirmed in the monitor function.
information (Code No. 041: Engine cooling water temperature)

Engine cooling water
temperature sensor
fault Engine cooling water
1 E05 (male) Resistance value
(Internal disconnec- temperature
tion or short-circuit- Between (1) and (2) 90 – 3.5 kΩ
ing) 10 – 100 °C
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) (1) and E05 (female) (2) Below 1 Ω
value
defective contact
Wiring harness between P02 (female) (13) and E05 (female) (1) Below 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (1) and E05 Resistance
Above 1 MΩ
circuit) (female) (2) and grounding value
Short-circuiting of !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) (1) and E05
Monitor panel Engine cooling water
5 P02 (female) Resistance value
defective temperature
Between (1) and (13) 90 – 3.5 kΩ
10 – 100 °C
Between (1) and grounding 90 – 3.5 kΩ
PC160LC-7 20-425
(1)
E-16 Hydraulic oil temperature gauge does not display correctly
(1) Hydraulic oil temperature rises normally, but the

Failure • Hydraulic oil temperature gauge does not dis- display does not exceed the white range (C).
information play correctly. (2) Hydraulic oil temperature remains stable, but the
display rises up the red range (H).
Relative • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No. 044: Hydraulic oil temperature)

Hydraulic oil temper-
ature sensor fault
1 (Internal disconnec- A61 (male) Hydraulic oil temperature Resistance value
tion or short-circuit- Between (1) and (2) 90 – 3.5 kΩ
ing) 10 – 100 °C
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) (12) and A61 (female) (2) Below 1 Ω
value
defective contact
Wiring harness between P02 (female) (13) and A61 (female) (1) Below 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (12) and A61 Resistance
Above 1 MΩ
4
(Contact with 24 V Between wiring harness between P02 (female) (12) and A61
Monitor panel Engine cooling water
5 P02 (female) Resistance value
defective temperature
Between (12) and (13) 90 – 3.5 kΩ
10 – 100 °C
Between (12) and grounding 90 – 3.5 kΩ
20-426 PC160LC-7
(1)
E-17 Fuel gauge does not display correctly
(1) Though fuel was refilled, the display does not

Failure exceed the red range (E).
• Fuel gauge does not display correctly.
information (2) Though the remaining fuel level is low, the dis-
play does not drop below the green range (F).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 042: Fuel sensor voltage)

Fuel level sensor
fault
1 (Internal disconnec- A60 (male) Fuel level Resistance value
tion or short-circuit- FULL (Upper limit) Approx. 12 Ω
ing) Between (1) and grounding

2 (Disconnection or
Resistance
defective contact Wiring harness between P02 (female) (2) and A60 (female) (1) Below 1 Ω
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (2) and A60 Resistance
Above 1 MΩ
4
(Contact with 24 V Between wiring harness between P02 (female) (2) and A60
Monitor panel P02 (female) Fuel level Resistance value
5
defective
FULL (Upper limit) Approx. 12 Ω
PC160LC-7 20-427
(1)
E-18 Swing lock monitor does not display correctly
(1) Though the swing lock switch was turned ON,

Failure the swing lock monitor does not light up.
• Swing lock monitor does not display correctly.
information (2) Though the swing lock switch was turned OFF,
the swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.

Swing lock switch
fault
1 (Internal disconnec- X05 (female) Swing lock switch Resistance value
tion or short-circuit- OFF Above 1 MΩ
ing) Between (1) and (2)
ON Below 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness from P02 (female) (17) to J02 to X05 (male) (1) Below 1 Ω
value
defective contact
Wiring harness from X05 (male) (2) to J05 to grounding Below 1 Ω
value
3 (Contact with Between wiring harness from P02 (female) (17) to J02 and
grounding (GND) Resistance
X05 (male) (1), or P02 (female) (17) to C02 (female) (38) and Above 1 MΩ
circuit) value
grounding
Short-circuiting of ing the troubleshooting.
wiring harness
4 Between wiring harness from P02 (female) (17) to J02 and
(Contact with 24 V
circuit) X05 (male) (1), or P02 (female) (17) to C02 (female) (38) and Voltage Below 1 V
grounding
Monitor panel P02 Swing lock switch Voltage
5
defective
OFF 20 – 30 V
ON Below 1 V
20-428 PC160LC-7
(1)
PC160LC-7 20-429
(1)
E-19 When monitor switch is operated, nothing is displayed
Failure • When monitor switch is operated, nothing is dis- (1) When mode selector switch is operated, working
information played. mode monitor is not displayed.
Relative
—
information
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective
Failure • When monitor switch is operated, nothing is dis- (2) When LCD monitor adjustment switch is oper-
information played. ated, mode selection screen is not displayed.
Relative
—
information

cause and
(3) When selector switch is operated, flow rate

Failure • When monitor switch is operated, nothing is dis-
adjustment screen or flow rate selection screen
information played.
is not displayed.
Relative
—
information

cause and
Failure • When monitor switch is operated, nothing is dis- (4) When maintenance switch is operated, item
information played. selection screen is not displayed.
Relative
—
information

cause and
Failure • When monitor switch is operated, nothing is dis- (5) When automatic deceleration switch is operated,
information played. automatic deceleration monitor is not displayed.
Relative
• When the automatic decelerator does not operate either, conduct the troubleshooting for E-5.
information

cause and
20-430 PC160LC-7
(1)
Failure • When monitor switch is operated, nothing is dis- (6) When travel speed selector switch is operated,
information played. travel speed monitor is not displayed.
Relative
• When the travel speed does not change either, conduct the troubleshooting for H-2.
information

cause and
Failure • When monitor switch is operated, nothing is dis- (7) When wiper switch is operated, wiper monitor is
information played. not displayed.
Relative
• When the wiper does not operate either, conduct the troubleshooting for E-20.
information

cause and
PC160LC-7 20-431
(1)
E-20 Windshield wiper and window washer does not work
Failure • Windshield wiper and window washer does not

(1) The windshield wiper does not work.
information work
Relative • Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.

Window rear limit
switch fault
1 (Internal disconnec- W03 (male) Front window Resistance value
tion or short-circuit- When installed at front Above 1 MΩ
When retracted at rear Below 1 Ω
Windshield wiper !Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
motor fault during the troubleshooting.
2 (Internal disconnec- W04 (female) Continuity
tion or short-circuit-
ing) Between (3) and (1) There is continuity
ing harness
Wiring harness between P01 (female) (9) and W04 (female) Resistance
(3) value
defective contact
with connector) Wiring harness between P01 (female) (10) and W04 (female) Resistance
Below 1 Ω
(1) value
4 (Contact with
grounding (GND) cir- Between wiring harness between P02 (female) (15) and W03 Resistance
Above 1 MΩ
cuit) (female) (1) value
Monitor panel fault
(window rear limit P02 Front window Voltage
switch system) When installed at front 20 – 30 V
When retracted at rear Below 1 V
5 !Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Monitor panel fault P01 Windshield wiper switch Resistance value
(Windshield wiper
motor system) OFF Below 3 V
Between (10) and grounding Below 3 V ⇔ 20 – 30 V
ON
(Constant cycle)
20-432 PC160LC-7
(1)
PC160LC-7 20-433
(1)
Serial No.: 10001 – 11000
Failure • Windshield wiper or windshield washer does not

(2) Windshield washer does not operate.
information operate.
Relative
—
information

Washer motor defec-
tive
2 (Internal disconnec- A50 (male) Resistance value
tion or grounding Between (1) and (2) 5 – 20 z
fault)
ing harness
Resistance
3 (Disconnection or Wiring harness from FB1-4 to J03 to J06 and A50 (female) (1) Below 1 z
value
defective contact
with connector) Wiring harness from A50 (female) (2) to J04 and P01 Resistance
Below 1 z
(female) (3) value
Grounding fault of Between wiring harness from FB1-4 to J03 to J06 and A50
Resistance
wiring harness (female) (1), or FB1-4 to D04 (female) (4), and to other rela- Above 1 Mz
4 value
(Contact with tive circuits and grounding
grounding circuit) Between wiring harness from A50 (female) (2) to J04 and
Resistance
P01 (female) (3), or A50 (female) (2) to D04 (female) (8) and Above 1 Mz
value
grounding
Monitor panel P01 Windshield washer switch Voltage
5
defective
OFF 20 – 30 V
ON Below 1 V
20-434 PC160LC-7
(4)
PC160LC-7 20-435
(1)
Failure • Windshield wiper or windshield washer does not

(2) Windshield washer does not operate.
information operate.
Relative
—
information

Washer motor defec-
tive
2 (Internal disconnec- A50 (male) Resistance value
tion or grounding Between (1) and (2) 5 – 20 z
fault)
ing harness
Resistance
3 (Disconnection or Wiring harness from FB1-4 to J03 to J06 and A50 (female) (1) Below 1 z
value
defective contact
with connector) Wiring harness from A50 (female) (2) to J04 and P01 Resistance
Below 1 z
(female) (3) value
Grounding fault of Between wiring harness from FB1-4 to J03 to J06 and A50
Resistance
wiring harness (female) (1), or FB1-4 to D02 (female) (3), and to other rela- Above 1 Mz
4 value
(Contact with tive circuits and grounding
grounding circuit) Between wiring harness from A50 (female) (2) to J04 and
Resistance
P01 (female) (3), or A50 (female) (2) to D02 (female) (7) and Above 1 Mz
value
grounding
Monitor panel P01 Windshield washer switch Voltage
5
defective
OFF 20 – 30 V
ON Below 1 V
20-435-1 PC160LC-7
(4)
PC160LC-7 20-435-2
(4)
E-21 Alarming buzzer cannot be cancelled
Failure
• Alarming buzzer cannot be cancelled.
information
Relative • Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.

Alarming buzzer during the troubleshooting.
cancellation switch Alarming buzzer
1 fault P03 (female) Resistance value
cancellation switch
tion) Release Above 1 MΩ
Between (1) and (2)
Depress Below 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) (16) and P03 (male) (1) Below 1 Ω
value
defective contact
Wiring harness from P03 (male) (2) to J05 and grounding Below 1 Ω
value
3
(Contact with 24 V Between wiring harness between P02 (female) (16) and P03
(male) (1) and grounding
Alarming buzzer
4 Monitor panel fault P02 Voltage
cancellation switch
Release 20 – 30 V
Depress Below 1 V
20-436 PC160LC-7
(1)
E-22 "Boom RAISE" is not correctly displayed in monitor function
Failure • "Boom RAISE" is not correctly displayed in mon- • "Boom RAISE" is not correctly displayed in the
information itor function. monitor function on the monitor panel.
Relative
—
information

!Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Boom RAISE PPC ing the troubleshooting.
hydraulic switch fault Right work equipment
1 (Internal disconnec- S06 (male) Resistance value
control lever
ing) NEUTRAL Above 1 MΩ
Between (1) and (2)
RAISE Below 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (10) and S06 (female) (1) Below 1 Ω
value
defective contact
Wiring harness between S06 (female) (2) and grounding Below 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (10) and S06 Resistance
Above 1 MΩ
4
(Contact with 24 V Between wiring harness between C03 (female) (10) and S06
Governor • pump Right work equipment
5 C03 Voltage
NEUTRAL 20 – 30 V
RAISE Below 1 V
PC160LC-7 20-437
(1)
E-23 "Boom LOWER" is not correctly displayed in monitor function
Failure • "Boom LOWER" is not correctly displayed in • "Boom LOWER" is not correctly displayed in the
information monitor function. monitor function on the monitor panel.
Relative
—
information

Boom LOWER PPC ing the troubleshooting.
control lever
Between (1) and (2)
LOWER Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
5 C03 Voltage
NEUTRAL 20 – 30 V
LOWER Below 1 V
20-438 PC160LC-7
(1)
E-24 "Arm IN" is not correctly displayed in monitor function
Failure • "Arm IN" is not correctly displayed in monitor • "Arm IN" is not correctly displayed in the monitor
information function. function (special function) on the monitor panel.
Relative
—
information

Arm IN PPC hydrau- ing the troubleshooting.
lic switch fault Left work equipment
control lever
Between (1) and (2)
IN Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
Governor • pump Left work equipment
5 C03 Voltage
NEUTRAL 20 – 30 V
IN Below 1 V
PC160LC-7 20-439
(1)
E-25 "Arm OUT" is not correctly displayed in monitor function
Failure • "Arm OUT" is not correctly displayed in monitor • "Arm OUT" is not correctly displayed in the monitor
Relative
—
information

Arm OUT PPC
hydraulic switch
defect Left work equipment
1 S08 (male) Resistance value
(Internal disconnec- control lever
tion and short-circuit- NEUTRAL Above 1 MΩ
OUT Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
Governor • pump Left work equipment
5 C03 Voltage
NEUTRAL 20 – 30 V
OUT Below 1 V
20-440 PC160LC-7
(1)
E-26 "Bucket CURL" is not correctly displayed in monitor function
Failure • "Bucket CURL" is not correctly displayed in moni- • "Bucket CURL" is not correctly displayed in the mon-
information tor function. itor function (special function) on the monitor panel.
Relative
—
information

Bucket CURL PPC ing the troubleshooting.
control lever
tion and short-circuit-
Between (1) and (2)
CURL Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
5 C03 Voltage
NEUTRAL 20 – 30 V
CURL Below 1 V
PC160LC-7 20-441
(1)
E-27 "Bucket DUMP" is not correctly displayed in monitor function
Failure • "Bucket DUMP" is not correctly displayed in moni- • "Bucket DUMP" is not correctly displayed in the mon-
information tor function. itor function (special function) on the monitor panel.
Relative
—
information

Bucket DUMP PPC ing the troubleshooting.
control lever
tion and short-circuit-
Between (1) and (2)
DUMP Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
5 C03 Voltage
NEUTRAL 20 – 30 V
DUMP Below 1 V
20-442 PC160LC-7
(1)
E-28 "SWING" is not correctly displayed in monitor function
Failure • "SWING" is not correctly displayed in monitor • "SWING" is not correctly displayed in the monitor
Relative
—
information

aTurn the engine starting switch OFF for the preparations, and keep the engine running dur-
Swing PPC hydraulic ing the troubleshooting.
switch, left, fault Left work equipment
control lever
ing) NEUTRAL Above 1 Mz
Between (1) and (2)
Left Below 1 z
Swing PPC hydraulic ing the troubleshooting.
switch, right, fault Left work equipment
control lever
ing) NEUTRAL Above 1 Mz

Between (1) and (2)
Right Below 1 z
Disconnection of wir- Wiring harness between C03 (female) (29) and S03 (female)
Resistance
ing harness (1), or wiring harness between C03 (female) (29) and S07 Below 1 z
value
3 (Disconnection or (female) (1)
with connector) Wiring harness between S03 (female) (2) and grounding Below 1 z
value
Resistance
Wiring harness between S07 (female) (2) and grounding Below 1 z
value
4 (Contact with Wiring harness between C03 (female) (29) and S03 (female)
(1), or wiring harness between C03 (female) (29) and S07 Above 1 Mz
circuit) value
Short-circuiting of during the troubleshooting.
wiring harness
5 Wiring harness between C03 (female) (29) and S03 (female)
(Contact with 24 V
circuit) (1), or wiring harness between C03 (female) (29) and S07 Voltage Below 1 V
Governor • pump C03 Swing lever Voltage
6
NEUTRAL 20 – 30 V
Right or left Below 1 V
PC160LC-7 20-443
(4)
20-444 PC160LC-7
(1)
E-29 "TRAVEL" is not correctly displayed in monitor function
Failure • "TRAVEL" is not correctly displayed in monitor • "TRAVEL" is not correctly displayed in the monitor
Relative
—
information

Travel PPC hydraulic
switch fault
1 (Internal disconnec- S30 (male) Travel control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
Forward or reverse Below 1 Ω
ing harness
Wiring harness from C03 (female) (39) to J01 and S30 Resistance
(female) (2) value
defective contact
Wiring harness from S30 (female) (1) to J05 and grounding Below 1 Ω
value
3 (Contact with
grounding (GND) Wiring harness from C03 (female) (39) to J01 to S30 (female) Resistance
Above 1 MΩ
circuit) (2) and grounding value
4
(Contact with 24 V Wiring harness from C03 (female) (39) to J01 to S30 (female)
(2) and grounding
5
NEUTRAL 20 – 30 V
Forward or reverse Below 1 V
20-446 PC160LC-7
(1)
PC160LC-7 20-447
(1)
E-30 "Travel differential pressure" is not correctly displayed in monitor function
• "Travel differential pressure" is not correctly dis-

Failure • "Travel differential pressure" is not correctly dis-
played in the monitor function (special function) on
information played in monitor function.
the monitor panel.
Relative • When pressure difference is created between the right and left travel PPC circuits (in steering), the travel
information differential mechanism is turned ON.

Travel steering PPC
hydraulic switch fault
1 (Internal disconnec- S31 (male) Travel control lever Resistance value
One side of right or left only Below 1 Ω
ing harness
Resistance
value
defective contact
Wiring harness from S31 (female) (2) to J05 and grounding Below 1 Ω
value
3 (Contact with
Above 1 MΩ
4
5
NEUTRAL 20 – 30 V
One side of right or left only Below 1 V
20-448 PC160LC-7
(1)
PC160LC-7 20-449
(1)
E-31 "Service" is not correctly displayed in monitor function
Failure • "Service" is not correctly displayed in monitor func- • "Service" is not correctly displayed in the monitor
information tion. function (special function) on the monitor panel.
Relative
—
information

Service (front) PPC
1 (Internal disconnec- S10 (male) Service pedal Resistance value
Front Below 1 Ω
Service (rear) PPC
2 (Internal disconnec- S11 (male) Service pedal Resistance value

Rear Below 1 Ω
Disconnection of wir- Wiring harness between C02 (female) (35) and S10 (female)
Resistance
ing harness (1), or wiring harness between C02 (female) (35) and S11 Below 1 Ω
value
3 (Disconnection or (female) (1)
with connector) Wiring harness between S10 (female) (2) and grounding Below 1 Ω
value
Resistance
value
4 (Contact with Wiring harness between C02 (female) (35) and S10 (female)
(1), or between wiring harness between C02 (female) (35) and Above 1 MΩ
circuit) value
Short-circuiting of ing the troubleshooting.
wiring harness
5 Wiring harness between C02 (female) (35) and S10 (female)
(Contact with 24 V
circuit) (1), or between wiring harness between C02 (female) (35) and Voltage Below 1 V
Governor • pump C02 Service pedal Voltage
6
NEUTRAL 20 – 30 V
Front or rear Below 1 V
20-450 PC160LC-7
(1)
PC160LC-7 20-451
(1)
E-32 Troubleshooting for air conditioner system

Serial No.: 10001 – 11000
Failure
• Air conditioner does not work.
information
Relative • For the electric circuit diagram inside air conditioner unit, see "Electric circuit diagram of air conditioner"
information in the collected circuit diagrams.

When the fuse No. 11 is blown, there is a big possibility that grounding fault occurred in the
1 Fuse No. 11 fault
circuit. (cause 3 reference)

ing harness
Resistance
2 (Disconnection or Wiring harness between FB1-11 outlet and M26 (male) (4) (5) Below 1 z
value
defective contact
Wiring harness between M26 (male) (8) and grounding Below 1 z
value
3 (Contact with
grounding (GND) Between wiring harness between FB1-11 outlet and M26
Voltage Above 1 Mz
circuit) (male) (4) (5) and grounding
Air conditioner unit M26 Voltage
4
defective
Between (4) (5) and (8) 20 – 30 V
If the result is as above, the air conditioner unit is defective.
20-452 PC160LC-7
(4)
PC160LC-7 20-453
(1)

Troubleshooting procedure for air conditioner system
a The control panel of the air conditioner constantly monitors the sensors and other devices in the system .
When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially.
a If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to
the procedure for “Troubleshooting by self-diagnosis notice”, and then;
• If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”.
• If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
Troubleshooting by self-diagnosis notice

a Check the “Self-diagnosis notice” on the control
panel according to the following procedure.
• How to display “Self-diagnosis notice”

1) Turn the starting switch ON.
2) Press OFF switch (1) and check that any-
thing is not displayed on display monitor (2).
3) Hold the UP switch ( ) and DOWN switch
( ) of temperature setting switch (3) simul-
taneously for 3 seconds or more.
4) Check the “Self-diagnosis notice” displayed
on display monitor (2).
• How to select “Self-diagnosis notice” Self-diagnosis notice

If multiple “Self-diagnosis notices” are recorded, E--
press the UP switch ( ) or DOWN switch ( ) E11
of temperature setting switch (3) to select E12
another notice. E15
E16
• How to delete “Self-diagnosis notice” E18
When reproducing the “Self-diagnosis notices” E43
or after removing the cause of a failure, press
E44
the switches on both sides of recirc/fresh air
E45
selector switch (4) simultaneously for 3 seconds
or more, and all the “Self-diagnosis notices” are
deleted.
• Finishing display of “Self-diagnosis notice”

To finish display of the “Self-diagnosis notice”,
press OFF switch (1) or turn the starting switch
OFF.
20-453-1 PC160LC-7
(4)
Self-diagnosis
notice Trouble Disconnection in recirculated air sensor
E11
Contents of
• Disconnection in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective recirculated
standard value in normal state
starting switch ON.

1 air sensor
THI (male) Resistance
Possible causes and
Between (1) and (2) 300 z – 430 kz
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12
Contents of
• Short circuit in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Related
information

Defective recirculated air
starting switch ON.

1 sensor (Internal short cir-
THI (male) Resistance
Possible causes and
cuit)
Between (1) and (2) 300 z – 430 kz
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
3
PC160LC-7 20-453-2
(4)
Self-diagnosis
notice Trouble Disconnection in water temperature sensor
E15
Contents of
• Disconnection in the water temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
Related
information

Defective water tempera-
starting switch ON.

1 ture sensor (Internal dis-
THW (male) Resistance
Possible causes and
connection)
Between (1) and (2) 95 z – 455 kz
harness (Disconnection Wiring harness between M30 (female) (14) and THW
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
3
Self-diagnosis
notice Trouble Short circuit in water temperature sensor
E16
Contents of
• Short circuit in the water temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
Related
information

Defective water tempera-
starting switch ON.

1 ture sensor (Internal
THW (male) Resistance
Possible causes and
short circuit)
Between (1) and (2) 95 z – 455 kz
harness (Disconnection Wiring harness between M30 (female) (14) and THW
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
3
20-453-3 PC160LC-7
(4)
Self-diagnosis
notice Trouble Short circuit in daylight sensor
E18
Contents of
• Short circuit in the daylight sensor system is detected.
trouble
• Assumes that the daylight sensor is not installed for control.
Related
information

Defective daylight sen-

1 The daylight sensor may be defective. Check it directly.
sor (Internal short circuit)
Possible causes and
harness (Disconnection Wiring harness between M30 (female) (16) and P15
connector) Wiring harness between M30 (female) (3) and P15
Resistance Max. 1 z
(female) (1)
3
Self-diagnosis
notice Trouble Abnormality in air outlet damper
E43
Contents of
• Abnormality in air outlet servomotor system is detected.
trouble
• Stops the air outlet servomotor.
control panel • <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.

Defective air outlet servo-
1 The air outlet servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.

Wiring harness between MV1 (female) (1) and M30
Possible causes and
Resistance Max. 1 z
(female) (3)
Disconnection in wiring Wiring harness between MV1 (female) (3) and M29
harness (Disconnection Resistance Max. 1 z
(female) (11)
2 in wiring harness or
defective contact in con- Wiring harness between MV1 (female) (5) and M30
Resistance Max. 1 z
nector) (female) (9)
Resistance Max. 1 z
(female) (8)
Resistance Max. 1 z
(female) (9)
Defective air conditioner If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may
3
system be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC160LC-7 20-453-4
(4)
Self-diagnosis
notice Trouble Abnormality in air mix damper
E44
Contents of
• Abnormality in air mix servomotor system is detected.
trouble
• Stops the air mix servomotor.

Defective air mix servo-
1 The air mix servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.

Wiring harness between MAM (female) (1) and M29
Possible causes and
Resistance Max. 1 z
(female) (11)
Disconnection in wiring Wiring harness between MAM (female) (3) and M30
(female) (3)
defective contact in con- Wiring harness between MAM (female) (5) and M30
Resistance Max. 1 z
Resistance Max. 1 z
(female) (4)
Resistance Max. 1 z
(female) (5)
3
20-453-5 PC160LC-7
(4)
Self-diagnosis
notice Trouble Abnormality in recirculated and fresh air damper
E45
Contents of
• Abnormality in recirculated and fresh air servomotor system is detected.
trouble
• Stops the recirculated and fresh air servomotor.

Defective recirculated
1 and fresh air servomotor The recirculated and fresh air servomotor may be defective. Check it directly.
(Internal defect)
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.
2 Defective fuse (in unit)
Possible causes and
Check the related circuits.

starting switch ON.
Disconnection in wiring Wiring harness between MRF (female) (1) and M29
(female) (6)
defective contact in con- Wiring harness between MRF (female) (3) and M29
Resistance Max. 1 z
Wiring harness between MRF (female) (7), fuse in unit,
Resistance Max. 1 z
and M33 (female) (3)
Defective air conditioner If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be
4
system defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC160LC-7 20-453-6
(4)
Electrical Circuit Diagram for Air Conditioner
20-453-7 PC160LC-7
(4)
Troubleshooting by failure phenomenon
Trouble • The air conditioner does not operate. (1) The air conditioner does not operate at all.
Related
information

1 Defective fuse No. 11 If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.)
starting switch ON.
Wiring harness between fuse 11 outlet and M33 (male)
Disconnection in wiring Resistance Max. 1z
(3)
harness (Disconnection
Wiring harness between M27 (female) (14) and M30
2 in wiring harness or Resistance Max. 1z
(female) (6)
defective contact in con-
nector) Wiring harness between M33 (male) (2) and chassis
Resistance Max. 1z
ground
Wiring harness between M29 (female) (12) and chassis
Resistance Max. 1z
ground
Possible causes and
Short circuit with chassis starting switch ON.
ground in wiring harness Between wiring harness between circuit breaker fuse 11
3 Resistance Min. 1 Mz
(Contact with ground cir- outlet and M33 (male) (3) and chassis ground
cuit) Between wiring harness between M27 (female) (14) and
Resistance Min. 1 Mz
M30 (female) (6) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Defective air conditioner M33 Voltage
4
unit Between (2) and (3) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air condi-
tioner is defective.
troubleshooting.
M30, M29 Voltage
5 Defective control panel
Between M30 (6) and M29 (12) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the control
panel is defective.
PC160LC-7 20-453-8
(4)
Trouble • The air conditioner does not operate. (2) Air does not come out (Air flow is insufficient).
Related
information

Defective blower relay starting switch ON.
2
(on coil side) R30 (male) Resistance
Between (1) and (3) 140 – 340 z
troubleshooting.
Defective blower relay
3 R30 Fan switch Voltage
(on contact side)
Between (4) and
ON (Operated) 20 – 30 V
chassis ground
Defective power transis- troubleshooting.
4
tor (Internal defect) Fan switch If air flow can be changed with fan switch,
Operate in range of Low, Medium, and High power transistor is normal.
troubleshooting.
Possible causes and
Defective blower motor MB (female) Fan switch Voltage

5
(Internal defect) Between (1) and (2) ON (Operated) 20 – 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor
is defective.
starting switch ON.
Wiring harness between fuse 11 outlet, fuse in unit, R30
Resistance Max. 1 z
(3), R31 (female) (1), and M30 (female) (6)
Wiring harness between M29 (female) (3) and R30
Resistance Max. 1 z
(female) (1)
Disconnection in wiring Resistance Max. 1 z
ground
harness (Disconnection
Wiring harness between MB (female) (1) and R30
6 in wiring harness or Resistance Max. 1 z
(female) (4)
defective contact in con-
nector) Wiring harness between MB (female) (2) and PTR
Resistance Max. 1 z
(female) (3)
Wiring harness between PTR (female) (1) and chassis
Resistance Max. 1 z
ground
Wiring harness between PTR (female) (2) and M30
Resistance Max. 1 z
(female) (7)
Wiring harness between PTR (female) (4) and M30
Resistance Max. 1 z
(female) (8)
7
20-453-9 PC160LC-7
(4)
Trouble • The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
Related
information

Defective compressor starting switch ON.
2
relay (on coil side) R31 (male) Resistance
Between (1) and (2) 140 – 340 z
troubleshooting (Setting of temperature: Highest cooling position).
Defective compressor
3 R31 Fan switch Voltage
relay (on contact side)
Between (4) and chassis
ON (Operated) 20 – 30 V
ground
Defective thermostat
4 The thermostat may be defective. Check it directly.
(Internal defect)
Defective high/low pres- starting switch ON.
5 sure switch (Internal dis-

P17 (male) Resistance
connection)
Possible causes and
Between (1) and (2) Max. 1 z

6 The compressor clutch may be defective. Check it directly.
clutch (Internal defect)
7 The compressor may be defective. Check it directly.
(Internal defect)
starting switch ON.
Wiring harness between M30 (female) (4) and P17
Resistance Max. 1 z
(female) (1)
Wiring harness between P17 (female) (2) and chassis
Resistance Max. 1 z
ground
Disconnection in wiring Wiring harness between fuse 11 outlet, R31 (female)
(2), fuse in unit, R31 (female) (1), and M30 (female) (6)
defective contact in con- Wiring harness between ST1 (female) (1) and R31
Resistance Max. 1 z
Wiring harness between M29 (female) (2) and ST1
Resistance Max. 1 z
(female) (2)
Resistance Max. 1 z
ground
Wiring harness between R31 (female) (4) and E06
Resistance Max. 1 z
(female) (1)
9
PC160LC-7 20-453-10
(4)
Electrical Circuit Diagram for Air Conditioner
20-453-11 PC160LC-7
(4)
E-33 Travel alarm does not sound or does not stop sounding
(1) The travel alarm does not sound while the

Failure • Travel alarm does not sound or does not stop machine is traveling.
information sounding. (2) The alarm begins to sound when the machine is
at a standstill.
Relative
—
information

When the fuse No. 15 is blown, there is a big possibility that grounding fault occurred in the
1 Fuse No. 15 fault
circuit. (cause 4 reference)
!Start the engine for the troubleshooting (Monitoring).

2 Travel signal fault Control lever operation: ON
019 Travel
Control lever NEUTRAL: OFF
If the monitor display is not correct, proceed to No. E-29 Troubleshooting.
ing harness
Wiring harness between FB1-15 outlet to J03 and A43 Resistance
(female) (1) value
defective contact
Wiring harness between A43 (female) (2) and J01 (19) Below 1 Ω
value
4 (Contact with
grounding (GND) Between wiring harness between FB1-15 outlet to J03 and Resistance
Above 1 MΩ
circuit) A43 (female) (1) and grounding value
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes
5 Travel alarm fault
listed in Item 1 through 4 above is found, the travel alarm is judged as defective)
20-454 PC160LC-7
(1)
PC160LC-7 20-455
(1)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS ...................................................... 20-504
H- 1 Speed or power of all work equipment, swing, and travel are low .................................................... 20-506
H- 2 Engine speed sharply drops or engine stalls .................................................................................... 20-507
H- 3 No work equipment, travel and swing move ..................................................................................... 20-508
H- 4 Abnormal noise is heard from around hydraulic pump ..................................................................... 20-508
H- 5 Auto-decelerator does not work ........................................................................................................ 20-509
H- 6 Fine control mode does not function................................................................................................. 20-509
H- 7 Speed or power of boom is low......................................................................................................... 20-510
H- 8 Speed or power of arm is low ............................................................................................................20-511
H- 9 Speed or power of bucket is low ....................................................................................................... 20-512
H-10 Work equipment does not move in its single operation .................................................................... 20-513
H-11 Hydraulic drift of work equipment is large......................................................................................... 20-514
H-12 Time lag of work equipment is large ................................................................................................. 20-515
H-13 One-touch power max system does not operate .............................................................................. 20-515
H-14 Work equipment loaded more is slower during compound operation ............................................... 20-516
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE ................................... 20-516
H-16 Travel speed lowers largely during compound operation of work equipment/swing + travel ............ 20-517
H-17 Machine deviates during travel ......................................................................................................... 20-518
H-18 Travel speed is low ........................................................................................................................... 20-519
H-19 Machine cannot be steered easily or steering power is low ............................................................. 20-520
H-20 Travel speed does not change or it is kept low or high..................................................................... 20-521
H-21 Track does not move (only either side)............................................................................................. 20-521
H-22 Machine does not swing ................................................................................................................... 20-522
H-23 Swing acceleration or swing speed is low ........................................................................................ 20-523
H-24 Excessive overrun when stopping swing .......................................................................................... 20-524
H-25 When upper structure stops swinging, it makes large shock ............................................................ 20-525
H-26 When upper structure stops swinging, it makes large sound............................................................ 20-525
H-27 Hydraulic drift of swing is large ......................................................................................................... 20-526
H-28 Attachment circuit does not change.................................................................................................. 20-527
H-29 Flow rate in attachment circuit cannot be adjusted........................................................................... 20-527
PC160LC-7 20-501
(1)

! Troubleshooting Table collectively carry the following information. Carry out troubleshooting work after fully
grasping their contents.
Failure information Phenomena occurring on machine

Relative information Information on occurred failures and troubleshooting

2
Cause for presumed
failure <Contents>
(The attached No. for • The standard values in normalcy by which to judge "good" or "no good" about
3
filing and reference presumed causes.
purpose only. It does not stand • References for making judgement of "good" or "no good"
for any priority)
4
PC160LC-7 20-503
(1)
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
20-504 PC160LC-7
(1)
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
! This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
PC160LC-7 20-505
(1)
TROUBLESHOOTING H-1
H-1 Speed or power of all work equipment, swing, and travel are low
Failure information • Speed or power of all work equipment, swing, and travel are low.
Relative information • Conduct the troubleshooting in working mode A.

!Keep the engine stopped for the preparations, and keep it running at high idling
Control levers Hydraulic oil temperature Unload pressure
1 Malfunction of unload valve Below 5.9 MPa
Approx. 50°C
{Below 60 kg/cm2}
All levers in NEUTRAL
Below 7.4 MPa
Approx. 80°C
{Below 75 kg/cm2}
Control lever Main relief pressure
Defective adjustment or opera- 33.6 – 37.0 MPa
2 Arm relieved in IN direction
tion of main relief valve
{343 – 378 kg/cm2}

If the oil pressure cannot be set normally by adjustment, the main relief valve may
be malfunctioning or may have an internal defect. Check the main relief valve
directly.
Malfunction of self-pressure Control levers Control circuit basic pressure
3
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Measured oil pressure Measurement conditions Oil pressure ratio
Defective adjustment or opera- Pump discharge pressure Swing lock: ON 1
4
tion of PC valve Arm: Relieved in IN
PC valve output pressure direction Approx. 0.6(Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the PC valve may be
malfunctioning or may have an internal defect. Check the PC valve directly.
Oil pressure ratio
Measured oil pressure Bucket curled
(Lever at stroke end)
Defective adjustment or opera-
5 Pump discharge pressure 1
tion of LS valve Almost same pressure
LS valve output pressure Approx. 0.6(Approx. 3/5)
If the oil pressure cannot be set normally by adjustment, the LS valve may be mal-
functioning or may have an internal defect. Check the LS valve directly.
6 Malfunction of servo piston The servo piston may have malfunction. Check it directly.
If there is none of the causes listed above, the piston pump may have problems of
7 Piston pump defective
lowering of performance, malfunction, internal defect, etc.
20-506 PC160LC-7
(1)
TROUBLESHOOTING H-2
H-2 Engine speed sharply drops or engine stalls
Failure information • Engine speed sharply drops or the engine stalls.


!Stop engine for preparations. Start troubleshooting at engine high idling.
Control lever Main relief pressure
33.6 – 37.0 MPa
Improper adjustment or mal- Arm IN relief
1 {343 – 378 kg/cm2}
functioning of main relief valve
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of the main relief valve or its internal failure is suspected. In that case,
check the valve itself.
Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
2
functioning of PC valve PC valve output pressure Arm IN relief Approx. 0.6(Approx. 3/5)
tioning of the PC valve or its internal failure is suspected. In that case, check the
valve itself.
Oil pressure ratio
Oil pressure to be mea-
sured All control levers in Bucket curled
NEUTRAL (control lever full stroke)
Improper adjustment or mal- Pump delivery pressure 1
3 Nearly equal pressure
functioning of LS valve LS valve output pressure Approx. 0.6(Approx. 3/5)
tioning of the LS valve or its internal failure is suspected. In that case, check the
valve itself.
Orifice or filter in servo equip- The orifice or filter in the pump servo equipment is suspected of clogging. Check
4
ment clogged the equipment itself.
5 Malfunction of servo piston The servo piston is suspected of malfunction. Check the piston itself.
PC160LC-7 20-507
(1)
TROUBLESHOOTING H-3, H-4
H-3 No work equipment, travel and swing move
Failure information • No work equipment, travel and swing move.

Relative information • Set the working mode at A mode for the troubleshooting.

Safety lock lever Main relief pressure

Malfunctioning of PPC lock 0 MPa
1 Locked
solenoid valve {0 kg/cm2}
2.84 – 3.43 MPa
Released
{29 – 35 kg/cm2}
Malfunctioning of self Control lever Control circuit source pressure
2
reducing pressure valve 2.84 – 3.43 MPa
All control levers in NEUTRAL position
{29 – 35 kg/cm2}
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it
in the following manner.
3 Piston pump defective
• Remove the main oil pressure measurement plug and crank the engine. If oil
flows out, it is in normal condition.
It is presumed that the pump shaft does not rotate due to some internal failure of
4 Damper defective
the dumper. Check the damper itself.
H-4 Abnormal noise is heard from around hydraulic pump
Failure information • An abnormal noise is heard from around the hydraulic pump.
Relative information —

1 Hydraulic oil level lowered Make a visual check.
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
3
clogged causing negative pressure inside the tank. Make a visual check.
Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
4
clogged negative pressure in the suction circuit. Make a visual check.
5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.
20-508 PC160LC-7
(1)
H-5 Auto-decelerator does not work
Failure information • Auto-decelerator does not work.

• This troubleshooting mode is applied when the auto-decelerator does not work, while operating
the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch
Relative information
only in the travel circuit -actually located inside PPC valve)
• Set the working mode at A mode for the troubleshooting.

Presumed cause and stan-
dard value in normalcy

Travel control lever PPC valve output pressure
Malfunctioning of NEUTRAL 0 MPa {0 kg/cm2}
1 travel PPC valve
(shuttle valve)
Above 2.7 MPa
Operation
{Above 28 kg/cm2}
H-6 Fine control mode does not function
Failure information • Fine control mode does not function.


Orifice in LS circuit
1 The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
clogged

Oil pressure ratio

Oil pressure to be measured All control levers in At bucket CURL
Improper adjust- NEUTRAL (control lever full stroke)
2 ment or malfunction- Pump delivery pressure 1
ing of LS valve Nearly equal oil pressure
LS valve output pressure Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunction-
ing of the LS valve or its internal failure is suspected. In that case, check the valve
itself.
Malfunctioning of
3 Malfunctioning of the servo piston is suspected. Check the piston itself.
servo piston
PC160LC-7 20-509
(1)
TROUBLESHOOTING H-7
H-7 Speed or power of boom is low
Failure information • Speed or power of boom is low.


Malfunction of right PPC valve Right work equipment control lever PPC valve output pressure
1
(boom circuit) NEUTRAL 0 MPa {0 kg/cm2}
Boom RAISE position Above 2.7 MPa
Boom LOWER position {Above 28 kg/cm2}
Malfunction of pump merge- Control levers Solenoid output pressure

2
divider solenoid valve All levers in NEUTRAL 0 MPa {0 kg/cm2}
Position for travel only 2.84 – 3.43 MPa

(on either or both sides) {29 – 35 kg/cm2}
Malfunction of pump merge- The pump merge-divider valve of the control valve may have a malfunction.
3
divider valve Check it directly.
Malfunction of boom control The spool of the boom control valve may have a malfunction. Check it directly
4
valve (spool) (including stroke limiting mechanism on RAISE side).
Malfunction of boom control
The pressure compensation valve of the boom control valve may have a malfunc-
5 valve (pressure compensation
tion. Check it directly.
valve)
Malfunction or defective seal-
The regeneration valve of the boom control valve may have a malfunction or its
6 ing of boom control valve
sealing may be defective. Check it directly.
(regeneration valve)
Malfunction of boom control The lock valve of the boom control valve may have a malfunction. Check it
7
valve (lock valve) directly.
The safety-suction valve of the boom control valve (on the head side) may have a
8 ing of boom control valve
malfunction or its sealing may be defective. Check it directly.
(safety-suction valve)
The suction valve of the boom control valve (on the bottom side) may have a mal-
9 ing of boom control valve (suc-
function or its sealing may be defective. Check it directly.
tion valve)
The centralized safety-suction valve of the control valve may have a malfunction
10 ing of centralized safety-suc-
or its sealing may be defective. Check it directly.
tion valve
11 Boom cylinder defective
Boom cylinder Leakage from cylinder
Relieved in RAISE direction 20 cc/min
20-510 PC160LC-7
(1)
TROUBLESHOOTING H-8
H-8 Speed or power of arm is low
Failure information • Speed or power of arm is low.


Malfunction of left PPC valve Left work equipment control lever PPC valve output pressure
1
(arm circuit) NEUTRAL 0 MPa {0 kg/cm2}
Arm IN position Above 2.7 MPa
Arm OUT position {Above 28 kg/cm2}

2
3
Malfunction of arm control The spool of the arm control valve may have a malfunction. Check it directly
4
valve (spool) (including stroke limiting mechanisms on IN side and OUT side).
Malfunction of arm control
The pressure compensation valve of the arm control valve may have a malfunc-
valve)
Malfunction of arm control
6 valve (lock valve) The lock valve of the arm control valve may have a malfunction. Check it directly.
(when lock valve is installed)
Malfunction or defective seal- The safety-suction valves of the arm control valve (on the bottom side and head
7 ing of arm control valve side) may have a malfunction or their sealing may be defective. Check them
(safety-suction valves) directly.
The centralized safety-suction valve of the control valve may have a malfunction
or its sealing may be defective. Check it directly.
tion valve
9 Arm cylinder defective
Arm cylinder Leakage from cylinder
Relieved in IN direction 20 cc/min
PC160LC-7 20-511
(1)
TROUBLESHOOTING H-9
H-9 Speed or power of bucket is low
Failure information • Speed or power of bucket is low.


!Keep the engine stopped for the preparations, and keep it running at high
idling during the troubleshooting.
Malfunction of right PPC valve Right work equipment control lever PPC valve output pressure
1
(bucket circuit) NEUTRAL 0 MPa {0 kg/cm2}
Bucket CURL position Above 2.7 MPa
Bucket DUMP position {Above 28 kg/cm2}

2

3
Malfunction of bucket control The spool of the bucket control valve may have a malfunction. Check it
4
valve (spool) directly.
Malfunction of bucket control
The pressure compensation valve of the bucket control valve may have a
malfunction. Check it directly.
valve)
Malfunction or defective seal- The safety-suction valves of the bucket control valve (on the bottom side
6 ing of bucket control valve and head side) may have a malfunction or their sealing may be defective.
(safety-suction valves) Check them directly.
The centralized safety-suction valve of the control valve may have a mal-
function or its sealing may be defective. Check it directly.
tion valve
8 Bucket cylinder defective
Bucket cylinder Leakage from cylinder
Relieved in CURL direction 20 cc/min
20-512 PC160LC-7
(1)
TROUBLESHOOTING H-10
H-10 Work equipment does not move in its single operation
• The boom does not move when operated inde-

pendently.
• Work equipment does not move in its single • The arm does not move when operated inde-
Failure information
operation pendently.
• The bucket does not move when operated in-
dependently.


Work equipment control lever PPC valve output pressure
1 Malfunctioning of PPC valve NEUTRAL 0 MPa {0 kg/cm2}
Above 2.7 MPa
Operation
{Above 28 kg/cm2}
Malfunctioning of work equip- The spool in the work equipment control valve is presumed to malfunction.
2
ment control valve (spool) Check the valve itself.
PC160LC-7 20-513
(1)
H-11 Hydraulic drift of work equipment is large
Failure information • Hydraulic drift of work equipment is large. (1) Hydraulic drift of boom is large.

1 Boom cylinder defective
Boom cylinder Leakage from cylinder
Relieved in RAISE direction 20 cc/min
Defective sealing of boom Sealing of the lock valve of the boom control valve may be defective. Check
2
control valve (lock valve) it directly.
Defective sealing of central- Sealing of the centralized safety-suction valve of the control valve may be
3
ized safety-suction valve defective. Check it directly.
Failure information • Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large.

1 Arm cylinder defective
Arm cylinder Leakage from cylinder

Relieved in IN direction 20 cc/min

Defective sealing of arm con- Sealing of the spool of the arm control valve may be defective. Check it
2
trol valve (spool) directly.
Defective sealing of arm con- Sealing of the suction valve of the arm control valve (on the bottom side)
3
trol valve (suction valve) may be defective. Check it directly.
Defective sealing of arm con-
Sealing of the lock valve of the arm control valve may be defective. Check it
4 trol valve (lock valve)
directly.
(when lock valve is installed)
5
Failure information • Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large.


1 Bucket cylinder defective
Bucket cylinder Leakage from cylinder
Relieved in CURL direction 20 cc/min
Defective sealing of bucket Sealing of the spool of the bucket control valve may be defective. Check it
2
control valve (spool) directly.
Defective sealing of bucket Sealing of the suction valve of the bucket control valve (on the bottom side)
3
control valve (suction valve) may be defective. Check it directly.
4
20-514 PC160LC-7
(1)
H-12 Time lag of work equipment is large
Failure information • Time lag of work equipment is large.


Malfunction of control valve

The regeneration valve of the control valve may have a malfunction. Check
1 (regeneration valve) [Only
it directly.
boom]
Malfunction of control valve The suction valve of the control valve (on the head side) may have a mal-
2
(suction valve). function. Check it directly.
H-13 One-touch power max system does not operate
Failure information • One-touch power max system does not operate.


Malfunction of 2-stage relief Swing lock switch Solenoid output pressure

1
solenoid valve OFF 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
ON
{29 – 35kg/cm2}
Malfunction of main relief The main relief valve of the control valve may have a malfunction. Check it
2
valve directly.
PC160LC-7 20-515
(1)
H-14 Work equipment loaded more is slower during compound operation
Failure information • Work equipment loaded more is slower during compound operation.
Relative information —

The pressure compensation valve of the work equipment loaded less may
have a malfunction. Check it directly.

Compound operation More loaded side Less loaded side
Malfunction of pressure com- Boom RAISE + Arm IN Boom Arm
1 pensation valve of work equip-
Boom RAISE + Arm OUT Arm Boom
ment loaded less
Boom RAISE + Bucket CURL Boom Bucket
Arm IN + Bucket CURL Arm Bucket
Boom LOWER + Arm OUT Arm Boom
H-15 Boom RAISE speed is low in compound operation of swing + boom RAISE
Failure information • Boom RAISE speed is low in compound operation of swing + boom RAISE.
• If the speed of single operation of the boom RAISE speed is slow, conduct troubleshooting for H-
7 first.

Malfunction or defective seal- The LS selector valve of the control valve may have a malfunction or its
1
ing of LS selector valve sealing may be defective. Check it directly.
20-516 PC160LC-7
(1)
H-16 Travel speed lowers largely during compound operation of work equipment/
swing + travel
Failure information • Travel speed lowers largely during compound operation of work equipment/swing + travel.


1

(on either or both sides) {29 – 35kg/cm2}
Malfunction of pump merge-
2 The pump merge-divider valve may have a malfunction. Check it directly.
divider valve
Malfunction of work equipment
The pressure compensation valve of the work equipment control valve may
3 control valve (pressure com-
have a malfunction. Check it directly.
pensation valve)
Malfunction of swing control
The pressure compensation valve of the swing control valve may have a
valve)
Malfunction of travel control
The pressure compensation valve of the travel control valve may have a
valve)
PC160LC-7 20-517
(1)
H-17 Machine deviates during travel
Failure information • Machine deviates during travel.


1
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Travel lever PPC valve output pressure
Malfunction of travel PPC
2 Above 2.7 MPa
valve Forward or reverse position
{Above 28 kg/cm2}
Difference in above output between Below 0.4 MPa
both sides {Below 4 kg/cm2}
Malfunction of pump merge- Travel lever Solenoid valve output pressure

3
divider valve All levers in NEUTRAL 0 MPa {0 kg/cm2}
Malfunction of travel junction Travel lever Solenoid valve output pressure

4
solenoid valve All levers in NEUTRAL 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Position for travel only on either side
{29 – 35 kg/cm2}
Approx. 50°C
{Below 60 kg/cm2}
Below 7.4 MPa
Approx. 80°C
{Below 75 kg/cm2}
divider valve
Malfunction of travel junction
7 The travel junction valve may have a malfunction. Check it directly.
valve
8 The spool of the travel control lever may have a malfunction. Check it directly.
lever (spool)
9 Travel motor defective
Travel lever Leakage from travel motor
Travel circuit relieved 27.2 /min
The final drive may have a defect in it. Check it directly. (It may be checked by
10 Final drive defective
abnormal sound, abnormal heating, metal chips in drain oil, etc.)
20-518 PC160LC-7
(1)
H-18 Travel speed is low
Failure information • Travel speed is low.


1
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Travel lever PPC valve output pressure
Malfunction of travel PPC
2 Above 2.7 MPa
valve Forward or reverse position
{Above 28 kg/cm2}
Difference in above output between Below 0.4 MPa
both sides {Below 4 kg/cm2}

3
Approx. 50°C
{Below 60 kg/cm2}
Below 7.4 MPa
Approx. 80°C
{Below 75 kg/cm2}
divider valve
lever (spool)
The pressure compensation valve of the travel control lever may have a malfunc-
7 lever (pressure compensation
valve)
Malfunction of travel control The suction valve of the travel control lever may have a malfunction. Check it
8
lever (suction valve) directly.
The final drive may have a defect in it. Check it directly. (It may be checked by
abnormal sound, abnormal heating, metal chips in drain oil, etc.)
PC160LC-7 20-519
(1)
H-19 Machine cannot be steered easily or steering power is low
Failure information • Machine cannot be steered easily or steering power is low.


PPC valve output pressure
Malfunction of travel PPC Travel lever
1 (at starting switch)
valve (steering spool)
In NEUTRAL on both sides 0 MPa {0 kg/cm2}
Above 2.7 MPa
Operated on either side
{Above 28 kg/cm2}

2

Malfunction of travel junction Travel lever Solenoid valve output pressure

3
solenoid valve All levers in NEUTRAL 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Position for travel only on either side
{29 – 35 kg/cm2}
Malfunction of hydraulic pump The check valve of the hydraulic pump may have a malfunction or its sealing may
4
(check valve) be defective. Check it directly.
Malfunction of hydraulic pump The shuttle valve of the hydraulic pump may have a malfunction or its sealing
5
(shuttle valve) may be defective. Check it directly.
divider valve
Malfunction of travel junction
7 The travel junction valve may have a malfunction. Check it directly.
valve
lever (spool)
The pressure compensation valve of the travel control lever may have a malfunc-
9 lever (pressure compensation
valve)
Malfunction of travel control The suction valve of the travel control lever may have a malfunction. Check it
10
lever (suction valve) directly.
The safety and check valve of the travel motor may have a malfunction. Check it
Malfunction of travel motor
11 directly. (It may be checked by exchanging the front and rear motors or the right
(Safety and check valve)
and left motors and checking change of the phenomenon.)
20-520 PC160LC-7
(1)
H-20 Travel speed does not change or it is kept low or high
Failure information • Travel speed does not change or it is kept low or high.


Solenoid valve output
Malfunction of travel speed Travel speed Travel lever
1 pressure
selector solenoid valve
Lo In NEUTRAL 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Hi Operated
{29 – 35 kg/cm2}
Malfunction of travel motor The speed-changer unit of the travel motor may have a malfunction. Check
2
(speed-changer unit) it directly.
H-21 Track does not move (only either side)
Failure information • Track does not move (only either side).


Defective seat of travel control The suction valve seat of the travel control lever may be defective. Check it
1
valve (suction valve) directly.
Defective seat of travel control The safety and check valve seat of the travel control lever may be defective.
2
valve (Safety and check valve) Check it directly.
Malfunction of travel motor The counterbalance valve of the travel motor may have a malfunction.
3
(counterbalance valve) Check it directly.
The final drive may have a defect in it. Check it directly. (It may be checked
by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
PC160LC-7 20-521
(1)
H-22 Machine does not swing
Failure information • Machine does not swing. (1) Machine does not swing in either direction.

Malfunction of swing holding Right work equipment control lever Solenoid valve output pressure
1
brake solenoid valve
Operated for swing 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunction of swing motor
2 The holding brake of the swing motor may have a malfunction. Check it directly.
(holding brake)
3 Swing motor defective
Left work equipment control lever Leakage from swing motor
Swing circuit relieved 10 /min
The swing machinery may have a defect in it. Check it directly. (It may be
4 Swing machinery defective
checked by abnormal sound, abnormal heating, metal chips in drain oil, etc.)
Failure information • Machine does not swing. (2) Machine does not swing in only one direction.

Malfunction of swing PPC Left work equipment control lever PPC valve output pressure
1
valve
Operated for swing Above 2.7 MPa {Above 28 kg/cm2}
2 The spool of the swing control valve may have a malfunction. Check it directly.
valve (spool)
Defective adjustment or mal- Left work equipment
3 function of swing motor (safety Swing lock switch Swing relief pressure
control lever
valve)
Swing circuits relieved 28.9 – 32.9 MPa
ON
(separately on both sides) {295 – 335 kg/cm2}
Defective sealing of swing Sealing of the suction valve of the swing motor may be defective. Check it
4
motor (suction valve) directly.
20-522 PC160LC-7
(1)
H-23 Swing acceleration or swing speed is low
(1) Swing acceleration or swing speed is low in

Failure information • Swing acceleration or swing speed is low.
both directions.

The pressure compensation valve of the swing control valve may have a

valve)
Malfunction of swing motor The holding brake of the swing motor may have a malfunction. Check it
2
(holding brake) directly.
3 Swing motor defective
Left work equipment control lever Leakage from swing motor
(2) Swing acceleration or swing speed is low in

Failure information • Swing acceleration or swing speed is low.
only one direction.

1
valve
0 MPa {0 kg/cm2}
In NEUTRAL

Malfunction of swing control The spool of the swing control valve may have a malfunction. Check it
2
control lever
valve)
ON
4
PC160LC-7 20-523
(1)
H-24 Excessive overrun when stopping swing
(1) Overrun of upper structure is large in both

Failure information • Excessive overrun when stopping swing.
directions.

and stan-dard value
Presumed cause
in normalcy
1 Swing motor defective Left work equipment control lever Leakage from swing motor
(2) Overrun of upper structure is large in only

Failure information • Excessive overrun when stopping swing.
one direction.

1
valve
The swing PPC slow return valves may be clogged. Check them directly.
Clogging of swing PPC slow
2 (They may be checked by exchanging with each other and checking change
return valves
of the phenomenon.)
Malfunction of swing control The spool of the swing control valve may have a malfunction. Check it
3
control lever
valve)
ON
5
20-524 PC160LC-7
(1)
H-25 When upper structure stops swinging, it makes large shock
Failure information • When upper structure stops swinging, it makes large shock.


1
valve
The swing PPC slow return valves may have a malfunction. Check them
Malfunction of swing PPC slow
2 directly. (They may be checked by exchanging with each other and check-
return valves
ing change of the phenomenon.)
Malfunction of swing motor The shockless valve of the swing motor may have malfunction. Check it
3
(shockless valve) directly.
H-26 When upper structure stops swinging, it makes large sound
Failure information • When upper structure stops swinging, it makes large sound.

Malfunction of back pressure
1 The back pressure check valve may have a malfunction. Check it directly.
check valve
The swing motor (safety valves) may have a malfunction. Check the valves
(safety valve)
The swing motor (suction valves) may have a malfunction. Check the
3 valves directly. (They may be checked by exchanging with each other and
(suction valves)
checking change of the phenomenon.)
PC160LC-7 20-525
(1)
H-27 Hydraulic drift of swing is large
Failure information • Hydraulic drift of swing is large. (1) When swing holding brake is operated
• If the swing lock switch is turned ON or the swing holding brake release switch is in the normal
Relative information position, the swing brake operates and the disc brake holds the upper structure.
• Conduct the troubleshooting in working mode A.

Malfunction of swing holding Right work equipment control lever Solenoid valve output pressure
1
brake solenoid valve In NEUTRAL 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Operated for swing
{29 – 35 kg/cm2}
Malfunction or internal defect The holding brake of the swing motor may have a malfunction or an internal
2
of swing motor (holding brake) defect. Check it directly.
Failure information • Hydraulic drift of swing is large. (2) When swing holding brake is released
• If the swing holding brake release is in the emergency position, the swing holding brake is re-
Relative information leased and the upper structure is held with only hydraulic pressure.
• Conduct the troubleshooting in working mode A.

Defective sealing of swing Sealing of the spool of the swing control valve may have a malfunction.
1
control valve (spool) Check it directly.

The safety valves of the swing motor may have a malfunction. Check them
Defective sealing of swing
motor (safety valve)
The suction valves of the swing motor may have a malfunction. Check them
Defective sealing of swing
motor (suction valve)
The shockless valve of the swing motor may have a malfunction or its seal-
4 ing of swing motor (shockless
ing may be defective. Check it directly.
valve)
20-526 PC160LC-7
(1)
H-28 Attachment circuit does not change

When attachment is installed
Failure information • The return circuit of the attachment circuit does not change.
• If an attachment is installed, the service circuit changes according to the selected working mode
as shown below.
1) In mode A or E: The double acting circuit is selected and the safety valve is set to the low
pressure.
2) In mode B: The single acting circuit is selected and the safety valve is set to the high pres-
sure.
* Setting of the safety valve on only port B side is changed. Port A is always set to the low
pressure.


Malfunction of attachment Working mode Solenoid valve output pressure

1
return selector solenoid valve Mode E or A 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Mode B
{29 – 35 kg/cm2}
Malfunction of attachment The attachment return selector valve may have a malfunction. Check it
2
return selector valve directly.
Malfunction of service control The safety valve of the service control valve (on port B side) may have a
3
valve (safety valve) malfunction. Check it directly.
H-29 Flow rate in attachment circuit cannot be adjusted

When attachment is installed
Failure information • Flow rate in attachment circuit cannot be adjusted.
• If an attachment is installed, the flow rate in the service circuit changes according to the selected
working mode.
• How to adjust the flow rate in modes A and E is different from that in mode B. For details, see
OPERATION MANUAL.

Malfunction of attachment flow The attachment flow rate adjustment EPC valve may have a malfunction.
1
rate adjustment EPC valve Check it directly.

PPC valve output
Wiring harness connector Service pedal
Malfunction of service PPC pressure
2
valve Disconnect connector In NEUTRAL 0 MPa {0 kg/cm2}
V30 of attachment flow
rate adjustment EPC Above 2.7 MPa
Operated
valve. {Above 28 kg/cm2}
PC160LC-7 20-527
(1)
TROUBLESHOOTING OF ENGINE
(S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-602

S- 1 Starting performance is poor (Starting always takes time)................................................................ 20-606
S- 2 Engine does not start ........................................................................................................................ 20-608
(1) Engine does not turn .................................................................................................................. 20-608
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) .............................. 20-609
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)............................ 20-610
S- 3 Engine does not pick up smoothly (Follow-up is poor) ..................................................................... 20- 611
S- 4 Engine stops during operations ........................................................................................................ 20-612
S- 5 Engine does not rotate smoothly (Hunting)....................................................................................... 20-613
S- 6 Engine lacks output (or lacks power) ................................................................................................ 20-614
S- 7 Exhaust smoke is black (Incomplete combustion) ............................................................................ 20-615
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-616
S- 9 Oil becomes contaminated quickly ................................................................................................... 20-617
S-10 Fuel consumption is excessive ......................................................................................................... 20-618
S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-619
S-12 Oil pressure monitor lights up (Drop in oil pressure)......................................................................... 20-620
S-13 Oil level rises (Water, fuel in oil)........................................................................................................ 20-621
S-14 Water temperature becomes too high (Overheating)........................................................................ 20-622
S-15 Abnormal noise is made ................................................................................................................... 20-623
S-16 Vibration is excessive ....................................................................................................................... 20-624
PC160LC-7 20-601
(4)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in [B] are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under [C] in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been marked
as having the highest probability from information
gained from [Questions] and [Check items].
20-602 PC160LC-7
(4)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and
mark the Cause column with E to use
as reference for locating the cause of
the failure. However, do not use this
when making calculations to narrow
down the causes.
2. Use the E in the Cause column as ref-
erence for [Degree of use (Operated for
long period)] in the [Questions] section
as reference. As a rule, do not use it
when calculating the points for locating
the cause, but it can be included if nec-
essary to determine the order for trou-
bleshooting.
PC160LC-7 20-603
(4)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
20-604 PC160LC-7
(4)
PC160LC-7 20-605
(4)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of –10°C or below,
ASTM D975 No. 2 diesel fuel is used)
a Battery charging rate
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
temperature
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
–10°C 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the value for the

charging rate of 70% in the above table.
• In cold areas the specific gravity must exceed the value
for the charging rate of 75% in the above table.
20-606 PC160LC-7
(4)
TROUBLESHOOTING S-1
PC160LC-7 20-607
(4)
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn
• Internal parts of engine seized

a If internal parts of the engine are seized, car-
ry out troubleshooting for "Engine stops dur-
ing operations".
• Failure in hydraulic pump system

• Defective electrical system
20-608 PC160LC-7
(4)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
General causes why engine turns but no exhaust

smoke comes out
• Supply of fuel impossible

• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
a Standards for use of fuel
PC160LC-7 20-609
(4)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
General causes why exhaust smoke comes out but

engine does not start
• Lack of rotating force due to defective electrical

system
• Improper selection of fuel
20-610 PC160LC-7
(4)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up

smoothly

• Improper condition of fuel injction
• Improper fuel used
PC160LC-7 20-611
(4)
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops during operations
• Seized parts inside engine

• Overheating
a If there is overheating and the engine stops,
carry out troubleshooting for overheating.
• Failure in hydraulic pump

a If the engine stops because of a failure in the
hydraulic pump, carry out troubleshooting for
H mode.
20-612 PC160LC-7
(4)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (Hunting)
Ge neral c auses why engine does not r otate

smoothly
• Air in fuel system

• Defective governor mechanism
• Defective governor motor mechanism
a If hunting stops when governor spring is dis-
connected, carry out troubleshooting for E
mode.
PC160LC-7 20-613
(4)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output

• Improper fuel used
(if non-specified fuel is used, output drops)
• Lack of output due to overtaking
a If there is overheating and lack of output,
carry out troubleshooting for overheating.
20-614 PC160LC-7
(4)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black

PC160LC-7 20-615
(4)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
a Do not run the engine at idling for more than 20

minutes continuously. (Both low and high idling)
General causes why oil consumption is excessive
• Abnormal combustion of oil

• External leakage of oil
• Wear of lubrication system
20-616 PC160LC-7
(4)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated

quickly
• Entry of exhaust gas due to internal wear

• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
PC160LC-7 20-617
(4)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive
• Leakage of fuel
20-618 PC160LC-7
(4)
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
• Internal leakage in lubrication system

• Internal leakage in cooling system
PC160LC-7 20-619
(4)
S-12 Oil pressure monitor lights up (Drop in oil pressure)
General causes why oil pressure monitor lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection
20-620 PC160LC-7
(4)
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the cooling water, carry out trou-

bleshooting for "Oil is in cooling water".
General causes why oil level rises
• Water in oil (milky white)

• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
PC160LC-7 20-621
(4)
S-14 Water temperature becomes too high (Overheating)
General causes why water temperature becomes

too high
• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in hydraulic pump system
a Carry out troubleshooting for H mode.
20-622 PC160LC-7
(4)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an exter-

nal noise.
General causes why abnormal noise is made
• Abnormality due to defective parts

• Abnormal combustion
• Air sucked in from intake system
PC160LC-7 20-623
(4)
S-16 Vibration is excessive
a If there is abnormal noise together with the vibra-

tion, carry out troubleshooting also for "Abnormal
noise is made".
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)

• Improper alignment
• Abnormal combustion
20-624 PC160LC-7
(4)
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL ..................30- 3 IDLER

PRECAUTIONS WHEN PERFORMING Special tools ............................................. 30-45
OPERATION.............................................30- 5 Disassembly............................................. 30-45
SPECIAL TOOL LIST...................................30- 7 Assembly.................................................. 30-46
SKETCHES OF SPECIAL TOOLS ..............30-10 RECOIL SPRING
STARTING MOTOR Special tools ............................................. 30-48
Removal and Installation ..........................30-11 Disassembly............................................. 30-48
FUEL INJECTION PUMP Assembly.................................................. 30-49
Special tools..............................................30-12 TRACK ROLLER
Removal....................................................30-12 Special tools ............................................. 30-50
Installation.................................................30-14 Disassembly and Assembly ..................... 30-50
ENGINE FRONT SEAL CARRIER ROLLER
Installation............................................. 30-17-1 Disassembly and Assembly ..................... 30-51
ENGINE REAR SEAL SWING MOTOR AND SWING MACHINERY
Removal....................................................30-18 Removal and Installation.......................... 30-52
Installation.................................................30-19 Special tools ............................................. 30-53
CYLINDER HEAD Disassembly............................................. 30-53
Special tools..............................................30-20 Assembly.................................................. 30-56
Removal....................................................30-20 SWING MOTOR
Installation.................................................30-23 Special tools ............................................. 30-61
RADIATOR Disassembly............................................. 30-61
Removal and Installation ..........................30-26 Assembly.................................................. 30-64
AFTER COOLER CENTER SWIVEL JOINT
Removal and Installation ..........................30-27 Removal ................................................... 30-69
HYDRAULIC OIL COOLER Installation ................................................ 30-70
Removal and Installation ..........................30-28 Special tools ............................................. 30-71
ENGINE AND HYDRAULIC PUMP Disassembly and Assembly ..................... 30-71
Special tools..............................................30-29 WORK EQUIPMENT
Installation.................................................30-32 Removal ................................................... 30-72
TRUCK SHOE Installation ................................................ 30-74
Special tools..............................................30-34 REVOLVING FRAME
Expansion .................................................30-34 Removal ................................................... 30-75
Installation.................................................30-35 Installation ................................................ 30-76
SPROCKET SWING CIRCLE
Removal and Installation ..........................30-36 Removal and Installation.......................... 30-77
FINAL DRIVE HYDRAULIC TANK
Removal and Installation ..........................30-37 Removal ................................................... 30-78
Special tools..............................................30-38 Installation ................................................ 30-80
Disassembly .............................................30-38
Assembly ..................................................30-40
PC160LC-7 30-1
(4)
CONTROL VALVE
Removal ................................................. 30- 81
Installation .............................................. 30- 84
Disassembly and Assembly ................... 30- 85
HYDRAULIC PUMP
Special tools ........................................... 30- 87
Removal ................................................. 30- 87
Installation .............................................. 30- 88
HYDRAULIC PUMP INPUT SHAFT
OIL SEAL
Special tools ........................................... 30- 89
Removal and Installation........................ 30- 89
WORK EQUIPMENT PPC VALVE
TRAVEL PPC VALVE
HYDRAULIC CYLINDER
Special tools ........................................... 30- 92
Disassembly........................................... 30- 92
Assembly................................................ 30- 94
COUNTERWEIGHT
Removal and Installation........................ 30- 98
AIR CONDITIONER UNIT
Special tools ........................................... 30- 99
Removal ................................................. 30- 99
Installation .............................................. 30-101
OPERATOR'S CAB
Removal ................................................. 30-102
Installation .............................................. 30-104
OPERATOR'S CAB GLASS
(STUCK GLASS) ..................................... 30-105
Special tools ........................................... 30-106
Removal ................................................. 30-106
Installation .............................................. 30-107
FRONT WINDOW
Removal ................................................. 30-116
Installation .............................................. 30-118
MONITOR
Removal and Installation........................ 30-121
GOVERNOR, PUMP CONTROLLER
Removal and Installation........................ 30-122
30-2 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS INSTALLATION OF PARTS
• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing part
kind of information are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
t: Special tools which cannot be substi- are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
q: Speciall tools which are very useful if stand for the following.
k
available, can be substituted with com-
This mark indicates safety-related pre-
mercially available tools.
cautions, which must be followed when
2) Distinction of new and existing special tools. doing the work.
N: Tools with new part numbers, newly a This marks gives guidance or precau-
developed for this model. tions when doing the procedure.
2 This mark stands for a specific coating

R: Tools with upgraded part numbers,
remodeled from already available tools
for other models. agent to be used.
3 This mark indicates the specified torque.

Blank: Tools already available for other models,
used without any modification.
5
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the spe- This mark indicates an amount of oil or
cial tool is presented in the section of water to be added.
Sketches for Special Tools.
a Part No. of special tools starting with 79*T SKETCHES OF SPECIAL TOOLS
means that they are locally made parts and as
such not interchangeable with those made by • Various special tools are illustrated for the con-
Komatsu in Japan e.g. 79*T---×××---××××. venience of local manufacture.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,

precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
k This mark indicates safety-related pre-
doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water be drained.
4 This mark shows the weight of a part or a

device.
PC160LC-7 30-3
(2)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS
• Special tools which are deemed necessary for ASSEMBLY

disassembly and assembly are listed in this sec-
tion. • Section titled ASSEMBLY contain procedures,
• List of the special tools contains the following precautions and the know-how for the work, as
kind of information. well as the amount of oil or water to be added.
1) Necessity • Various symbols used in the ASSEMBLY Section
t: Special tools which cannot be substi- are explained and listed below.
k
tuted, should always be used.
This mark indicates safety-related pre-
q: Speciall tools which are very useful if
available, can be substituted with com-
doing the work.
mercially available tools.
a This marks gives guidance or precau-
2) Distinction of new and existing special tools. tions when doing the procedure.
2 This mark stands for a specific coating
N: Tools with new part numbers, newly
developed for this model.
agent to be used.
3 This mark indicates the specified torque.
R: Tools with upgraded part numbers,
remodeled from already available tools
5
for other models.
Blank: Tools already available for other models, This mark indicates an amount of oil or
used without any modification. water to be added.
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of SKETCHES OF SPECIAL TOOLS
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T 1) Vartious special tools are illustrated for the
means that they are locally made parts and convenience of local manufacture.
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T---×××--
-××××.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-

dures, precautions and the amount of oil or water
to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k This mark indicates safety-related precau-
tions which must be followed when doing
the work.
a This mark gives guidance or precautions
when doing the procedure.
6 This mark shows oil or water to be

drained.
30-4 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
PRECAUTIONS WHEN PERFORMING OPERATION

Be sure to follow the general precautions given below when performing removal or installation (disassmbly or
assembly) of units.
1. Precautions when performing removal work
• If the engine coolant water contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
• To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the
wiring, hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify and show their installation position and help to prevent any
mistakes when re-installing.
• Count and check the number and thickness of the shims, and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
A. Face seal type hoses and tubes

Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
B. Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
C. If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PC160LC-7 30-5
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with tow or three drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After installing snap rings, check that the snap ring is installed securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run it at low idle.
2. Operate the work equipment control lever to operate the hydraulic cylinders, 4 – 5 times, stopping the
cylinder 100 mm from the end of their stroke.
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operations

• If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the spec-
ified level. Run the engine to circulate the coolant water through the system. Then check the coolant
water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed for repair, Bleed the air from the system after
reassembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t.........Cannot be substituted, must always be installed (used)
q.........Extremely useful if available or, can be substituted with commercially available part.
a New/Remodel: N .........Tools with new part numbers, newly developed for this model.
: R .........Tools with upgraded part numbers, remodeled from items already available for other
models.
:Blank:...Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special (See SKETCHES
OF SPECIAL TOOLS).
Necessity
Remodel
Sketch
New/
Q’ty
Component Symbol Part No. Part Name Nature of work, remarks
Fuel injection pump Removal, installation of fuel

assembly
1 795-799-1390 Puller t 1
injection pump assembly
Removal of nozzle holder
A 2 795-799-1171 Puller t 1
assembly
Cylinder head assembly
Tightening of cylinder head
3 790-331-1110 Wrench t 1
bolt
Engine front seal, dust

1 795-799-2610 Installer t 1 Installation of front seal
B
seal
2 795-799-2620 Installer t 1 Installation of dust seal
Engine rear seal C 795-931-1100 Seal puller q 1 Installation of rear seal
Engine and hydraulic

1 796-460-1210 Oil stopper q 1
D Oil stopper
pump assembly
2 796-770-1320 Adapter q 1
790-101-2501 Push puller q 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
Center swivel joint Disassembly of center swivel
E • 790-101-2540 • Washer 1
assembly joint assembly
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
1 796-427-1200 Wrench t 1 Removal, installation of nut
796T-427-1220 Push tool t 1 Q

790-101-2510 Block t 1
792-104-3940 Bolt t 2
Final drive assembly F 2 01580-11613 Nut t 2 Installation of bearing
01613-31645 Washer t 2
790-105-2100 Jack t 1
790-101-1102 Pump t 1
3 791-545-1510 Installer t 1 Installation of floating seal
PC160LC-7 30-7
(4)
Necessity
Remodel
Sketch
New/
Q’ty
1 KBATZ080080 Wrench t 1 N
Swing motor and swing Removal, installation of
machinery assembly
G 2 KBATZ030190 Adapter t 1 N
ring nut
3 KBATZ060400 Stopper t 1 N
790-101-5201 Push tool KIT q 1
• 790-101-5221 • Grip
1 Press fitting of bushing
• 01010-51225 • Bolt
Idler assembly H
• 790-101-5271 • Plate
3 791-601-1000 Oil pump q 1 Filling with oil
791-685-8006 Compressor t 1
790-201-2780 Spacer t 1
791-635-3160 Extension t 1
Disassembly, assembly of
1
Cylinder recoil spring assembly
790-101-1600
(686 kN {70t}) t 1
790-101-1102 Pump t 1
Recoil spring assembly J
791-640-2180 Guide bolt t 1
• 790-201-1620 • Plate
2 Installation of dust seal
• 790-101-5021 • Grip
• 01010-50816 • Bolt
• 790-101-5081 • Plate
• 790-101-5021 • Grip
Carrier roller assembly K
• 01010-50816 • Bolt
• 790-101-5221 • Grip
• 01010-51225 • Bolt
Track roller assembly L
• 790-101-5261 • Plate
30-8 PC160LC-7
(4)
Necessity
Remodel
Sketch
Q’ty
New/
791-630-3000 Remover and t 1

installer
790-101-1300 Cylinder t 1
Expansion and installation of
Track shoe assembly M track shoe assembly
790-101-1102 Pump t 1
790-331-1110 Wrench t 1
Hydraulic pump input shaft

791-463-1350 Push tool t 1
oil seal N Press fitting of oil seal
790-201-2740 Spacer t 1
Cylinder repair Disassembly, assembly of
1 790-502-1003
stand t 1
hydraulic cylinder assembly
790-102-4300 Wrench assembly t 1
2 Removal, installation of piston
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Ring (for boom
796-720-1660
and bucket) q 1
07281-01159 Clamp (for boom q 1 Installation of piston ring

and bucket)
4
796-720-1670 Ring (for arm) q 1
07281-01279 Clamp (for arm) q 1
790-201-1702 Push tool KIT t 1
• 790-201-1821 • Push tool 1

(for boom)
• 790-201-1940 • Push tool 1
Hydraulic cylinder (for arm) Press fitting of cylinder head
Q 5 bushing
assembly • Push tool
• 790-201-1811 1
(for bucket)
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
790-201-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1630 • Plate (for boom) 1

Installation of dust seal
6
• 790-201-1620 • Plate (for bucket) 1
790-201-1980 Plate (for arm) q 1
790-201-5021 Grip q 1
01010-50816 Bolt q 1
796-900-1200 Remover t 1
Puller
Work equipment assembly R 790-101-4000
(490 kN {50 t}, long) t 1 Removal of foot pin
Pump
790-101-1102
(294 kN {30}) t 1
PC160LC-7 30-9
(4)
Necessity
Remodel
Sketch
Q’ty
New/
799-703-1200 Service tool KIT t 1
799-703-1100 Vacuum pump t 1

(100 V)
Air conditioner unit Vacuum pump Collection of and refilling with
assembly S 799-703-1111
(220 V) t 1 refrigerant
Vacuum pump
799-703-1121
(240 V) t 1
799-703-1401 Gas leak detector t 1
Operator's cab glass

1 793-498-1210 Lifter (Suction cup) t 2
X Fixing of window glass
(Stuck glass)
2 20Y-54-13180 Adapter t 2
30-9-1 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches
F2 PUSH TOOL
30-10 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL AND INSTALLATION

OF STARTING MOTOR
ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open the engine hood.
2. Disconnect connector T13 (1) and terminal B (2).

[*1]
3. Remove the mounting bolts and starting motor

assembly (3). [*2]
INSTALLATION
• Carry out installation in the reverse order to
removal.
3 Mounting nut of terminal B:

[*1]
17.7 – 24.5 Nm {1.8 – 2.5 kgm}
[*2]
a Apply gasket sealant (LG-1) to the starting
motor gasket.
a Apply the gasket sealant in the form of a con-
tinuous string 1 mm thick around the area 4
mm from the inside edge of the starting
motor gasket.
a Apply the gasket sealant to both sides of the
starting motor gasket.
3 Mounting bolt:
43 ± 6 Nm {4.38 ± 0.61 kgm}
PC160LC-7 30-11
(2)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP

OF FUEL INJECTION PUMP
ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
A 1 795-799-1390 Puller t 1
REMOVAL
k Disconnect the cable from the negative (–) ter- 8. Remove 4 delivery tubes (7).
9. Remove fuel tubes (8) and (9) between the fuel
1. Close the fuel stop valve. filter and fuel injection pump.
2. Open the engine hood. 10. Remove lubrication tubes (10) and (11).
3. Remove plate (1). 11. Remove governor spring (12) from the governor
lever. [*1]
4. Remove fan guard (2).
12. Set No. 1 cylinder piston to the compression top

5. Move oil level gauge guide (3). dead center and fix the drive gear of the fuel
injection pump to the injection timing.
6. Disconnect connector V07 (4). a For details, see TESTING AND ADJUSTING,
Inspection and adjustment of fuel injection
7. Disconnect fuel inlet hose (5) and fuel outlet timing.
hose (6).
a Insert a wooden plug, etc. in the discon-
nected hose to prevent the fuel from flowing
out.
30-12 PC160LC-7
(2)
13. Turn and remove cap (14). 16. Remove fuel injection pump lower bracket (17)
a Use a filter wrench, etc. to remove the cap. and mounting bolts and nuts (18).
17. Remove 4 mounting nuts (19) and fuel injection

14. Remove nut (15) and washer (16) of the fuel pump assembly (20). [*3]
injection pump. [*2]
a Take care not to drop the nut and washer in
the case.
15. Using tool A1, disconnect the shaft and drive

gear of the fuel injection pump.
PC160LC-7 30-13
(2)
INSTALLATION 4. Install fuel injection pump assembly (20) and
3 Mounting nut: 43 ± 6 Nm {4.4 ± 0.6 kgm}

tighten 4 mounting nuts (19).
removal.
[*1]
a Adjust the governor lever stroke. For details,
see TESTING AND ADJUSTING, Special
functions of monitor panel.
[*2] [*3]
a Install the fuel injection pump assembly accord-
ing to the following procedure.
1. Using timing pin (13), check that the injection

timing of the drive gear is fixed.
5. Fit washer (16) and tighten nut (15) temporarily.

a Take care not to drop the nut and washer in
the case.
k Tighten the nut to the following torque tem-

porarily so that it will not damage the timing
pin.
3 Temporary tightening torque of nut:
12.5 ± 2.5 Nm {1.25 ± 0.25 kgm}
2. Remove plug (21) of the fuel injection pump.
3. Turn over and insert timing pin (22) of the fuel

injection pump and check that its cut is fitted to
projection (a) in the pump.
a If you can insert the timing pin smoothly, the
injection timing is normal.
a If you cannot insert the timing pin, the injec-
tion timing is abnormal. In this case, adjust
the injection timing. (See TESTING AND
ADJUSTING, Inspection and adjustment of
fuel injection timing.) 6. Return the timing pin of the fuel injection pump
and that of the drive gear to their original posi-
tions.
7. Tighten nut (15) of the fuel injection pump per-

manently.
3 Permanent tightening torque of nut:
95 ± 10 Nm {9.7 ± 1.02 kgm}
k Before starting the engine, check that timing

pin (13) of the drive gear and timing pin (22)
of the fuel injection pump are returned.
30-14 PC160LC-7
(2)
Bleeding air
• Bleed air from the fuel piping according to the fol-
lowing procedure.
1. Fill the fuel tank with fuel (until the float reaches
the highest level).
2. Loosen eyebolt (23).
3. Remove cap (24). Loosen the knob of the feed

pump and move it up and down to let fuel flow
out of the mounting part of eyebolt (23) until bub-
bles do not come out any more.
4. Tighten eyebolt (23).
5. Start the engine and check that fuel does not

leak from the fuel system.
PC160LC-7 30-15
(2)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND INSTALLATION k Take care not to catch your hands between
the tensioner and pulley.
OF ENGINE FRONT SEAL
9. Remove fan pulley (9).
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 795-799-2610 Installer t 1
B
2 795-799-2620 Installer t 1
REMOVAL

10. Remove 4 mounting bolts (10) and crank pulley
1. Drain the coolant. (11). [*2]
a Drain the coolant to a degree that it will not a Remove the crank pulley with its timing mark
leak when hose (1) is disconnected. (a) matched to pointer (12) or make match
marks on the crank pulley and front cover so
2. Remove hoses (1) and (2). that you can position the crank pulley cor-
rectly when installing it.
3. Remove fan guards (3) and (4).
11. Remove 20 mounting bolts (13) and front cover
4. Remove air conditioner compressor belt. [*1] (14). [*3]
5. Disconnect connector E06 (16) and remove air

conditioner compressor (5) and bracket and
move them toward the counterweight.
a Do not separate the air conditioner piping.
6. Remove fan shroud (6).

a Take care that the fan shroud will not inter-
fere with the other parts.
7. Remove the cooling fan.
8. Install lever [1] to tensioner (7) and move the

lever in the direction of the arrow to remove fan
belt (8).
30-16 PC160LC-7
(4)
12. Remove engine front seal (15) from front cover

(14). [*4]
a If the dust seal is installed, remove it, too.
PC160LC-7 30-17
(4)
INSTALLATION 3. Dust seal

a Even if a dust seal has not been installed, install
• Carry out installation in the reverse order to the dust seal contained in the front seal kit.
removal. 1) Using tool B2, press fit dust seal (16) to the
end of the crankshaft.
[*1] a Press fit the dust seal until the inside end
a Install the air conditioner compressor belt. of tool B2 touches the end of the crank-
For details, see TESTING AND ADJUSTING, shaft.
Inspection and adjustment of air compressor
belt tension.
[*2]
a Install the belt to the position from which it
was removed.
a Install the crank pulley temporarily and fan
belt, and then tighten the mounting bolts to
3 Mounting bolt:
the specified torque.
125 ± 5 Nm {12.75 ± 0.51 kgm}

[*3] [*4]
1. Front oil seal
1) Set front oil seal (15) to tool B1.
a Since plastic part [2] on the inside of the
front oil seal is used to guide the front
cover to the crankshaft, do not remove it
from the front oil seal.
2) Press fit front oil seal (15) to front cover (14).
a Press fit the front oil seal until the shoul-
der of tool B1 touches the inside end of
the front cover.
2. Front cover
1) Apply ThreeBond 1207D or equivalent in the
form of a string 1 – 2 mm thick to the gasket
fitting face of the front cover.
2) Install the gasket to the front cover, and then
install them to the engine.
3) Tighten the 20 mounting bolts in the following
3 Front cover mounting bolt:

order.
24 ± 4 Nm {2.45 ± 0.4 kgm}

4) Remove plastic part [2] (front oil seal guide)
on the inside of the front cover.
30-17-1 PC160LC-7
(4)
PC160LC-7 30-17-2
(4)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL AND INSTALLATION 4. Remove rear oil seal (3). [*2]

a Method of removing with seal puller:
OF ENGINE REAR SEAL 1) Make a hole about 3 mm in diameter on the
seal carrier of rear oil seal (3) with a drill.
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
C 795-931-1100 Seal puller q 1
REMOVAL
1. Remove the hydraulic pump assembly. For

details, see Removal and installation of hydraulic
pump assembly.
2) Screw the tip of seal puller C into the drilled
2. Remove damper assembly (1). hole and slide the hammer to remove rear oil
seal (3).
3. Set guide bolts [1] and lift off flywheel assembly

(2). [*1] a Method of removing with screwdriver:
4 Flywheel assembly: 25 kg
• When removing rear oil seal (3) by breaking
the seal carrier with a screwdriver, take care
not to damage the seal mounting part of the
flywheel housing and the seal contact sur-
face ot the crankshaft.
30-18 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
INSTALLATION 2) Insert rear oil seal (4) and pilot [2] together
in the crankshaft and push the seal carrier of
• Carry out installation in the reverse order to rear oil seal (4) into the flywheel housing.
removal. a Before inserting the rear oil seal, clean,
degrease, and dry the seal contact surface
[*1] of the crankshaft.
a Tighten the mounting bolts of the flywheel 3) Pull out pilot [2] and push in rear oil seal (4)
further.
3 Mounting bolt of flywheel assembly:
assembly in the following numerical order.
137 ± 7 Nm {13.97 ± 0.71 kgm}
4) Using aligning tool [3], insert the oil seal to

the proper depth.
[*2] a Lightly hit the top, bottom, right, and left
a Install the rear oil seal according to the fol- of the aligning tool with a hammer to
lowing procedure. push in the seal, taking care that the seal
1) Insert pilot [2] in new rear oil seal (4). carrier will not be bent.
a Before inserting the pilot, clean, degrease,
and dry the lip surface of the rear oil seal.
• Refilling with oil
5 Damper case oil: approx. 0.75 l
PC160LC-7 30-19
(4)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL AND INSTALLATION 8. Disconnect terminal E01 (4).
OF CYLINDER HEAD 9. Remove the bracket mounting bolts of engine oil

ASSEMBLY level gauge guide (5) and move the level gauge
guide.
SPECIAL TOOLS
10. Remove 4 delivery tubes (6).
New/Remodel
Symbol
11. Remove tubes (7) and (8) between fuel filter and
Necessity
Part No. Part name
Sketch
fuel injection pump.
Q'ty
12. Remove bracket (9) and fuel filter as a unit. [*3]
2 795-799-1171 Puller t 1
A
3 790-331-1110 Wrench t 1
13. Remove air intake connector (10) and ribbon
heater (11). [*4]
REMOVAL a Cover the openings with adhesive tapes, etc.

to prevent foreign matter from entering the
engine.
1. Drain the coolant.
6 Coolant: 18.6 l
2. Close the fuel stop valve.
4. Disconnect hose (1) from the engine. [*1]
5. Remove fan guard (2).
6. Remove the air conditioner compressor belt. [*2]

14. Remove heat insulation covers (12) and (13).
7. Disconnect connector E06 (35), and then
remove air conditioner compressor (3) and 15. Remove muffler (14). [*5]
bracket and move them toward the counter-
weight.
a Do not separate the air conditioner piping.
30-20 PC160LC-7
(2)
16. Disconnect hoses (15) and (16). [*6]
17. Disconnect tubes (17) and (18). [*7]
18. Remove turbocharger assembly (19). [*8]
25. Disconnect connector E05 (26) in the rear of the

left of the engine.
19. Remove exhaust manifold (20). [*9]
26. Disconnect spill tube (28).
27. Remove 4 nozzle holder assemblies (27).

20. Referring to REMOVAL AND INSTALLATION OF
ENGINE FRONT SEAL, Removal procedure
steps 2 – 9, remove the cooling fan pulley.
21. Remove the tensioner.
23. Disconnect terminal B (23) and connector E12

(24).
24. Remove alternator (25) and bracket.
a If it is difficult to pull the nozzle holder assem-

blies out of the cylinder head, use tool A2.
PC160LC-7 30-21
(2)
a Cover the nozzle holder assembly mounting 30. Remove push rods (31). [*13]
parts to prevent foreign matter from entering
the engine.
31. Lift off cylinder head assembly (32). [*14]
28. Remove head cover (29). [*11] 4 Cylinder head assembly: 40 kg
32. Remove cylinder head gasket (33).
29. Remove rocker arm assemblies (30). [*12]

a Loosen the locknut and loosen the adjust-
ment screw of each rocker arm 2 – 3 turns.
30-22 PC160LC-7
(2)
INSTALLATION 3 Tube (17):

Turbocharger side:
• Carry out installation in the reverse order to 10.3 ± 1.2 Nm {1.1 ± 0.1 kgm}
removal. Cylinder block side:
3 Tube (18):10 ± 2 Nm {1.0 ± 0.2 kgm}

35 ± 5 Nm {3.6 ± 0.5 kgm}
3 Hose clamp
[*1]
1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

3 Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm}
[*8]
2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*2] [*9]
a Install the air conditioner compressor belt. a Tighten the mounting bolts in the following
3 Mounting bolt:
numerical order.
belt tension. 1st time : Tighten all the bolts to
43 ± 6 Nm {4.38 ± 0.61 kgm}.
[*3] 2nd time: Tighten only bolts 1 – 4 to
a Apply gasket sealant to the threads of the 43 ± 6 Nm {4.38 ± 0.61 kgm}.
bolt (only 1 piece) on the head cover side
among the 3 fuel filter bracket mounting
bolts.
[*4]
a Apply gasket sealant to the threads of only
the 2 of the air intake connector mounting
bolts indicated by the arrows in the following
figure
3 Clamp of hose (22):

[*10]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Mounting bolt:
[*11]
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*12] [*13] [*14]

[*5] a Install the rocker arm assembly and cylinder
a When connecting the exhaust pipe to under head assembly according to the following
the muffler, apply thermosetting sealant procedure.
(Firegum manufactured by Nihon Holts Co., a Check that there is not foreign matter on the
3 Clamp nut of muffler U-bolt:

Ltd. or equivalent) all round the pipe end. cylinder head mounting face and in the cylin-
der.
9.8 – 14.7 Nm {1.0 – 1.5 kgm} 1) Set cylinder head gasket (33) to the cyl-
inder block.

[*6] a Check that the gasket is matched to
the holes of the block.
10.0 – 11.0 Nm {1.02 – 1.12 kgm}
Clamp of hose (16):
1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
PC160LC-7 30-23
(2)
2) Sling cylinder head assembly (32) and set it 3 Cylinder head bolt:
to the cylinder block. 1st time : Tighten all the bolts to
90 ± 5 Nm {9.18 ± 0.51 kgm} in
the numerical order shown in
the figure.
2nd time: Tighten bolts 3, 6, 11, and 14 to
120 ± 5 Nm {12.24 ± 0.51 kgm}
in order.
3rd time : Using tool A3, tighten all the
bolts by 90° ± 5° in the numeri-
cal order shown in the figure.
(Angle tightening)
a When not using tool A3, make marks
on the bolts and cylinder head, and
then tighten each bolt by the above
angle.
3) Install push rods (31).
4) Install rocker arm assemblies (30) and
tighten mounting bolts (34) with the fingers.
a Check that the balls of adjustment
screws (35) are fitted to the sockets of
push rods (31).
5) Tighten the cylinder head bolts in the follow-

ing numerical order in 3 times.
2 Threads and seat of mounting bolt:
Engine oil (SAE15W-40)
6) Tighten rocker arm assembly mounting bolts

(34) permanently.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
30-24 PC160LC-7
(2)
7) Adjust the valve clearance. For details, see

TESTING AND ADJUSTING, Adjustment of
valve clearance.
• Refilling with water

Add water to the specified level. Run the engine
to circulate the water through the system. Then,
check the water level again.
5 Cooling water: 18.6 l
• Bleeding air
Bleed air from the fuel piping. For details, see
REMOVAL AND INSTALLATION OF FUEL INJEC-
TION PUMP ASSEMBLY.
PC160LC-7 30-25
(2)
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL AND INSTALLATION 5. Remove the 2 mounting bolts and lift off radiator
assembly (6).
OF RADIATOR ASSEMBLY a You can lift up and remove the radiator
assembly with the hands.
4 Radiator assembly: 11 kg
REMOVAL
INSTALLATION
removal.
3. Open the engine hood and disconnect hoses (3) [*1]

and (4). [*2] a Tighten the clamp of hose (2) with the bolt
right down.
4. Remove the mounting bolts of cover (5) and 3 Clamp of hose (2):
move the cover toward the engine. 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*2]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

a Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
30-26 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY AFTERCOOLER

OF AFTERCOOLER
ASSEMBLY
REMOVAL
1. Disconnect hose (1). [*1]
INSTALLATION

removal.
[*1]
a Tighten the hose clamp with the bolt right
2. Open the engine hood, remove clamp (2), and
3 Hose clamp:
down.
disconnect hose (3). [*2]
1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
3. Remove the mounting bolts of cover (4) and
2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
move the cover toward the engine.

[*2]
1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
4. Remove the 2 mounting bolts and lift off after-

cooler assembly (5).
a You can lift up and remove the aftercooler
assembly with the hands.
4 Aftercooler assembly: 9 kg
PC160LC-7 30-27
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER

OF HYDRAULIC OIL COOLER
ASSEMBLY
REMOVAL
1. Loosen plug (1) on the bottom of the hydraulic oil

cooler to drain the hydraulic oil from the cooler
and piping.
a Before draining the oil, open the hydraulic
tank cap to release the internal pressure of
the tank.
6 Hydraulic oil cooler: 5.4 l
5. Remove the 3 mounting bolts and lift off hydrau-

lic oil cooler assembly (5).
4 Hydraulic oil cooler assembly: 20 kg
2. Open the side cover and remove tube (2).
NSTALLATION
removal.
• Refilling with oil (Hydraulic tank)

a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic oil cooler: 5.4 l (EO10-CD)

3. Open the engine hood and remove tube (3).
4. Remove the mounting bolts of cover (4) and

move the cover toward the engine.
30-28 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP

OF ENGINE AND HYDRAULIC
PUMP ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
796-460-1210 Oil stopper q 1
D
796-770-1320 Adapter q 1
REMOVAL 5. Remove hoses (2) and (3). [*2]
k Disconnect the cable from the negative (–) ter- 6. Disconnect hoses (4), (5), and (6) from the
minal of the battery. engine. [*3]
k Lower the work equipment to the ground and
7. Remove fan guards (7) and (8).
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
8. Remove the air conditioner compressor belt and
of the hydraulic tank.
disconnect connector E06 (9). Remove air con-
ditioner compressor (10) and bracket and move
a Put tags to the disconnected hoses and tubes to
them toward the counterweight. [*4]
prevent a mistake in re-connecting them.
a Do not disconnect the air conditioner piping.
9. Remove the cooling fan.
6 Coolant: 18.6 l
10. Remove plate (11).
2. Remove the hydraulic tank strainer. Using tool
D, stop the oil.
a When not using tool D, remove the drain plug
to drain the oil from the hydraulic tank. [*1]
6 Hydraulic tank: 121 l
3. Close the fuel stop valve.
4. Lift off engine hood (1).

4 Engine hood: 40 kg
PC160LC-7 30-29
(2)
11. Remove plates (12) and (13) and covers (14) 15. Disconnect fuel hoses (21) and 22.
and (15). a Plug the hoses to prevent fuel from leaking.
16. Disconnect terminal V07 (23).
12. Disconnect connector E12 (16), terminal B (17),

and connector E12 (18).
17. Disconnect terminal E02 (24).
13. Disconnect hose (19). [*5]
18. Disconnect connector E03 (25).

14. Disconnect connector T13 (20) and terminal B
under the starting motor. 19. Remove bracket (26).
30-30 PC160LC-7
(2)
20. Disconnect connectors E01 (27) and E05 (28) 23. Disconnect connectors V21 (33) and A61 (34)
and remove the wiring harness clamp. and remove the wiring harness clamp.
24. Disconnect hoses (35) and (36) and tube (37).

a Prepare a container to receive oil flowing out
through tube (37).
21. Disconnect hose (29).
25. Disconnect hoses (38), (39), (40), and (41).
26. Disconnect ground wire (42).
27. Remove the 4 mounting bolts of oil filter bracket

(43) and move the oil filter toward the engine.
22. Disconnect connectors E04 (30), E11 (31), and

E10 (32).
28. Remove 4 engine mounting bolts (44). [*6]
PC160LC-7 30-31
(2)
29. Lift off engine and hydraulic pump assembly INSTALLATION

(45).
a Check that all the wires and pipes are dis- • Carry out installation in the reverse order to
connected. removal.
4 Engine and oil pump assembly:

3 Hydraulic tank drain plug:
[*1]
600 kg
58.5 – 78.5 Nm {5.97 – 8.0 kgm}

[*2]

8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*3]

10.0 – 11.0 Nm {1.02 – 1.12 kgm}
1st time : 10.8 ± 1 Nm {1.1 ± 0.1 kgm}

2nd time: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*4]
a Install the air conditioner compressor belt.
belt tension.

[*5]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Engine mounting bolt:

[*6]
245 – 308.7 Nm {25 – 31.5 kgm}

a If the engine mounting bracket was removed
from the engine, tighten its mounting bolts to
the following torque.
a When tightening the mounting bolts of both
mounting brackets on the engine front side,
put the top of the projection on the back side
of the brackets to the underside of the
3 Mounting bolt of engine mounting bracket:

engine.
98 – 122.5 Nm {10 – 12.5 kgm}

Add water to the specified level. Run the engine
to circulate the water through the system. Then,
check the water level again.
30-32 PC160LC-7
(2)

5 Hydraulic tank: 121 l (EO10-CD)
• Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.
PC160LC-7 30-33
(2)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
EXPANSION AND 3. Using tool M, pull out master pin (2). [*2]
INSTALLATION OF TRACK
SHOE ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
Remover and
791-630-3000
installer t 1
M
790-101-1300 Cylinder t 1
790-101-1102 Pump t 1
790-331-1110 Wrench t 1 4. Remove tool M and move the machine forward
so that temporary pin [1] will be in front of the
idler, then set block [2].
EXPANSION
5. Pull out temporary pin [1] and remove the dust
1. Stop the machine so that the master pin will be seal. Move the machine in reverse to expand
between the idler and carrier roller and the track track shoe (3). [*3]
shoe can be expanded in the forward and back-
ward directions.
2. Lower the work equipment to the ground and

loosen lubricator (1) to slacken the track shoe.
[*1]
k Since the internal pressure of the adjust-

ment cylinder is very high, do not loosen
the lubricator more than 1 turn. If the
grease does not come out sufficiently, move
the machine forward and in reverse.
30-34 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION [*2]
a Using tool M, press fit the master pin so that
• Carry out installation in the reverse order to its projection a will be as follows.
removal. • Dimension a: 2.5 ± 1 mm
[*1]
a Adjust the tension of the track shoe. For
detail, see TESTING AND ADJUSTING,
Inspection and adjustment of track shoe ten-
sion.
• Procedure for tightening shoe bolts and nuts

1. Install each shoe nut (4) so that its rounded side
(R) will be fitted to the seat on the link side.
a If the shoe nut is installed reversely, its cor-
ner will interfere with the seat on the link side
and it will not be fitted to the seat, and that
can loosen the bolt.
2. Tighten the bolt. [*3]

a Check that the mating faces are fitted and a When fitting the dust seal, apply grease (G2-
LI) to its contact face against the bushing.
3 1st time : 490 ± 50 Nm {50 ± 5 kgm}
retighten the bolt.
2nd time: 120° ± 10° Nm

(Angle tightening)
PC160LC-7 30-35
(2)
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL AND INSTALLATION INSTALLATION

OF SPROCKET • Carry out installation in the reverse order to
removal.
REMOVAL
2 Threads of sprocket mounting bolt:
[*1]
1. Expand the track shoe assembly. For details,
3 Sprocket mounting bolt:

see EXPANSION OF TRACK SHOE ASSEM- Adhesive (LT-2)
BLY.
441 – 490 Nm {45 – 50 kgm}
2. Swing the work equipment by 90° and push up
the machine with it, and then set blocks [1]
between the track frame and track shoe.
3. Remove the 20 mounting bolts and lift off

sprocket (1). [*1]
4 Sprocket: 40 kg
30-36 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY FIANAL DRIVE
REMOVAL AND INSTALLATION 4. Remove the 18 mounting bolts from final drive
assembly (6) and lift if off to remove. [*1]
OF FINAL DRIVE ASSEMBLY a Be careful. Do not damage the face of the fit-
ting seal at the base of the hose.
REMOVAL a When lifting off the final drive assembly, do
not use a tapped hole for lifting the cover.
4 Final drive assembly: 330kg
1. Remove the sprocket, refer to the removing
sprocket section in this manual.
k Lower the work equipment to the ground for
safety. Stop the engine and loosen the oil filler
cap on the hydraulic tank to release pressure
inside.
2. Remove cover (1).
INSTALLATION
• Install in reverse order to removal.
3 Final drive assembly mounting bolt:

[*1]
3. Disconnect four travel motor hoses (2), (3), (4) 245 – 309 Nm {25 – 31.5 kgm}
and (5).
• Reflling hydraulic oil
Refill hydraulic oil through the oil filler port to the
specified level, and left the oil circulate in the
hydraulic system by starting the engine.
Then check the oil level again.
• Bleeding air
PC160LC-7 30-37
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY AND
ASSEMBLY OF FINAL
DRIVE ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 796-427-1200 Wrench t 1
796T-427-1220 Push tool t 1 Q
790-101-2510 Block t 1
792-104-3940 Bolt t 2
4. No. 1 carrier assembly
F 2 01580-11613 Nut t 2 1) Remove No. 1 carrier assembly (3).
01613-31645 Washer t 2
790-105-2100 Jack t 1
790-101-1102 Pump t 1
3 791-545-1510 Installer t 1
DISASSEMBLY
1. Draining oil
Remove the drain plug to drain the oil from the
final drive case.
6 Final drive case: 3.5 l
2. Cover 2) Push in pin (4) to drive shaft (5) out of carrier

Remove the mounting bolts. Using eyebolts [1], (6).
remove cover (1). a After removing the shaft, remove pin (4).
3) Remove thrust washer (7), gear (8), bearing
(9), and thrust washer (10).
3. Washer
Remove washer (2).
5. No. 1 sun gear shaft
Remove No. 1 sun gear shaft (11).
30-38 PC160LC-7
(2)
3) Remove thrust washer (20), gear (21), bearing

(22), and thrust washer (23).
4) Remove thrust washer (15).
6. Thrust washer
Remove thrust washer (13).
9. Nut
7. No. 2 sun gear 1) Remove lock plate (24).
Remove No. 2 sun gear (14). 2) Using tool F1, remove nut (25).
8. No. 2 carrier assembly 10. Hub assembly

1) Remove No. 2 carrier assembly (16). 1) Using eyebolts [2], remove hub assembly
(26) from the travel motor.
2) Push in pin (17) to drive shaft (18) out of car-

rier (19).
a After removing the shaft, remove pin
(17).
PC160LC-7 30-39
(2)
2) Remove floating seal (27). ASSEMBLY

3) Remove bearings (28) and (29) from hub
(30). a Clean the all parts and check them for dirt or
a When removing bearing (28), do not hit damage. Coat their sliding surfaces with engine
the bearing plastic retainer. oil (EO30-CD) before installing.
1. Hub assembly
1) Using the push tool, press fit bearings (28)
and (29) to hub (30).
2) Using tool F3, install floating seal (27).
a Thoroughly degrease and dry the O-ring
and O-ring fitting surface of the floating
seal before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
a After installing the floating seal, thinly
apply engine oil (EO30-CD) to the sliding
surfaces.
4) Remove floating seal (31) from travel motor
(32).
30-40 PC160LC-7
(2)
3) Using tool F3, install floating seal (31) to

travel motor (32).
a For the procedure for installation, see 2).
3) Measure thickness b of the nut.

4) Obtain a – b = c.
5) Using tool F1, tighten nut (25) until dimen-
4) Using eyebolts [2], set hub assembly (26) to sion d is c 0/-0.1.
the travel motor.
5) Using and lightly hitting the push tool, press
fit the bearing.
6) Using push-pull gauge [3], measure the start-

ing tangential force of the hub in its revolving
direction on the motor case.
2. Nut a Starting tangential force:
1) Using tool F2, press the bearing inner race. Max. 294 N {Max. 30 kg}
a Do not heat the bearing or press or hit
the plastic retainer directly.
a Pressing force:
8.8 – 12.7 kN {0.9 – 1.3 tons}
a Before pressing the bearing inner race,
revolve the hub 2 – 3 turns.
2) Under the above condition, measure dimen-
sion a.
PC160LC-7 30-41
(2)
7) Install lock plate (24).

a Install the lock plate around cut e of the
travel motor, fitting it to the spline thor-
2 Threads of mounting bolt:

oughly (under condition f).
Adhesive (LT-2)
a Do not apply adhesive (LT-2) to the
threads of the mating nut.
3) Aligning the pin holes of shaft (18) and car-

rier, lightly hit the shaft with a plastic ham-
mer, etc. to install.
a When installing the shaft, revolve the
planetary gear and take care not to dam-
age the thrust washers.
4) Insert pin (17).
a Replace the pin with new one.
a After inserting the pin, caulk the carrier
by the part where the pin is inserted.
a After assembling the carrier, check that
gear (21) revolves smoothly.

1) Install thrust washer (15).
2) Install bearing (22) to gear (21). Fit upper
and lower thrust washers (20) and (23) and
set the gear assembly to carrier (19).
a Replace thrust washers (20) and (23) 5) Install No. 2 carrier assembly (16).
with new ones. a Install No. 2 carrier assembly (16) so that
a There is a caulking mark made when the the 3 gear shaft ends will be in the 3 hol-
pin was inserted at the end of carrier side lows at the motor case end.
hole g and the inside wall of the hole is
swelled at that mark. Flatten the swelled
part in advance.
30-42 PC160LC-7
(2)
a Replace thrust washers (7) and (10) with

new ones.
a There is a caulking mark made when the
pin was inserted at the end of carrier side
hole h and the inside wall of the hole is
swelled at that mark. Flatten the swelled
part in advance.
4. No. 2 sun gear

Install No. 2 sun gear (14).
5. Thrust washer
Install thrust washer (13).
2) Aligning the pin holes of shaft (5) and carrier,

lightly hit the shaft with a plastic hammer, etc.
to install.
a When installing the shaft, revolve the
planetary gear and take care not to dam-
age the thrust washers.
3) Insert pin (4).
a Replace the pin with new one.
a After inserting the pin, caulk the carrier
by the part where the pin is inserted.
a After assembling the carrier, check that
gear (8) revolves smoothly.
6. No. 1 sun gear shaft

Install No. 1 sun gear shaft (11).

1) Install bearing (9) to gear (8). Fit upper and
lower thrust washers (7) and (10) and set the
gear assembly to carrier (6).
PC160LC-7 30-43
(2)
4) Install No. 1 carrier assembly (3). 10. Refilling with oil

Tighten the drain plug and add engine oil through
the oil filler.
5 Final drive case: Approx. 3.5 l (EO30-CD)
a After installing the final drive assembly to the

chassis, check the oil level again at the specified
position.
8. Washer
Install washer (2).
9. Cover
Using eyebolts [1], install cover (1) and tighten
2 Cover mounting face:

the mounting bolts.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
30-44 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY AND 3. Detach idler (4) from shaft (5) and support asem-
bly (7).
ASSEMBLY OF IDLER a The idler contains 70 – 80 cc of oil. Drain the
ASSEMBLY oil at this stage if disassembly. Take care and
spread a cloth on the floor to prevent smear-
SPECIAL TOOLS ing the floor with flushing oil.
New/Remodel
4. Remove floating seal (6) on the opposite side
Symbol
from idler (4), shaft (5) and support assembly (7).
Necessity
Part No. Part name
Sketch
Q'ty
• 790-101-5221 • Grip
• 01010-51225 • Bolt
H
• 790-101-5271 • Plate
790-434-1630 Installer t 1
790-601-1000 Oil pump q 1
DISASSEMBLY
5. Remove dowel pin (8) to detach support (7) from

shaft (5).
6. Remove bushings (9) and (10) from idler (4).
1. Remove dowel pin (1) and then support (2).
2. Remove floating seal (3) from support (2) and

idler (4).
PC160LC-7 30-45
(2)
ASSEMBLY a After inserting the floating seal, check that

inclination of the seal is less than 1mm and
1. Using tool H1, press fit bushings (9) and (10) to that protrusion a of the of the seal remains
idler (4). within the range of 5 – 7mm.
a Press fitting load: 43 – 108 kN {4.4 – 11 ton}
4. Assemble shaft (5) and support (7) assembly to

2. Fit O-ring and install support (7) to shaft (5) with idler (4).
dowel pin (8).
3. Using tool H2, install floating seal (6) to idler (4),

shaft (5) and support (7) assembly.
a Floating seal
Before installing the floating seal, completely
degrease both contact surfaces of an O-ring
and the floating seal (hatched area in the
illustration). Furthermore, take care so that
no dust will stick to the contact surface of the
floating seal.
30-46 PC160LC-7
(2)
5. Using tool H2 install floating seal (3) to idler (4) 6. Install O-ring then install support (2) with dowel
and support (2). pin (1).
a Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or 7. Using tool H3, add oil and tighten the plug.
5 Oil: Applox. 70 – 80 cc (SAE30)

dust get stuck to it.
a Remove all grease and oil from the contact
surface of the O-ring and the floating seal. 3 Plug: 157 – 255 Nm {16 – 26 kgm}
PC160LC-7 30-47
(2)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY AND 1. Piston assembly

Remove piston assembly (2) from recoil spring
ASSEMBLY OF RECOIL assembly (1).
SPRING ASSEMBLY
2. Disassembly of recoil spring assembly
SPECIAL TOOLS 1) Set recoil spring assembly (1) to tool J1.
k The recoil spring is under large installed
New/Remodel
load, so be very sure to set the tool
Symbol
Necessity
Part No. Part name properly.
Sketch
Failure to do this is dangerous.
Q'ty
a Installed load of spring: 108.8 kN {11,100 kg}
791-685-8006 Compressor t 1
790-201-2780 Spacer t 1
791-635-3160 Extension t 1
1 Cylinder
790-101-1600 (686 kN {70t}) t 1
J
790-101-1102 Pump t 1
791-640-2180 Guide bolt t 1
• 790-201-1620 • Plate 1
2
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
DISASSEMBLY 2) Apply haidraulic pressure slowly to compress

spring and remove lock plate (3).
Then remove nut (4).
a Compress the spring to a point where the
nut becomes loose.
a Release the hydraulic pressure slowly
and release the tension of the spring.
a Free length of spring: 558.5 mm.
3) Remove yoke (6), cylinder (7), and dust seal
(8) from spring (5).
3. Disassembly of piston assembly

1) Remove lock plate (10) from piston (9), then
remove valve (11).
2) Remove snap ring (12), then remove U-
packing (13) and ring (14).
30-48 PC160LC-7
(6)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY 2) Assemble cylinder (7) and yoke (6) to spring
2 Sliding portion of cylinder:

(5), and set in tool J1.
Grease (G2-LI)
3) Apply hydraulic pressure slowly to compress

the spring and tighten nut (4) so that the
installed length of the spring is dimension a,
then secure it with lock plate (3).
a Installed length a of spring: 437 mm
1. Assembly of piston assembly

1) Assemble ring (14) and U-packing (13) to
piston (9) and secure with snap ring (12).
2) Tighten valve (11) temporarily, and secure
with lock plate (10).
2. Assembly of recoil spring assembly

1) Using tool J2, install dust seal (8) to cylinder
(7). 4) Remove recoil spring assembly (1) from tool
J1.
3. Asswmble piston assembly (2) to recoil spring
2 Sliding portion of piston: Grease (G2-LI)

assembly (1).
2 Wear ring: Grease (G2-LI)

a install the piston assembly so the valve
installing position is on the outside.
a Fill the inside of the cylinder with 300cc of
grease (G2-LI), then bleed the air and check
that the grease comes out of the grease
hole.
PC160LC-7 30-49
(2)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY AND
ASSEMBLY OF TRACK a When installing floating seals (5) and (6), thor-
ROLLER ASSEMBLY oughly clean, degrease, and dry the contact sur-
faces of the O-rings and floating seals (hatched
SPECIAL TOOLS parts). Take care that dirt will not stick to the
floating seal contact surfaces.
a After installing the floating seals, check that their
New/Remodel
Symbol
slant is less than 1 mm and their projection a is 7
Necessity
Part No. Part name
Sketch
– 11 mm.
Q'ty
• 790-101-5221 • Grip
1
• 01010-51225 • Bolt
L
• 790-101-5261 • Plate
2 790-434-1640 Installer t 1
3 791-601-1000 Oil pump q 1
DISASSEMBLY
a Disassemble according to the following figure.
ASSEMBLY a Using tool L3, fill the track roller assembly with
oil and tighten plug (8).
5 Track roller:
a Assemble according to the following figure.
a Only precautions for assembly are explained
3 Plug (8): 10 – 20 Nm {1 – 2 kgm}

below. Assemble the track roller assembly simi- Applox. 190 – 200 cc (EO30-CD)
larly to the idler assembly, unless otherwise
specified.
a Tighten mounting bolts (11) of the track roller
3 1st time : 196 ± 20 Nm {20 ± 2 kgm}

assembly to the following torque.
2nd time : 90° ± 5° (Angle tightening)
30-50 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISASSEMBLY AND a When installing floating seals (7) and (8), thor-
oughly clean, degrease, and dry the contact sur-
ASSEMBLY OF CARRIER faces of the O-rings and floating seals (hatched
ROLLER ASSEMBLY parts). Take care that dirt will not stick to the
floating seal contact surfaces.
SPECIAL TOOLS a After installing the floating seals, check that their
slant is less than 1 mm and their projection a is 5
New/Remodel
– 7 mm.
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
• 790-101-5081 • Plate
1
• 790-101-5021 • Grip
K
• 01010-50816 • Bolt
2 790-434-1660 Installer t 1
3 791-601-1000 Oil pump q 1
DISASSEMBLY
a Assemble according to the following figure. a Using tool K3, fill the carrier roller assembly with
oil and tighten plug (10).
5 Carrier roller: 75 – 85 cc (EO30-CD)

ASSEMBLY

below.
a Assemble the carrier roller assembly similarly to
the idler assembly, unless otherwise specified.
PC160LC-7 30-51
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY

3. Remove 13 mounting bolts. Using forcing screw
OF SWING MOTOR AND [1], lift off swing motor and swing machinery
SWING MACHINERY assembly (8).
ASSEMBLY a Take care that the assembly will not interfere
with the hoses around it.
REMOVAL 4 Swing motor and swing machinery
k Release the residual pressure in the hydraulic

assembly: 180 kg
circuit. For details, see TESTING AND

ADJUSTING, Release of residual pressure from
hydraulic circuitt.
k Lower the work equipment to the ground in a
stable position and set the safety lock lever to
the LOCK position.
INSTALLATION

removal.

2. Disconnect 6 hoses (2) – (7). system. Then, check the oil level again.
• (2) : Between swing motor and control valve
(Port MA) • Bleeding air
• (3) : Between swing motor and control valve a For details, see TESTING AND ADJUSTING,
(Port MB) Bleeding air from each part.
• (4) : Suction hose (Port S)
• (5) : Pilot hose for releasing swing brake
(Port PB)
• (6) : Drain hose between swing motor and
swivel joint (Port DB)
• (7) : Drain hose between swing motor and
hydraulic tank (Port DB)
30-52 PC160LC-7
(2)
DISASSEMBLY AND
ASSEMBLY OF SWING
MOTOR AND SWING
MACHINERY ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 KBATZ080080 Wrench t 1 N
G 2 KBATZ030190 Adapter t 1 N
3 KBATZ060400 Stopper t 1 N 2) Remove No. 1 carrier assembly (6).
a Insert a flat-head screwdriver, etc. under
planetary gear (7) to float and remove
DISASSEMBLY the planetary gear.
1. Draining oil
Loosen the drain plug and drain the oil from the
swing machinery case.
6 Swing machinery case: 4.5 l
2. Swing motor assembly

1) Set the swing motor and swing machinery
assembly on blocks.
2) Pull out level gauge (1) and remove pipe (2)
and bracket.
a Turn and remove pipe (2).
3) Loosen the mounting nut of pipe (3) and
remove the pipe and bracket together.
4) Lift off swing motor assembly (4). 4. Cover
a Make match marks on the swing motor Remove cover (16).
case and cover (16) for reassembly. a Make match marks on cover (16) and ring
gear (26) for reassembly.

1) Remove No. 1 sun gear (5).
PC160LC-7 30-53
(2)

1) Remove No. 2 sun gear (17).
7. Ring nut
2) Using a bar, etc., float and remove No. 2 carrier 1) Using punch [1], etc., straighten the bent
assembly (18). parts (3 places) of ring nut (27) around the
pinion shaft spline.
6. Ring gear
Remove ring gear (26). 2) Place the flange of housing (28) on a block
a Make match marks on ring gear (26) and and float the pinion shaft at the center.
housing (28) for reassembly. 3) Install tool G1 to the pinion shaft and install
tool G2 to the ring nut.
30-54 PC160LC-7
(2)
8. Housing and pinion shaft

1) Remove 6 mounting screws (32) of front
cover (31).
4) Fix tool G2. Using power wrench (25-time

power) [2], turn tool G1 to loosen the ring
nut. 2) Using puller [3], separate housing (28) and
• Tightening torque of ring nut (Reference): pinion shaft assembly (29).
1100 – 1200 Nm {112.2 – 122.3 kgm}
3) Using a press, separate pinion shaft assem-

5) Remove ring nut (27). bly (29) and bearing (30).
PC160LC-7 30-55
(2)
4) Remove front cover (31) and spacer (36). ASSEMBLY
1. Housing and pinion shaft

1) Using tool G3, install oil seal (35) to housing
(28) as shown in the following figure.
a Press fit the oil seal until its end reaches
the housing end.
5) Remove seal ring (33) from front cover (31).
2) Using push tool [4], press fit spacer (36) to

pinion shaft (29).
6) Remove bearing (34) and oil seal (35) from

housing (28).
3) Install seal ring (33) to front cover (31).
30-56 PC160LC-7
(2)
4) Set front cover (31) to pinion shaft (29).
5) Using push tool [5], press fit bearing (30) to

pinion shaft (29). 7) Using push tool [6], press fit pinion shaft
a Press fit the bearing until the inner race assembly (29) to housing (28).
2 Bearing:Grease
end reaches the spacer. a Press fit the bearing until the end of bear-
ing (30) reaches the end of housing (28).
(SHELL RETINAX HD-2 or
equivalent)
2 Mounting screw:
8) Tighten 6 front cover mounting screws (32).
6) Set pinion shaft assembly (29) to housing

3 Mounting screw: 25 Nm {2.5 kgm}
LOCTITE 243 or equivalent
2 Housing:Grease (SHELL RETINAX

(28).
HD-2 or equivalent)
PC160LC-7 30-57
(2)
9) Using push tool [7], press fit bearing (34).

a Press fit bearing (34) until its end
reaches the shoulder of pinion shaft (29).
4) Fix tool G2. Using power wrench (25-time

power) [2], turn tool G1 to tighten the ring
3 Ring nut:
2. Ring nut nut.
1) Install ring nut (27) to the pinion shaft.
1100 – 1200 Nm {112.2 – 122.3 kgm}
2) Place the flange of housing (28) on blocks

and float the pinion shaft at the center. 5) Using a punch, etc., bend the inside parts of
3) Install tool G1 to the pinion shaft and install ring nut (27) toward the spline of pinion shaft
tool G2 to the ring nut. (29).
a Bend 3 parts at intervals of 120°.
30-58 PC160LC-7
(2)
3. No. 2 carrier assembly 5. Cover

1) Install No. 2 carrier assembly (18). 1) Fit the O-ring to the ring gear mounting face
of cover (16).
2) Install cover (16).
a Match the match marks made when the
cover was removed.
2) Install No. 2 sun gear (17).

1) Install No. 1 carrier assembly (6).
4. Ring gear
1) Fit the O-ring to the housing.
2) Install ring gear (26).
ring gear was removed.
PC160LC-7 30-59
(2)
2) Install No. 1 sun gear (5).
3) Check that dimension a from the end of 8. Refilling with oil
5 Swing machinery case: 4.5 l (EO30-CD)

cover (16) to the end of No. 1 sun gear (5) is
as follows.
0
• Dimension a = 1.5 – 0.5 mm
7. Swing motor assembly

1) Install swing motor assembly (4).
3 Mounting bolt:
swing motor assembly was removed.
85 ± 4.3 Nm {8.7 ± 0.44 kgm}
3 Pipe mounting nut (2 places):

2) Install pipe (3) and bracket.
56.4 ± 7.3 Nm {5.8 ± 0.74 kgm}

3) Install pipe (2) and bracket and insert level
3 Pipe:
gauge (1).
12.3 ± 2.5 Nm {1.25 ± 0.25 kgm}
30-60 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR
DISASSEMBLY AND 2) Remove valve plate (3) from the cover

assembly.
ASSEMBLY OF SWING
MOTOR ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
D1 799-301-1600 Oil leak tester kit t 1
DISASSEMBLY
1. Set the swing motor and swing machinery 3) Remove 2 plugs (4), 2 springs (5), and 2
assembly on blocks. poppets (6).
2. Reverse prevention valve assembly 4) Remove relief valve assembly (7).

Remove reverse prevention valve assembly (1). a Do not disassemble the relief valve
assembly.
a Note that the poppet seat at the relief
valve end may be left in the cover.
5) Remove 2 plugs (40).
3. Cover assembly
1) Remove cover assembly (2).
a Note that the valve plate may fall from
the cover assembly.
6) Remove bearing outer race (8).
PC160LC-7 30-61
(2)
4. Springs
Remove 16 springs (9).
a There are outer springs (large) and inner
springs (small). Only the outer springs (large)
are installed to 4 places a.
7. Discs and plates

Remove 3 discs (14) and 2 plates (15).
a The number of the discs includes the one
removed in step 6.
5. Brake piston
Using tool D1, supply compressed air to port PB
of the case to float and remove brake piston (10).
a When installing the cover, make match
marks on the brake piston and case so that
the dowel pin of the cover will not shift from
the dowel pin hole of the brake piston.
k If high-pressure air is supplied, the brake

piston jumps out. Accordingly, supply very
low-pressure air at first and check the
movement of the brake piston, and then
adjust the air pressure.
8. Cylinder block assembly

1) Place case (21) on its side.
2) Pull out cylinder block assembly (11).
a When removing the cylinder block
assembly, slant the case down a little so
that the internal parts (piston, retainer
holder, and pin) will not be left in the
case.
6. Collar
Using a puller, etc., remove collar (13).
a Remove 1 disc (14) so that you can remove
the collar easily.
30-62 PC160LC-7
(2)
3) Lift up retainer plate (17) and remove it and

piston (18) together from cylinder block (11).
4) Separate retainer plate (17) and piston (18).
9. Thrust plate
Remove thrust plate (19).
5) Remove retainer holder (16).
10. Shaft and case

6) Remove 3 pins (12). 1) Remove bearing inner race (20).
7) Press down collar (30) with a press, etc. and

remove snap ring (31).
8) Remove collar (30), spring (32), and collar
(33).
PC160LC-7 30-63
(2)
2) Turn over case (21) and set it on blocks. ASSEMBLY

3) Remove snap ring (22).
4) Press the end of shaft (23) with a press, etc. a Clean the all parts and check them for dirt or
to remove the shaft. damage.
a Coat the sliding surfaces of each part with
engine oil (EO10-CD).
1. Shaft and case

1) Using push tool [1], press fit bearing (25) to
shaft (23).
a Press fit the bearing until the end of its
inner race reaches the shoulder of the
shaft.
5) Remove bearing (25) from shaft (23).
2) Using push tool [2], press fit oil seal (24) to

case (21) as shown in the following figure.
a Press fit the oil seal until its end reaches
2 Lip surface of oil seal: Grease (G2-LI)

the case end.
6) Remove oil seal (24) from case (21).
30-64 PC160LC-7
(2)
3) Press the end of shaft (23) with a press, etc. 3. Cylinder block assembly
to press fit it to case (21). 1) Install collar (33), spring (32), and collar (30).
a Press fit the shaft until the end of the 2) Press down collar (30) with a press, etc., and
bearing outer race reaches the case end. install snap ring (31).
4) Install snap ring (22).
3) Install 3 pins (12).

5) Install inner race (20). a Apply grease (G2-LI) to the pins so that
they will not fall when the cylinder block
assembly is installed.
2. Thrust plate
Install thrust plate (19).
a Install the thrust plate with small hole side b 4) Install retainer holder (16).
up.
PC160LC-7 30-65
(2)
5) Install piston (18) to retainer plate (17). 4. Discs and plates

a Set chamfered periphery c of retainer Install 3 discs (14) and 2 plates (15) alternately.
plate (17) toward the cylinder block side. a When installing discs, set their wider no-
6) Install the retainer plate and piston assembly spline teeth sides d and narrower no-spline
to the cylinder block assembly (11). teeth sides e to each other respectively.
a Apply engine oil (EO10-CD) fully to the a The wider and narrower no-spline teeth sides
sliding surfaces of the piston and cylinder may be installed in any direction of the cylin-
block. der block.
7) Place case (21) on its side. 5. Collar
2 Periphery of O-ring: Grease (G2-LI)

8) Install cylinder block assembly (11) to the 1) Fit the O-ring to collar (13).
case.
a Take care that the piston will not come 2) Using push tool [3], press fit collar (13)
out of the cylinder block. evenly.
30-66 PC160LC-7
(2)
6. Brake piston

1) Fit the O-ring to brake piston (10).
2) Using push tool [4], press fit brake piston

(10) evenly.
a When press fitting the brake piston, align
the intermediate point between tap hole
(f) of the brake piston and dowel pin hole
(g) with the center of port (h) of the case
so that the dowel pin of the cover will be
aligned with the dowel pin hole of the
brake piston when the cover is installed
(in step 8). (Match the match marks
made when the brake piston was
removed.)

3) Fit the O-ring to the case. 8. Cover assembly
1) Using push tool [5], press fit bearing outer
race (8) to cover (2).
a Press fit the bearing outer race until its
end reaches the cover end.
7. Springs
Install 16 springs (9).
a There are outer springs (large) and inner
springs (small). Install only the outer springs
(large) to 4 places a.
PC160LC-7 30-67
(2)

2) Install 2 plugs (40). 6) Install cover assembly (2).
a When installing the cover assembly,
3 Plug: 46 ± 0.98 Nm {4.7 ± 0.1 kgm}
match the dowel pin on the cover side to
the dowel pin hole on the brake piston
3) Fit the backup ring and O-ring and install 2 side.
2 Periphery of backup ring and O-ring:

relief valve assemblys (7). a Do not apply an impact to the cover
assembly. If it is applied, the valve plate
3 Relief valve assembly:

Grease (G2-LI) may fall.
373 ± 20 Nm {38.0 ± 2.0 kgm}

4) Install 2 poppets (6), 2 springs (5), and plugs

(4).
3 Plug: 157 ± 10 Nm {16.0 ± 1.0 kgm}
3 Mounting bolt:
7) Tighten the mounting bolts.
294 ± 20 Nm {29.9 ± 2.0 kgm}
9. Reverse prevention valve assembly
3 Mounting bolt:
Install reverse prevention valve assembly (1).
5) Install valve plate (3).
a When installing the valve plate, set its cir- 32.4 ± 2.0 Nm {3.3 ± 0.2 kgm}
cularly grooved side toward the cover
and match the cut on its periphery to the
dowel pin.
a Apply grease (G2-LI) to the cover mount-
ing face so that the valve plate will not fall
when the cover assembly is installed.
30-68 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

OF CENTER SWIVEL JOINT
ASSEMBLY
REMOVAL

circuit. For details, see TESTING AND
hydraulic circuit.
a Put tags to the disconnected hoses and
tubes to prevent a mistake in re-connecting
them.
1. Disconnect 14 hoses (1) – (14).

a Hose (9) may be disconnected from the
swing motor.
• (1) : Between center swivel joint (Port DR)
and left travel motor (Port T)
and right travel motor (Port T)
• (3) : Between center swivel joint (Port B) and
right travel motor (Port PB)
• (4) : Between center swivel joint (Port D) and
left travel motor (Port PA)
• (5) : Between center swivel joint (Port A) and
right travel motor (Port PA)
• (6) : Between center swivel joint (Port C) and
left travel motor (Port PB)
• (7) : Between center swivel joint (Port E) and
left travel motor (Port P)
right travel motor (Port P)
and swing motor (Port DB)
solenoid valve
• (11) : Between center swivel joint (Port B) and
control valve right travel (Port B2)
• (12) : Between center swivel joint (Port D) and
control valve left travel (Port B3)
• (13) : Between center swivel joint (Port A) and
control valve right travel (Port A2)
• (14) : Between center swivel joint (Port C) and
control valve left travel (Port A3)
2. Remove pin (15).
PC160LC-7 30-69
(2)
3. Remove the 4 mounting bolts and lift off center INSTALLATION

swivel joint assembly (16). [*1]
4 Center swivel joint assembly: 40 kg
removal.
[*1]
a When installing center swivel joint assembly
(16), set ports B and D toward the front of the
machine (in the direction of the arrow). [(17)
in the following figure indicates the sprocket.]

• Bleeding air
30-70 PC160LC-7
(2)
DISASSEMBLY AND 3. Using tool E, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
ASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY 4. Remove seal (6) from swivel shaft (5).
SPECIAL TOOLS 5. Remove O-ring (7) and slipper seal (8) from
swivel rotor (4).
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
790-101-2501 Push puller q 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
E • 790-101-2540 • Washer 1
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
ASSEMBLY
DISASSEMBLY
1. Assemble slipper seal (8) and O-ring (7) to
swivel rotor (4).
2. Assemble seal (6) in swivel shaft (5).
3. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic hammer to
2 Contact surface of rotor, shaft:

install.
Grease (G2-LI)
a When installing the rotor, be extremely care-
ful not to damage the slipper seal and the O-
ring.
4. Install ring (3) and secure with snap ring (2).
3 Mounting bolt:
5. Fit O-ring and install cover (1).
31.4 ± 2.9Nm {3.2 ± 0.3 kgm}
2. Remove snap ring (2).
PC160LC-7 30-71
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

OF WORK EQUIPMENT
ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
796-900-1200 Remover t 1
R 790-101-4000
Puller
(490 kN {50t} long) t 1
790-101-1102
Pump
(294 kN {30t}) t 1
4. Start the engine and retract the piston rod.
a Fasten the piston rod with wire so that it will
REMOVAL not slip out and lower the cylinder onto a
k Except the arm and bucket fully. Lower the work

stand, or place a support under the bottom of
the cylinder to support it. In the latter case,
equipment to the ground and set the safety lock remove the grease fitting on the bottom side

lever to the lock position. first.
a Remove the bottom cylinder on the other
circuit. For details, see TESTING AND side in the same manner.
hydraulic circuit. 5. Disconnect 2 bucket cylinder hoses (6) and 2
arm cylinder hoses (7), two for each.
1. Disconnect grease hose (1). a Put tags to the disconnected hoses and
them.
a Put an oil stopper plug to each hose connect-
ing part and bind the hose with ropes, etc. so
that it will not be an obstacle to the work.
2. Sling boom cylinder assembly (2), and remove

lock bolt (3).
3. Remove plate (4), then remove head pin (5). [*1]

a There are shims installed, so check the num-
ber and thickness, and keep them in a safe
plate.
30-72 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
6. Disconnect connector A42 (8). 8. Lift work equipment assembly (11) and disas-
semble it.
4 Work equipment assembly: 2,700 kg
7. Lift off work equipment and remove plate (9) and

then pin (10) at the foot. [*2]
• When removing them, first remove plate (9)

and then remove pin (10) at the foot, using
tool R.
a Shims are installed, so do not forget to check
their number and each location of installa-
tion.
PC160LC-7 30-73
(2)
IINSTALLATION k When aligning the position of the pin hole,

never insert your fingers into the pin hole.
• Install in reverse order of removal. a Adjust clearance a between boom (14) and
frame (15) with shim (13) (Thickness: 2.0
[*1] mm) so that it will be less than 1 mm.
a When tightening the locknut, tighten so that • Thickness of standard shims: 2.0, 2.5,
clearance a between the plate and nut is 0.5 3.0 and 3.5 mm.
– 1.5 mm.
2 Inside surface of bushing when assem-

• Refilling with oil (hydraulic tank)
bling pin: Run the engine to circulate the oil through the
2 Grease after assembling pin:

Anti-friction compound (LM-P) system. Then check the oil level again.
Grease (LM-G) • Bleeding air
k When aligning the position of the pin hole,

never insert your fingers into the pin hole.
a Adjust the shim thickness so that clearance a

between cylinder rod (12) and plate (4) is
below 1.5 mm.
a Standard shim thickness: 1.0 mm and
2.0 mm.
2 Inside surface of bushing when assem-

[*2]
bling pin:
2 Grease after assembling pin:

Anti-friction compound (LM-P)
Grease (LM-G)
30-74 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL AND INSTALLATION 7. Remove plate (3) and pin (4) and lift off boom
cylinder assembly (2).
OF REVOLVING FRAME a Remove the boom cylinder on the opposite
ASSEMBLY side simultaneously.
4 Boom cylinder assembly: 130 kg
REMOVAL
1. Remove the work equipment assembly. For

details, see REMOVAL AND INSTALLATION OF
WORK EQUIPMENT.
2. Remove the counterweight assembly. For details,

see REMOVAL AND INSTALLATION OF COUN-
TERWEIGHT.
3. Remove the engine hood.
4. Remove the plate from the rear of the engine

compartment (between the engine compartment
and counterweight).
a Move or remove other parts which may inter- 8. Disconnect 6 hoses (5) – (10) above the swivel
fere with the sling of the revolving frame joint assembly.
assembly. a Put tags to the disconnected hoses and
5. Disconnect 4 hoses (1). them.
a For detail of the routes of the hoses, see
REMOVAL AND INSTALLATION OF SWIVEL
JOINT ASSEMBLY.
9. Pull out the pin on the center swivel joint side

and disconnect plate (11) from the swivel joint.
6. Sling boom cylinder assembly (2) temporarily.
PC160LC-7 30-75
(2)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
10. Remove the 32 mounting bolts and lift off revolv- INSTALLATION
ing frame assembly (12). [*1]
a Using a lever block, etc., balance the revolv- • Carry out installation in the reverse order to
ing frame assembly in longitudinal and lateral removal.
directions, and then remove the all mounting
2 Mating face of swing circle:

bolts, except the 2 each on the front and rear [*1]
k When removing the revolving frame assem-

sides.
bly, take care that it will not interfere with the 2 Threads of revolving frame mounting
center swivel joint assembly. bolt: Adhesive (LT-2)
4 Revolving frame assembly: 3,050 kg 3 Revolving frame mounting bolt:
1st time : 294.2 ± 29.4 Nm {30 ± 3kgm}
2nd time: Retighten by 60° or to
588 – 677 Nm {60 – 69 kgm}

• Bleeding air
30-76 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL AND INSTALLATION INSTALLATION

OF SWING CIRCLE ASSEMBLY • Carry out installation in the reverse order to
removal.
REMOVAL
2 Threads of swing circle mounting bolt:
[*1]
1. Remove the revolving frame assembly. For
3 Swing circle mounting bolt:

details, see REMOVAL AND INSTALLATION OF Adhesive (LT-2)
REVOLVING FRAME ASSEMBLY.
1st time : 191.2 ± 19.6 Nm {19.5 ± 2 kgm}
2. Remove 36 mounting bolts (1). [*1] 2nd time: Retighten by 48° ± 5°
(Angle tightening)
[*2]
a Set the soft zone (marked with S) of the inner
race on the right side of the machine. (The
2 Quantity of grease for circle:

arrow indicates the front of the machine.)
Grease (G2-LI), 14.6 l
3. Lift off swing circle assembly (2). [*2]

4 Swing circle assembly: 270 kg
PC160LC-7 30-77
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND INSTALLATION 5. Remove cover (4).
OF HYDRAULIC TANK
ASSEMBLY
REMOVAL
1. Drain oil from the hydraulic tank. [*1]
6. Disconnect connector A60 (5).
7. Remove handrail (6).
8. Move tool case assembly (7) forward.
3. Disconnect hose (2).
4. Remove clamp mounting bolt (3).
30-78 PC160LC-7
(2)
10. Remove cover (9) and plates (10) and (11). 14. Disconnect 7 hoses (16) – (22).
11. Remove the mounting bolts of oil filter bracket

(12) and frame (13).
12. Disconnect connector A61 (14).
13. Remove pipe and hose assembly (15). [*2]

a Prepare a container to receive oil.
15. Remove the undercover and 6 lower mounting

bolts and lift off hydraulic tank assembly (23).[*3]
4 Hydraulic tank assembly: 120 kg
PC160LC-7 30-79
(2)
INSTALLATION

removal.

[*1]
58.5 – 78.5 {5.97 – 8.0 kgm}
[*2]
a Tighten hose clamp screws (24) at 180° to
3 Hose clamp:90 ± 5 Nm {8.8 ± 0.5 kgm}

each other as shown below.
3 Mounting bolt:
[*3]
245.2 – 308.9 Nm {25 – 31.5 kgm}

Bleeding air
• Bleed air. For details, see TESTING AND
30-80 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL AND INSTALLATION 3. Disconnect the following hoses from the front of
the control valve.
OF CONTROL VALVE • (1) : Bucket cylinder (Head side)
ASSEMBLY • (2) : Bucket cylinder (Bottom side)
• (3) : Arm cylinder (Head side)
REMOVAL • (4): Arm cylinder (Bottom side)
• (5): Travel PPC valve
k Lower the work equipment to the ground and • (6): Travel PPC valve
stop the engine. Then, loosen the hydraulic oil • (7): Hydraulic tank
filler cap slowly to release the internal pressure • (8): Pump LS valve
of the hydraulic tank. • (9): Right travel motor
k Set the safety lock lever in the LOCK position.

• (10) : Right travel motor
• (11) : Left travel motor
a Put tags to the disconnected hoses and tubes to • (12): Left travel motor
prevent a mistake in re-connecting them. • (13): Swing motor
• The 7-spool valve specification (6-spool valve + • (14): Swing motor
service valve) without an attachment is explained
below.
1. Open the engine hood and remove cover (1).
2. Remove covers (2) and (3).
PC160LC-7 30-81
(4)
4. Disconnect the following hoses and wiring con- 5. Disconnect the following hoses and wiring con-
nector from the left of the control valve. nector from the right of the control valve.
• (15) : Bucket CURL PPC valve • (26) : Main pump
(Hose band: White) • (27) : Bucket DUMP PPC valve
• (16) : Arm IN PPC valve (Hose band: Blue) (Hose band: Black)
• (17) : Boom LOWER PPC valve • (28) : Arm OUT PPC valve (Hose band: Yellow)
(Hose band: Blown) • (29) : Boom RAISE PPC valve
• (18) : Boom cylinder (Head side) (Hose band: Green)
• (19) : Oil cooler • (30) : Boom cylinder (Bottom side)
• (20) : Pump merge-divider valve solenoid valve • (31) : Hydraulic tank
• (21) : Travel junction valve solenoid valve • (32) : 2-stage relief solenoid valve
• (22) : Left travel REVERSE PPC valve • (33) : Left travel FORWARD PPC valve
• (23) : Right travel REVERSE PPC valve (Hose band: Red)
(Hose band: Blue) • (34) : Right travel FORWARD PPC valve
• (24) : Swing RIGHT PPC valve (Hose band: Green)
• (25) : R pump pressure sensor connector A52 • (35) : Swing LEFT PPC valve
(Hose band: Red)
• (36) : Swing motor
• (37) : F pump pressure sensor connector A51
• (38) : Oil pressure pickup hose
(under pump merge-divider block)
30-82 PC160LC-7
(2)
7. Remove the 4 mounting bolts and lift off control

valve assembly (46).
4 Control valve assembly: 140 kg
6. Disconnect the following hoses from the rear of

the control valve.
• (39): Hydraulic tank
• (42): Main pump
• (43): Main pump
• (44): Oil pressure pickup hose
• (45): Boom RAISE PPC valve
PC160LC-7 30-83
(2)
INSTALLATION

removal.

• Bleeding air
30-84 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE

ASSEMBLY
a Only precautions for assembling the control valve assembly are described below.
a For the tightening torque of the control valve parts which are not shown in the following sectional view and
explanation, see STRUCTURE AND OPERATION, Maintenance standard, CONTROL VALVE.
ASSEMBLY
a When tightening plugs (1) and (2) shown in the

above figure, apply a drop (approx. 0.02 g) of
LOCTITE (No. 638) to each of their parts "a"
shown in the figure at right.
• Dimension a = 2 – 3 mm
3 Plugs (1) and (2):
14.7 – 19.6 Nm {1.5 – 2 kgm}
PC160LC-7 30-85
(2)
a Tighten the 4 combination nuts on the top of the

control valve in the following numerical order in 3
times.
a The arrow in the figure indicates the front of the
3 Combination nut:
machine.
1st time : 58.8 – 68.8 Nm {6 – 7 kgm}

2nd time : 78.5 – 88.3 Nm {8 – 9 kgm}
3rd time :
98.1 – 113 Nm {10 – 11.5 kgm}
a Tighten the 4 combination nuts on the underside

of the control valve in the following numerical
order in 3 times.
a The arrow in the figure indicates the front of the
3 Combination bolt:
machine.
1st time : 19.6 – 29.4 Nm {2 – 3 kgm}

2nd time : 39.2 – 49.0 Nm {4 – 5 kgm}
3rd time : 58.8 – 73.5 Nm {6 – 7.5 kgm}
30-86 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

OF HYDRAULIC PUMP
ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
796-460-1210 Oil stopper q 1
D
796-770-1320 Adapter q 1
REMOVAL 4. Remove plates (2) and (3) and covers (4) and

(5).

stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
a Put tags to the disconnected hoses and tubes to
prevent a mistake in re-connecting them.
1. Remove the hydraulic tank strainer. Using tool

D, stop oil from flowing out.
a When not using tool D, remove the drain plug
and drain oil from the hydraulic tank. [*1]

5. Disconnect connectors V21 (6) and A61 (7) and
remove the wiring harness clamp.
6. Disconnect hoses (8) and (9) and tube (10).

a Prepare a container to receive oil flowing out
of tube (10).
2. Drain oil from the damper case.
6 Damper case: 0.75 l
3. Lift off engine hood (1).

4 Engine hood: 40 kg
PC160LC-7 30-87
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
7. Disconnect hoses (11), (12), (13), and (14). INSTALLATION

8. Disconnect ground wire (15). • Carry out installation in the reverse order to
removal.

[*1]
58.5 – 78.5 Nm {5.9 - 8.0 kgm}
2 Hydraulic pump shaft spline:

[*2]
Lubricant containing molybdenum

disulfide (LM-G)
2 Mating face of hydraulic pump case:
• Refilling with oil (Damper case)

9. Lift off hydraulic pump assembly (16). [*2] a Add oil through the oil filler to the specified level.
4 Hydraulic pump assembly: 140 kg
5 Damper case: 0.75 l (EO30-CD)

• Bleeding air
30-88 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP INPUT SHAFT OIL SEAL
REMOVAL AND INSTALLA- INSTALLATION

TION OF HYDRAULIC PUMP • Carry out installation in the reverse order to
INPUT SHAFT OIL SEAL removal.
SPECIAL TOOLS [*1]

a Using tool N, press fit oil seal (3).
2 Lip and periphery of oil seal:
New/Remodel
Symbol
Necessity
Part No. Part name Grease (G2-LI)
Sketch
a Apply grease thinly to the periphery of the oil
Q'ty
seal.
791-463-1350 Push tool t 1
N
790-201-2740 Spacer t 1
REMOVAL
1. Remove the hydraulic pump assembly. For

details, see REMOVAL AND INSTALLATION OF
HYDRAULIC PUMP ASSEMBLY.
2. Remove snap ring (1) and spacer (2).
3. Pry off oil seal (3) with a screwdriver, etc. [*1]

a Take extreme care not to damage the shaft.
PC160LC-7 30-89
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
DISASSEMBLY AND ASSEM- a When installing pistons (10), apply grease (G2-
LI) to their outside and the inside of the valve
BLY OF WORK EQUIPMENT body holes.
PPC VALVE ASSEMBLY
a Tighten mounting bolts (16) of plates (14) and
DISASSEMBLY (15) (to be tightened together) to the following
torque.
3 Mounting bolt:
a Disassemble according to the following figure.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
ASSEMBLY
a Assemble according to the following figure. a Apply grease (G2 -LI) to the rocking parts of joint
a Only precautions for assembly are explained (17) and contact surfaces of disc (18) and pis-
below. tons (10) by the following quantity.
• Rocking part of joint: 2 – 4 ml/all round
• Contact parts of disc and pistons:
0.3 – 0.8 ml/1 part
a Install joint (17) to valve body (1) according to
the following procedure.
1) Degrease and dry the threads of the joint and
body thoroughly.
2) Apply 1 drop (approx. 0.02 g) of LOCTITE
(No. 262) each to the 2 parts of dimension a
from the end of the body screw hole.
• Dimension a : 5 – 7 mm
3) Tighten joint (17) to the following torque.

3 Joint: 39 – 49 Nm {4 – 5 kgm}
a Install springs (6) with the small-diameter (inside
diameter) end turns on the shims (5) side. a Tighten nut (19) to the following torque.
3 Nut: 69 – 88 Nm {7 – 9 kgm}
• Diameters of spring end turn (Inside diame-
ter)
Small diameter end turn : 4.9 mm
Large diameter end turn : 5.55 mm a Adjust the play of the lever. For details, see
TESTING AND ADJUSTING, Adjustment of work
a Springs (8) and (9) are used for different hydrau- equipment and swing PPC valve.
lic ports. When installing them, see the following
table.
a The position of each port is stamped on the
underside of valve body (1).
Position of
Spring Part No. Free length
port
P1, P2 (9) 702-16-53590 44.45 mm
P3, P4 (8) 702-16-53470 42.48 mm
30-90 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY AND ASSEM-

BLY OF TRAVEL PPC VALVE
ASSEMBLY
DISASSEMBLY
a Disassemble according to the figure at right.
ASSEMBLY
a Assemble according to the figure at right.

below.
a Install spring (11) with the small-diameter (inside

diameter) end turn on the shim (12) side.
• Diameters of spring end turn (Inside diame-
ter)
Small diameter end turn : 4.9 mm
Large diameter end turn: 5.55 mm
a When installing piston (8), apply grease (G2-LI)

to its outside and the inside of the valve body
hole.
a Apply 0.3 – 0.8 ml of grease (G2-LI) to the con-

tact surfaces of lever and piston (8).
a Install washers (4) by the thickness and quantity

checked when disassembled to the original posi-
tion.
a Tighten mounting bolts (3) to the following

torque.
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
a Tighten mounting bolts (1) to the following

torque.
3 Mounting bolt:
25 – 31 Nm {2.5 – 3.2 kgm}
PC160LC-7 30-91
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEM-

BLY OF HYDRAULIC CYLIN-
DER ASSEMBLY
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 790-502-1003 Cylinder repair stand t 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
4) Set piston rod assembly (2) to tool Q1.
796-720-1660
Ring
(for boom and bucket) q 1
4
07281-01159
Clamp
(for boom and bucket) q 1
796-720-1670 Ring (for arm) q 1

07281-01279 Clamp (for arm) q 1
790-201-1702 Push tool kit t 1
• 790-201-1821 • Push tool (for boom) 1
• 790-201-1940 • Push tool (for arm) 1
Q
5 • Push tool
• 790-201-1811 1
(for bucket)
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
790-201-1500 Push tool kit q 1
• 790-201-5021 • Grip 1 5) Remove piston assembly lock screw (3).
• 01010-50816 • Bolt 1 a If the screw is so caulked that you cannot
• 790-201-1630 • Plate (for boom) 1
remove it, tighten it temporarily and cut
6 the threads on it, and then remove it.
• 790-201-1620 • Plate (for bucket) 1
790-201-1980 Plate (for arm) q 1
790-201-5021 Grip q 1
01010-50816 Bolt q 1
DISASSEMBLY
a The following explanation is common to the

boom, arm, and bucket cylinders, unless other-
wise specified.
1. Piston rod assembly

1) Remove the piping from the cylinder assem-
bly.
2) Remove the mounting bolts and cylinder
head assembly (1).
3) Pull out piston rod assembly (2).
a Put a container under the cylinder to
receive oil.
30-92 PC160LC-7
(2)
6) Using tool Q2, remove piston assembly (4). 2. Disassembly of piston assembly
1) Remove rings (11), wear rings (12), and pis-
ton ring (13).
2) Remove the O-ring and backup rings (14).
7) Remove plunger (5) and collar (6).

a Perform this work for only the boom and
arm cylinders.
8) Remove cylinder head assembly (7). 3. Disassembly of cylinder head assembly
1) Remove the O-ring and backup ring (15).
2) Remove snap ring (16) and dust seal (17).
3) Remove rod packing (18), buffer ring (19),
and bushing (20).
9) Remove cap (8), 11 balls (9), and plunger

(10).
a Take care not to lose the balls.
a Perform this work for only the arm cylin-
der.
PC160LC-7 30-93
(2)
ASSEMBLY 2) Using tool Q4, install piston ring (13).
a The following explanation is common to the

boom, arm, and bucket cylinders, unless other-
wise specified.
a Take care not to damage the packings, dust
seals, O-rings, etc.
a Clean the all parts. After installing them, cover
the piping ports and pin holes to prevent dirt from
entering.
a Do not insert each backup ring forcibly, but warm
it in water at 50 – 60 °C and then insert it.
1. Assembly of cylinder head assembly

1) Using tool Q5, press fit bushing (20).
2) Install buffer ring (19) and rod packing (18). 3) Install backup rings (14) and O-ring.
3) Using tool Q6, install dust seal (17) and 4) Install wear rings (12).
secure it with snap ring (16). 5) Install rings (11).
4) Install backup ring (15) and O-ring. a Do not increase the closed gap of the
ring too much.
2 Ring groove: Grease (G2-LI)
3. Piston rod assembly

1) Set piston rod assembly (2) to tool Q1.
2. Assembly of piston assembly

1) Set piston ring (13) to tool Q3 and turn the
handle 8 – 10 times to expand the piston
ring.
30-94 PC160LC-7
(2)
2) Install cylinder head assembly (7).

3) Fit the O-ring and backup ring to collar (6),
and then install them.
arm cylinders.
4) Install plunger (5).
arm cylinders.
7) Tighten screw (3).

2 Threads of screw:
Adhesive (LOCTITE No. 262)
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
8) Caulk threaded part a by 4 places with a
5) Set plunger (10) to the piston rod. Install 11 punch.
balls (9) and secure them with cap (8).
a After installing the plunger, check that it
has a little play at its end.
a Perform this work for only the arm cylin-
der.
• When reusing the rod and piston assem-

bly, assemble them according to the fol-
lowing procedure.
a Clean the parts thoroughly and remove
metal chips, dirt, etc.
6) Tighten piston assembly (4). Then, using
tool Q2, tighten piston assembly (4) until the
screw holes are aligned.
a Remove the burrs from the threads with
a file.
PC160LC-7 30-95
(2)
• When replacing either or both of the rod and pis- 12) Tighten screw (3).
2 Threads of screw:
ton assembly (2), assemble the new parts
Adhesive (LOCTITE No. 262)
3 Screw:
a Make a mark of the cushion plug position on the
end of the rod having the bottom cushion. (Per-
form this work for only the arm cylinder.) 58.9 – 73.6 Nm {6 – 7.5 kgm}
9) Using tool Q2, tighten piston assembly (4) 13) Caulk the threaded part by 4 places with a
until it reaches end b of the rod. punch.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, check that
plunger (5) has some play.
arm cylinders.
14) Install piston rod assembly (2).

a Set the abutment joint of the ring at a
side and insert the piston rod, aligning it
with the cylinder tube.
a After inserting the piston rod, check that
the ring is not broken or removed, and
then insert to the end.
10) Make a screw hole to install screw (3).
a Apply a drill to the V-groove of the
threaded parts of piston (4) and rod (2)
and make a hole.
a When making a hole on the cylinder hav-
ing the bottom cushion, make it around
the cushion plug. (Perform this work for
only the arm cylinder.)
• Dimensions of screw hole (mm)
Tap drill Tap drill Tap to be Tapping
diameter hole depth used depth
10.3 27 12 x 1.75 20
11) After making the hole, remove all metal chips

and dirt.
30-96 PC160LC-7
(2)
15) Tighten the mounting bolts of cylinder head

assembly (1).
3 Mounting bolt:
Boom/Bucket cylinder:
270 ± 39.0 Nm {27.5 ± 4.0 kgm}
Bucket cylinder:
172 ± 24.5 Nm {17.5 ± 2.5 kgm}
16) Install the piping.

a Tighten the bolts to install the piping
band to the cylinder to the following
torque.
3 27.4 ± 6.9 Nm {2.8 ± 0.7 kgm}
PC160LC-7 30-97
(2)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

OF COUNTERWEIGHT
REMOVAL
1. Set eyebolts [1] to counterweight assembly (1)

and sling the counterweight assembly tempo-
rarily.
2. Remove 4 mounting bolts (2). [*1]
3. Lift off counterweight assembly (1).

a Take care not hit the counterweight against
3 Counterweight: 2,900 kg
the engine. [*2]
INSTALLATION

removal.
2 Threads of mounting bolt:

[*1]
Adhesive (LT-2)
3 Mounting bolt:
2,160 – 2,450 Nm {220 – 250 kgm}
[*2]
a Install the counterweight so that the clear-
ance between it and the revolving frame and
the clearance between it and exterior door
will be 10 ± 5 mm on each side.
30-98 PC160LC-7
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL AND INSTALLATION 3. Pull dowm outside air filler cover operating clos-
ing lever (2).
OF AIR CONDITIONER UNIT
ASSEMBLY
Serial No.: 10001 – 11000
SPECIAL TOOLS
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
799-703-1100 Vacuum pump (100V) t 1
S 799-703-1111 Vacuum pump (220V) t 1
799-703-1121 Vacuum pump (240V) t 1 4. Remove outside air filter (3).
REMOVAL
k First, disconnect the cable from the negative

terminal (–) of the battery.
k Collect the air conditioner gas (R134a).
1. Drain coolant.
6 Coolant: Approx. 18.6 l
2. Remove floor mat (1).

5. Remove monitor panel lower covers (4) and (5).
a When removing cover (4), first remove the
M19 wiring for cigarette lighter.
PC160LC-7 30-99
(4)
6. Remove dust (6). 11. Remove cover (15).
7. Remove covers (7), (8) and (9). 12. Disconnect cab intermediate connectors (18) at
the following two points.
• H09: Upper side
• H08: Lower sid
13. Disconnect radio antenne (19).
14. Remove plate (20) and then remove cover (21).
8. Remove duct (10).
9. Remove plate (11) and then remove duct (12).
10. Remove plate (13) and duct (14).
16. Disconnect connectors at the following seven

points.
• (23): D01
• (24): D02
• (25): C09
• (26): From top to bottom, M26, M27, M28
and M33.
17. Remove the mounting clamp and disconnect air

conditioner wiring connector (27).
30-100 PC160LC-7
(4)
18. Remove the four mounting bolts and remove INSTALLATION

governor pump control assembly (28).
a Put the governor pump control assenbly • Install in reverse order of removal.
aside. a Install hoses in the air conditioner circuit with
care so that dirt, dust, water, etc. may not enter
19. Remove cover (29). them.
a Install air conditioner hoses only after checking
that an O-ring is in place at the connecting part.
a Check that there is no damage on O-rings, or
that they have not deteriorated.
[*1]
a Coat the threads of the refrigerant piping at
the connecting part with compressor oil (ND-
OIL8), and then tighten the piping with a dou-
ble-ended spanner.
3 Hoses clamp screw:
8.83 – 14.7 Nm {0.9 – 1.5 kgm}
3 Hoses screw M16 x 1.5:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Hoses screw M24 x 1.5:
20. Disconnect air conditioner hoses (30) and (31)
as well as air conditioner tubes (32) and (33). [*1]
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
21. Remove the eight mounting bolts and remove air
conditioner unit assembly (34). • Filling air conditioner gas.
a When removing the air conditioner unit Fill the air conditioner circuit with air conditioner
assembly, do not forget to disconnect the two gas (R134a), using tool S.
air conditioner hoses connected to the bot-
tom.
PC160LC-7 30-101
(4)
Serial No.: 11001 and up 4. Remove duct (5), cover (6), and plate (7).
SPECIAL TOOLS 5. Remove plate (8) and duct (9).

a Remove the duct lock clip.
New/Remodel
6. Remove ducts (10) and (11).
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
799-703-1100 Vacuum pump (100V) t 1
S 799-703-1111 Vacuum pump (220V) t 1
799-703-1121 Vacuum pump (240V) t 1
REMOVAL

k Collect the air conditioner gas (R134a). 7. Disconnect connectors D01 (12), D02 (13), C09
(14), R22 (15), R20 (16), and K19 (17).
1. Swing the upper structure by 90°.
8. Remove and sling controller (18).
9. Remove plate (19).
3. Remove rear covers (1), (2), (3), and (4).
10. Disconnect air conditioner unit connectors M27
(20) and M33 (21).
30-101-1 PC160LC-7
(4)
11. Remove the air conditioner unit undercover. INSTALLATION

a Part A
removal.
a When installing the air conditioner circuit hoses,
take care that dirt, water, etc. will not enter them.
a When connecting each air conditioner hose,
check that the O-ring is fitted to the joint.
a Check that each O-ring is free from flaw and
deterioration.
[*1]
a Apply compressor oil (ND-OIL8) to the
threads of the refrigerant pipe joints and
tighten each nut with double spanner.
3 Hose clamp (M6 bolt):
12. Remove mounting bolt (24) and connector (25). 8 – 12 Nm {0.8 – 1.2 kgm}
[*1] 3 Hose screw of M16 x 1.5:
12 – 15 Nm {1.2 – 1.5 kgm}
3 Hose screw of M22 x 1.5:
13. Disconnect heater hoses (22) and (23) and air
conditioner tube (26). [*1]
a Put tags to the disconnected hoses and 20 – 25 Nm {2.0 – 2.5 kgm}
tubes to prevent a mistake in re-connecting 3 Hose screw of M24 x 1.5:
them. 30 – 35 Nm {3.0 – 3.5 kgm}
• Charging air conditioner with refrigerant gas

Using tool S, charge the air conditioner circuit
with refrigerant (R134a).
14. Remove the 7 mounting bolts and air conditioner

unit assembly (27).
PC160LC-7 30-101-2
(4)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB

OF OPERATOR'S CAB
Serial No.: 10001 – 11000
REMOVAL
k Disconnect the cable from the negative (-) ter-

1. Remove floor mat (1).
4. Disconnect cab wiring intermediate connectors

H10 (7), H11 (8), and H12 (9).
6. Remove plates (12) and (13).
2. Remove covers (2) and (3) under the monitor

panel.
a Before removing cover (2), disconnect ciga-
rette lighter connector M19.
7. Pull fresh air filter cover lever (14).
3. Remove rear covers (4), (5), and (6).
30-102 PC160LC-7
(4)
8. Remove fresh air filter (15).

9. Remove duct (16). (See the previous page.)
14. Disconnect windshield washer hose (23).
15. Remove step plate (24).

11. Disconnect 2 cab wiring intermediate connectors
(20). 16. Remove 5 mounting bolts (25) and 4 mounting
• H09: Upper side nuts (26).
• H08: Lower side a Check the length of the bolts.
12. Disconnect radio antenna (21).
PC160LC-7 30-103
(2)
17. Lift off operator's cab assembly (27).

4 Operator's cab assembly: 280 kg
INSTALLATION

removal.
30-104 PC160LC-7
(2)
Serial No.: 11001 and up 5. Remove air conditioner connector plate (14).
REMOVAL

1. Remove rear covers (1), (2), (3), and (4).
6. Disconnect connectors M71 (15), H10 (16), H11

(17), and H12 (18).
7. Disconnect upper and lower duct joints (19) and

(20).
8. Remove controller sub-plate (21) and incline it

2. Remove duct (5), cover (6), and plate (7). against the air conditioner.
3. Remove plate (8), duct (9) and the element.

a Remove the duct lock clip.
9. Remove cover (22) and floor mat (23).
4. Remove clip (10) and disconnect cab wiring con-

nectors M45 (11), H08 (12), and H09 (13).
PC160LC-7 30-104-1
(4)
10. Move right console (24) into the cab. 17. Take grommet (35) out of the right front of the
cab.
11. Remove monitor panel undercover (25).
18. Disconnect the windshield washer hose from
(36).
19. Remove 4 mounting bolts (37) and 5 mounting

bolts (38).
a Check the types of the bolts.
a In the initial period, 7 mounting bolts (38) are
used.
12. Disconnect cab wiring connector W04 (26)

(Wiper motor).

a Both (27) and (28) are 2 in number.
a Cut the tie-wrap on the monitor wiring har-
ness.
14. Remove cover (29) and monitor assembly (30). 20. Using lever block [1], lift off operator's cab
assembly (39).
4 Operator's cab assembly: 300 kg
15. Disconnect radio antenna (31).
16. Remove clip (32) and take wiring harness (33)

out of grommet (34).
30-104-2 PC160LC-7
(4)
21. When starting the engine while the operator's INSTALLATION

cab is removed (for transportation, etc.), use the
following brackets. • Carry out installation in the reverse order to
1) Bracket (41) for controller (40) removal.
Part No.: 208-53-13920
2) Bracket (42) for monitor panel assembly (30)

Part No.: 208-53-13910
PC160LC-7 30-104-3
(4)
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS

(STUCK GLASS)
* Among the panes of window glass on the 4 sides (1) : Right side window glass
of the operator's cab, 4 panes (1) – (4) are stuck. (2) : Left side rear window glass
In this section, the procedure for replacing the (3) : Door lower window glass
stuck glass is explained. (4) : Front window glass
When replacing front window glass (4), remove (5) : Front window assembly
front window assembly (5). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the (6) : Both-sided adhesive tape
front window assembly is installed to the opera- (16): Center trim seal
tor's cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
PC160LC-7 30-105
(2)
SPECIAL TOOLS (The figure shows the operator's cab of a

wheel loader.)
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 793-498-1210 Lifter (Suction cup) t 2
X
2 20Y-54-13180 Adapter t 2
REMOVAL
* Remove the window glass to be replaced

1. Using seal cutter [1], cut the adhesive between

broken window glass (7) and operator's cab a If the window glass is broken finely, it may be
(metal sheet) (8). removed with knife [4] and a screwdriver.
a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape with
knife [4].
(The figure shows the operator's cab of a

wheel loader.)
a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to cut 2. Remove the window glass.
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the fric-
tional heat, apply lubricant to it.
30-106 PC160LC-7
(2)
INSTALLATION (The figure shows the operator's cab of a wheel

loader.)
1. Using a knife and scraper [5], remove the
remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking sur-
faces) of the operator's cab.
a Remove the adhesive and both-sided adhe-
sive tape to a degree that they will not affect
adhesion of the new adhesive. Take care not
to scratch the painted surfaces. (If the
painted surfaces are scratched, adhesion will
be lowered.)
(The figure shows the operator's cab of a

wheel loader.)
3. Apply primer (10).

a The using limit of primer (10) is 4 months
after the date of manufacture. Do not use
primer (10) after this limit.
a Use the primer within 2 hours after unpack-
ing it.
a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
unpacked for the first time. (Discard the
primer 24 hours after it is packed.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a refrig-
2. Remove oil, dust, dirt, etc. from the sticking sur- erator, leave it at the room temperature
faces of cab (8) and window glass (9) with white for at least half a day before stirring it. (If
gasoline. the primer is unpacked just after taken
a If the sticking surfaces are not cleaned well, out of the refrigerator, water will be con-
the glass may not be stuck perfectly. densed. Accordingly, leave the primer at
a Clean the all black part on the back side of the room temperature for a sufficient
the window glass. time.)
a After cleaning the sticking surfaces, leave 2) When reusing primer brush (11), wash it in
them for at least 5 minutes to dry. white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer glass primer.
PC160LC-7 30-107
(2)
3) Evenly apply paint primer to the surfaces to a In addition to the above parts, apply the
stick both-sided adhesive tapes and the sur- primer to right side window glass (1) and
faces out of those surfaces on operator's cab door lower window glass (3).
(8) which will be coated with the adhesive. • Range to apply primer additionally for right
2 Paint primer:
side window glass (1): (b)
• Range to apply primer additionally for door
SUNSTAR PAINT PRIMER 580
lower window glass (3): (c)
SUPER or equivalent
a After applying the primer, leave it for at least
a Do not apply the primer more than 2
5 minutes (within 8 hours) to dry.
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Parts to be coated with primer: Apply the

primer all over dimension (a).
• Dimension to apply primer (a): 25 mm
a Never apply wrong primer. If the glass primer

is applied by mistake, wipe it off with white
gasoline.
30-108 PC160LC-7
(2)
4) Evenly apply glass primer to the sticking sur- 4. Stick both-sided adhesive tape (6) along the
2 Glass primer:
faces of window glass (9). inside edge of the glass sticking section.
a Do not remove the release tape of the both-
SUNSTAR GLASS PRIMER 580 sided adhesive tape on the glass sticking
SUPER or equivalent side before sticking the glass.
a Do not apply the primer more than 2 a When sticking the both-sided adhesive tape,
times. (If it is applied more than 2 times, do not touch the cleaned surface as long as
its performance will be lowered.) possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
a Parts to be coated with primer: Apply the

primer to the sticking surfaces of window
glass (9) and all over dimension (d) a When sticking both-sided adhesive tape (6)
which will be on both-sided adhesive around a frame, do not lap its finishing end
tape (6) and operator's cab (8). over the starting end but make clearance e of
a Do not apply the primer to the boarder about 5 mm between them.
about 5 mm wide between the black part 1) Stick both-sided adhesive tape (6) for right
and transparent part of the glass. side window glass (1) as shown in the figure.
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
PC160LC-7 30-109
(2)
a Stick both-sided adhesive tape (6a) addi- 3) Stick both-sided adhesive tape (6) for door
tionally for right side window glass (1). lower window glass (3) as shown in the fig-
• Positions to stick additional both-sided ure.
adhesive tape for right side window
glass:
(f) : 50 mm
(g) : 90 mm
(h) : 250 mm
a Stick both-sided adhesive tape (6b) addi-

tionally for door lower window glass (3).
a Positions to stick additional both-sided
adhesive tape for door lower window
glass:
2) Stick both-sided adhesive tape (6) for left (j) : 110 mm
side rear window glass (2) as shown in the (k) : 90 mm
figure. (m) : 200 mm
30-110 PC160LC-7
(2)
4) Stick both-sided adhesive tape (6) for front 5. Position the new window glass.
window glass (4) as shown in the figure. 1) Check the clearance between the window
glass and the operator's cab on the right, left,
upper, and lower sides, and then adjust it
evenly.
2) Stick tapes [6] between window glass (9) and
operator's cab (8) and draw positioning line
n.
a Stick tapes [6] to the right, left, and lower
parts of the right side window glass, left
side rear window glass, and door lower
window glass for accurate positioning.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, and then
remove the window glass.
a Do not remove the tapes left on the win-
a Stick both-sided adhesive tape (6c) of dow glass and operator's cab before
the lower side of the front window glass installing the window glass.
along the outside edge of the lower line,
differently from other both-sided adhe-
sive tapes (6). (If it is stuck along the
inside, it will be seen through the trans-
parent part of the glass.)
PC160LC-7 30-111
(2)
a When positioning front window glass (4), 2) Cut the tip of the adhesive nozzle (14) so
set its horizontal position to the frame that dimensions (q) and (r) will be as follows.
width and set its vertical position so that • Dimension (q) : 10 mm
height difference (p) between it and the • Dimension (r) : 15 mm
frame top will be 3 mm.
3) Set adhesive cartridge (12) to caulking gun

6. Apply adhesive. [7].
a Use either of the 2 types of the adhesive. a An electric caulking gun is more efficient.
2 Adhesive (Summer):
SUNSTAR PENGUINE SEAL 580
2 Adhesive (Winter):
SUPER "S"

SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use the
adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of 4) Remove the release tape of the both-sided
adhesive cartridge (12) and install the noz- adhesive tape on the glass side.
zle.
30-112 PC160LC-7
(2)
5) Apply adhesive (15) to the outside of both- a Apply adhesive (15) additionally for addi-
sided adhesive tape (6) of the operator's cab. tional both-sided adhesive tape (6a) of
the right side window glass and addi-
tional both-sided adhesive tape (6b) of
door lower window glass.
a Apply adhesive (15) to dimensions (s)

and (t) of both-sided adhesive tape (6) of
operator's cab (8).
• Dimension (s) : 10 mm
• Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (6).
a Apply the adhesive evenly.
PC160LC-7 30-113
(2)
7. Install the window glass. a After installing front window glass (4), fill
1) Install window glass (9), matching it to the the clearances between it and center trim
lines of the positioning tapes drawn in step 5. seal (16) with caulking material in range
a Since the window glass cannot be (s) to dimensions (t) and (u).
removed and stuck again, stick it very After applying the primer to glass (4) of
carefully. section A – A, apply adhesive as caulk-
a Stick the glass within 5 minutes after ing material.
applying the adhesive. • Caulking dimension (t) : 2 mm
2) After sticking window glass (9), press all • Caulking dimension (u): 5 mm
around it until it is stuck to the both-sided a When caulking, mask the glass side and
adhesive tape. form the adhesive with a rubber spatula
a Press the corners of the window glass as shown in the figure.
firmly. a Wipe off projected adhesive.
2 Glass primer:
SUNSTAR GLASS PRIMER 580
2 Adhesive:
SUPER

SUPER "S" or "W"
a You can perform this work efficiently by

pulling window glass (9) from inside of
the operator's cab with suction cup X1.
30-114 PC160LC-7
(2)
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right window glass (1) to the primer and adhesive from the operator's cab and
operator's cab, insert stopper rubbers X2 to 2 window glass.
places (v) at the bottom of the glass to fix the a Using white gasoline, wipe off the adhesive
glass. before it is dried up.
a When cleaning the glass, do not give an
impact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humidity
of 60%).
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape to fit them completely.
PC160LC-7 30-115
(2)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
REMOVAL AND INSTALLATION 7. Remove rollers (8) and (9) under the both sides
of the front window.
OF FRONT WINDOW
ASSEMBLY
stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor's cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.
REMOVAL
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
2. Remove left corner blocks (1) and (2) and right

corner block (3). [*1]
3. Remove left striker bolt (4), right striker bolt (5),

left corner block bracket, and right corner block
bracket (7). [*2]
4. Install left striker bolt (4) to the operator's cab

again and tighten it lightly.
a This bolt will be used to hang the pull-up
assist cable in step 8.
8. Remove left lower pin (10). [*3]

a If left lower pin (10) is removed, plate (12) at
the end of pull-up assist cable (11) comes
off.
a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is applied

to the rear of the operator's cab. Accord-
ingly, take care when removing left lower
pin (10) to disconnect pull-up assist cable
(11).
5. Release the rear locks.
6. Lower the front window assembly carefully a lit-

tle. Put out rollers (8) and (9) under the both
sides of the front window through the portion
from which the corner blocks were removed in
step 3 (the portion where the rail is open) and
hold them.
30-116 PC160LC-7
(4)
11. Twist front window assembly (13) to the right and

left to remove both upper rollers (14) and (15)
from the rails, and then remove front window
assembly (13).
9. Put out the bottom of front window assembly (13)

through the rail opening portion and lower it
gradually.
10. Lower front window assembly (13) completely.

a Do not let the front window assembly touch
the monitor.
PC160LC-7 30-117
(4)
INSTALLATION 4. Install right corner block (3) and fix right corner
block bracket (7) with right striker bolt (5).
• Carry out installation in the reverse order to a Tighten the striker bolt securely after adjust-
removal. ing it in step 6.
a Install the right corner block so that there will
[*1] [*2] be no level difference at part a.
• Adjust opening and closing of the front window a Install the right corner block so that level dif-
assembly according to the following procedure. ference b between the rail and right corner
block (3) at part PF will be 0 – 1.0 mm.
1. Open and close the front window to check that it Check that the right corner block is not pro-
does not interfere with the rails and the rollers jected from the rail at the rolling surface of
are not hitch. the roller.
a Secure roller clearance c at part PJ.
2. If there is any problem in opening or closing of
the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and then
tighten the mounting bolts again.
3 Mounting bolt: 98 Nm {1.0 kgm}
3. Raise the front window assembly and fix it with

the rear locks (on both sides).
a Check that the locks in the rear of the opera-
tor's cab are applied securely.
30-118 PC160LC-7
(4)
5. Install left corner blocks (1) and (2) and secure 6. Adjust the striker bolts according to the following
left corner bracket (6) with left striker bolt (4). procedure (Adjust the "CLOSE" positions of the
a Tighten the striker bolt securely after adjust- front window assembly locks).
ing it in step 6. 1) Tighten left striker bolt (4) and right striker
a Install the left corner blocks so that there will bolt (5) at roughly right positions so that front
be no level difference at 2 part d. window glass (18) will be fitted to cab-side
a Secure roller clearance e. trim seal (19).
PC160LC-7 30-119
(4)
2) Open and close the front window assembly

and check the working condition of both
locks (20) and (21).
i) If both locks do not work normally, move
the striker bolts toward the rear of the
cab and tighten them again.
ii) After moving the striker bolts, check the
fitness of the front window glass and cab-
side trim seal which was checked in step
1).
iii) Repeat the work in i) and ii) until the fit-
ness of the front window and the working
condition of both locks (20) and (21) are
acceptable, and then tighten the striker
bolts.
7. After adjusting the striker bolts, splash water 9. Adjust the front window stoppers.
heavily over the front window glass and check 1) After adjusting "closing" lock of the front win-
that the water does not leak into the cab. dow assembly in step 8, check the contact of
both front window stoppers (23).
8. Adjust the "opening" lock of the front window 2) If both stoppers (23) do not contact normally,
assembly. adjust and fix them at places where they con-
1) After adjusting the "closing" lock of the front tact normally.
window in steps 6 and 7, raise the front win-
dow assembly to the ceiling.
2) Set the right and left front window assembly
locks at the rear of the operator's cab to the
"OPEN" positions, and then check the follow-
ing items.
• Check that right and left locks (20) and
(21) are closed normally.
• Check that right and left locks (20) and
(21) are inserted in parallel in right and
left striker plates (22).
• Check that right and left rubber stoppers
(24) are in contact with the front window
assembly and their deflection allowance
is 1.5 – 3.0 mm.
3) After checking the above items, if necessary,
adjust them by moving right and left striker
plates (22) at the rear of the operator's cab.
30-120 PC160LC-7
(4)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW, MONITOR
10. Check the latching effort of the front window REMOVAL AND INSTALLATION
assembly.
1) After finishing steps 6 – 9, check that latching OF MONITOR ASSEMBLY
efforts of both locks (20) and (21) are even.
a Check the latching efforts on both "clos- REMOVAL
ing" side (in the front of the operator's k First, disconnect the cable from the negative
cab) and "opening" side (in the rear of terminal (–) of the battery.
the operator's cab).
1. Remove cover (1) and then disconnect the wiring
connector P15 for air conditioner sunlight sensor
(2).
a Lift the cover up to remove it.
2. Remove the three mounting screws and remove
monitor assembly (3).
a Disconnect monitor panel wiring connectors
P01, P02 and P03 at the three points, and
then remove the monitor assembly.
[*3]
3 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
INSTALLATION
• Install in reverse order of removal.
PC160LC-7 30-121
(4)
DISASSEMBLY AND ASSEMBLY GOVERNOR, PUMP CONTROLLER
REMOVAL AND INSTALLATION OF GOVERNOR, PUMP

CONTROLLER ASSEMBLY
Serial No.: 10001 – 11000 Serial No.: 11001 and up
REMOVAL REMOVAL
k First, disconnect the cable from the negative k First, disconnect the cable from the negative
terminal (–) of the battery. terminal (–) of the battery.
1. Remove cover (1). 1. Remove covers (1), (2) and (3).
2. Disconnect governor, pump controller wiring con- 2. Disconnect governor, pump controller wiring con-
nectors C01 (2), C02 (3) and C03 (4). nectors C01 (4), C02 (5) and C03 (6).
3. Remove the four mounting bolts and remove 3. Remove the four mounting bolts and remove
governor, pump controller assembly (5). governor, pump controller assembly (7).
INSTALLATION INSTALLATION
• Install in reverse order of removal. • Install in reverse order of removal.
30-122 PC160LC-7
(4)
90 OTHERS
Hydraulic circuit diagram............................................... 90- 3

Serial No.: 10001 – 11000
Electrical circuit diagram (1/4)..................................... 90- 5
Electrical circuit diagram (4/4)......................................90-11
Electrical circuit diagram (1/4)..................................... 90-13
PC160LC-7 90-1
(4)
HYDRAULIC CIRCUIT DIAGRAM
PC160LC-7 90-3
ELECTRICAL CIRCUIT DIAGRAM (1/4)
Serial No.: 10001 – 11000
PC160LC-7 90-5
(4)
Serial No.: 10001 – 11000
PC160LC-7 90-7
(4)
Serial No.: 10001 – 11000
PC160LC-7 90-9
(4)
Serial No.: 10001 – 11000
PC160LC-7 90-11
(4)
PC160LC-7 90-13
(4)
PC160LC-7 90-15
(4)
PC160LC-7 90-17
(4)
PC160LC-7 90-19
(4)

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SEBM028606

MACHINE MODEL SERIAL NUMBER

PC160LC-7 10001 and up

• PC160LC-7 mount the SAA4D102E-2 engine.

10 STRUCTURE, FUNCTION AND

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

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

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

k Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

! The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

METHOD OF USING THE CONVERSION TABLE

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

Liter to U.S. Gallon