Professional Documents
Culture Documents
PW160-7H
MACHINE MODEL SERIAL NUMBER
PW160-7H 00 H50051 AND UP 00
q This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local Komatsu distributor for those items you may require.
For details of the engine, see the 102 Series Engine Shop Manual.
2006
All Rights Reserved 00-1
Printed in Germany
CONTENTS
No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
90 OTHERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00
00-2
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation. Some
of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possi-
bly arise, first consider safety, and take the necessary actions to deal with the situation.
Mistakes in operation are extremely dangerous. Read 1. Before adding oil or making repairs, park the
the OPERATION & MAINTENANCE MANUAL carefully machine on hard, level ground, and block the
BEFORE operating the machine. wheels or tracks to prevent the machine from mov-
ing.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are 2. Before starting work, lower blade, ripper, bucket or
fixed to the machine. any other work equipment to the ground. If this is
not possible, insert the safety pin or use blocks to
2. When carrying out any operation, always wear prevent the work equipment from falling. In addi-
safety shoes and helmet. Do not wear loose work tion, be sure to lock all the control levers and hang
clothes, or clothes with buttons missing. warning signs on them.
Always wear safety glasses when hitting parts with a
hammer. 3. When disassembling or assembling, support the
Always wear safety glasses when grinding parts with machine with blocks, jacks or stands before start-
a grinder, etc. ing work.
PW160-7H
PW160-7H 00-3
FOREWORD SAFETY
2. The water and oil in the circuits are hot when the 13. When measuring hydraulic pressure, check that
engine is stopped, so be careful not to get burned. the measuring tool is correctly assembled before
Wait for the oil and water to cool before carrying taking any measurements.
out any work on the oil or water circuits.
14. Take care when removing or installing the tracks of
3. Before starting work, remove the leads from the track-type machines. When removing the track, the
battery. ALWAYS remove the lead from the nega- track separates suddenly, so never let anyone
tive (-) terminal first. stand at either end of the track.
00-4 PW160-7H
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu-
rate understanding of the product and by showing him the correct way to perform repairs and make judgements.
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 work-
shop. For ease of understanding, the manual is divided into the following sections. These sections are further
divided into each main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel,
coolant and lubricant specification charts.
This section explains the structure and function of each component. It serves not only to give an understanding
of the structure, but also serves as reference material for troubleshooting.
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 to Causes are
also included in this section.
This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
Shop manuals are issued as a guide to carrying out When a manual is revised, an edition mark (123) is
repairs. They are divided as follows: recorded on the bottom outside corner of the pages.
Electrical volume: Each issued as one to cover all Revised pages are shown at the LIST OF REVISED
models PAGES between the title page and SAFETY page.
Attachment volume:Each issued as one to cover all
models
SYMBOLS 00
10-5
PW160-7H 00-6
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
2. Sling wire ropes from the middle portion of the
hook. Slinging near the edge of the hook may
WARNING! Heavy parts (25 kg or more) cause the rope to slip off the hook during hoisting,
must be lifted with a hoist etc. and a serious accident can result. Hooks have
In the DISASSEMBLY AND maximum strength at the middle portion.
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol
If a part cannot be smoothly removed from the 100% 88% 79% 71% 41%
machine by hoisting, the following checks should be SAD00479
made:
1. Check for removal of all bolts fastening the part to
the relative parts. 3. Do not sling a heavy load with one rope alone, but
2. Check for existence of another part causing inter- sling with two or more ropes symmetrically wound
face with the part to be removed. on to the load.
WIRE ROPES 00
00-7 PW160-7H
FOREWORD PUSH-PULL TYPE COUPLERS
12
PUSH-PULL TYPE COUPLERS 00
There are 2 types of push-pull type couplers. The so see the table below when connecting and disconnect-
method of connecting and disconnecting are different, ing the coupler.
Type 1 Type 2
1. Hold the mouthpiece of the tightening portion. 1. Hold the mouthpiece of the tightening portion. Push
Push the body (2) in straight until the sliding pre- the body (2) in straight until the sliding prevention
vention ring (1) contacts the surface (a) of the ring (1) contacts the surface (a) of the hexagonal por-
hexagonal portion at the male end. tion at the male end.
2. Hold in the condition in Step 1. Push in until the 2. Hold in the condition in Step 1. Turn lever (4)
cover (3) contacts the surface (a) of the hexago- clockwise.
nal portion at the male end.
Disconnecting
3. Hold in the condition in Steps 1 and 2. Pull out 3. Hold in the condition in Steps 1 and 2. Pull out
entire body (2) to disconnect it. entire body (2) to disconnect it.
PW160-7H 00-8
FOREWORD PUSH-PULL TYPE COUPLERS
Type 1 Type 2
Hold the mouthpiece of the tightening portion. Hold the mouthpiece of the tightening portion.
Push body (2) in straight until sliding prevention Push body (2) in straight until sliding prevention
ring (1) contacts the contact surface (a) of the hex- ring (1) contacts the contact surface (a) of the hex-
agonal portion at the male end to connect it. agonal portion at the male end to connect it.
Connection
00-9 PW160-7H
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs 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 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive Used as adhesive or sealant for metal,
LT-3 Hardening Can
and hardening glass or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g Used as sealant for machined holes.
container
Holtz Used as heat-resisting sealant for repair-
790-126-9120 75 g Tube
MH 705 ing engine.
Quick hardening type adhesive.
Three
Polyethylene Cure time: within 5 sec. to 3 min.
bond 179-129-9140 50 g
container Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
Quick hardening type adhesive.
Aron- Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 2g minutes).
container
201 Used mainly for adhesion of rubbers,
plastics and metals.
Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc Used at joint portions subject to high
648-50 container
temperature.
Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
Features: Resistance to heat
Used as sealant for flange surfaces and
sealant
Gasket
PW160-7H 00-10
FOREWORD COATING MATERIALS
heat, cold.
Used as sealant for flange surface,
LG-6 09940-00011 250 g Tube
thread.
Used as sealant for oil pan, final drive
case, etc.
Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat hous-
ing, etc.
Three
Used as heat-resisting sealant for repair-
bond 790-129-9090 100 g Tube
ing engines.
1211
Used as lubricant for sliding parts (to pre-
LM-G 09940-00051 60 g Can
Molybdenum
vent squeaking).
disulphide
lubricant
SYG2-160CA steam.
SYG2-160CNCA
disulphide lubricant
400 g
Molybdenum
SYG2-400M (10 per Belows type Used for places with heavy load.
case)
00-11 PW160-7H
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY
AND ASSEMBLY.
mm mm Nm kgm
6 10 13.2 1.4 1.35 0.15
8 13 31.4 2.9 3.20 0.3
10 17 65.7 6.8 6.70 0.7
12 19 112 9.8 11.5 1.0
14 22 177 19 18 2.0
16 24 279 29 28.5 3
18 27 383 39 39 4
20 30 549 58 56 6
22 32 745 78 76 8
24 36 927 98 94.5 10
27 41 1320 140 135 15
30 46 1720 190 175 20
33 50 2210 240 225 25
36 55 2750 290 280 30
39 60 3280 340 335 35
mm mm Nm kgm
6 10 7.85 1.95 0.8 0.2
8 13 18.6 4.9 1.9 0.5
10 14 40.2 5.9 4.1 0.6
12 27 82.35 7.85 8.4 0.8
PW160-7H 00-12
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00
SAD00483
00-13 PW160-7H
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLTS AND NUTS) 00
Use these torque values for bolts and nuts (unit: mm).
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
mm Nm kgm
6 82 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
inch Nm kgm
1 60 9 6.12 0.92
PW160-7H 00-14
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
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: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of Cross sec- Applicable circuit
number (mm) rating (A)
strands strand (mm) tion (mm)
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
Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color
Red White White Red White White
Code WB BY RB YB GR LR
3 White & Black & Red & Yellow & Green &
Color Blue & Red
Black Yellow Black Black Red
Code WL BR RY YG GY LY
Auxiliary
4 White & Black & Red & Yel- Yellow & Green & Blue & Yel-
Color
Blue Red low Green Yellow low
Code WG RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color
Green Green Blue Black Black
Code RL YW GL
6 Yellow & Green &
Color Red & Blue
White Blue
00-15 PW160-7H
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
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.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
2
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
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
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
PW160-7H 00-16
FOREWORD CONVERSION TABLES
12
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
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 PW160-7H
FOREWORD CONVERSION TABLES
12
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
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
PW160-7H 00-18
FOREWORD CONVERSION TABLES
12
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 1352.63 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 PW160-7H
FOREWORD CONVERSION TABLES
12
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 19324 1949 1963 1977
140 1991 2005 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
PW160-7H 00-20
FOREWORD CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vise versa is to enter the accompanying table in the center or boldface column 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 Fahr-
enheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahren-
heit temperature on the right.
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
00-21 PW160-7H
FOREWORD UNITS
12
UNITS 00
In this manual, the measuring units are indicated with International 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}
PW160-7H 00-22
01 GENERAL
PW160-7H 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
1 PIECE BOOM
01-2 PW160-7H
GENERAL DIMENSIONS
DIMENSIONS
2 PIECE BOOM
PW160-7H 01-3
GENERAL WORKING RANGES
WORKING RANGES
1 PIECE BOOM
01-4 PW160-7H
GENERAL WORKING RANGES
2 PIECE BOOM
PW160-7H 01-5
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
PW160-7H
Machine model
01-6 PW160-7H
GENERAL SPECIFICATIONS
12
Machine model PW160-7H
Serial Number H50051 and up
Model SAA4D102E-2
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 4 - 102 x 120
Piston displacement l {cc} 3.9 {3900}
Performance
Type x No.
valve
Control
method 2 Piece Boom 8-spool + 1 service spool type x 1 Hydraulic
Hydraulic
PW160-7H 01-7
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
This weight table is for use when handling components or when transporting the machine.
Unit: kg
Machine model PW160-7H
Serial Number H50051 and up
Engine assembly 453.5
Engine 338
Damper 1.5
Hydraulic pump 114
Radiator oil cooler assembly 90
Hydraulic tank, filter assembly (excluding hydraulic oil) 123
Fuel tank (excluding fuel) 120
Revolving frame 1,620
Operators cab 286
Mechanical 38
Operators seat
Air Suspension 42
Counterweight 3,100
Swing machinery 170
Control valve 107
Travel motor 66
Center swivel joint 95
01-8 PW160-7H
GENERAL WEIGHT TABLE
12
1 PIECE BOOM
Unit: kg
Machine model PW160-7H
Serial Number H50051 and up
Boom assembly 980
2.1m 291
Arm assembly 2.5m 328
3.0m 442
Bucket assembly 460
Left Hand 135
Lift cylinder
Right Hand 135
Arm cylinder assembly 140
2.1m
Bucket cylinder 2.5m 90
assembly
3.0m
Link / pins assembly 112.8
Boom pin 20+12
Arm pin 12
PW160-7H 01-9
GENERAL WEIGHT TABLE
12
2 PIECE BOOM
Unit: kg
Machine model PW160-7H
Serial Number H50051 and up
1st Boom 470
Boom assembly
2nd Boom 684
2.1m 291
Arm assembly 2.5m 328
3.0m 442
Bucket assembly 460
Left Hand 128
Lift cylinder
Right Hand 128
Adjust cylinder 195
Arm cylinder assembly 215.4
2.1m
Bucket cylinder 2.5m 90
assembly
3.0m
Link / pins assembly 112.8
1st Boom 26.5
Boom pin
2nd Boom 26
Arm pin 12
01-10 PW160-7H
GENERAL FUEL, COOLANT AND LUBRICANTS
12
FUEL, COOLANT AND LUBRICANTS
SAE 30
SAE 10W
Engine oil pan 16 16
SAE 10W-30
SAE 15W-40
Engine
oil
Swing machinery case SAE 30 4.5 4.5
SAE 10W
SAE 10W-30
Hydraulic system 160 120
SAE 15W-40
Hydraulic
H046-HM (H)
oil
Front 11.5
Axles
Fuchs titan hydra 20W-40
Rear 9.5
Multi oil
Transmission + clutch BP traction 8 4.85 4.85
PW160-7H 01-11
GENERAL FUEL, COOLANT AND LUBRICANTS
01-12 PW160-7H
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Engine Related Parts . . . . . . . . . . . . . . . . . . . . . 10-2 CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Radiator Oil Cooler Charge air cooler . . . . . . 10-3 Centre Swivel Joint . . . . . . . . . . . . . . . . . . . . 10-102
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Travel PPC Pedal . . . . . . . . . . . . . . . . . . . . . 10-103
Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Work Equipment Swing PPC Valve . . . . . . 10-106
Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Service PPC Pedal . . . . . . . . . . . . . . . . . . . . 10-110
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Solenoid Valve Manifold . . . . . . . . . . . . . . . . 10-113
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Boom Safety Valve . . . . . . . . . . . . . . . . . . . . 10-122
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Hydraulic Cylinder (Boom-Arm-Bucket) . . . . 10-124
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 Outrigger Cylinder. . . . . . . . . . . . . . . . . . . . . 10-126
Clutch Control Circuit . . . . . . . . . . . . . . . . . . . . 10-27 Dozer Cylinder . . . . . . . . . . . . . . . . . . . . . . . 10-128
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 Work Equipment . . . . . . . . . . . . . . . . . . . . . . 10-130
Suspension Lock Cylinder . . . . . . . . . . . . . . . . 10-34 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . 10-134
Braking System . . . . . . . . . . . . . . . . . . . . . . . . 10-36 Electrical Wiring Diagram . . . . . . . . . . . . . . . 10-135
Brake/Steer Pump . . . . . . . . . . . . . . . . . . . . . . 10-38 Engine Control System . . . . . . . . . . . . . . . . . 10-136
Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 Electronic control System . . . . . . . . . . . . . . . 10-142
Power Brake Valve . . . . . . . . . . . . . . . . . . . . . 10-40 Machine Monitor System . . . . . . . . . . . . . . . 10-168
Accumulator for Brake System . . . . . . . . . . . . 10-42 Overload Warning Device . . . . . . . . . . . . . . . 10-196
Steering Train . . . . . . . . . . . . . . . . . . . . . . . . . 10-43 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
Steering Column . . . . . . . . . . . . . . . . . . . . . . . 10-44 1st Attachment Cicuit Hydraulic Perfomance
Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 (Main Valve Bypassed) . . . . . . . . . . . . . . . . . 10-204
Hydraulic Layout Drawing . . . . . . . . . . . . . . . . 10-46 Travel System . . . . . . . . . . . . . . . . . . . . . . . . 10-206
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . 10-48 Steering System . . . . . . . . . . . . . . . . . . . . . . 10-228
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 Service Brake and Suspension System . . . . 10-241
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . 10-50
Pilot Pressure Control System . . . . . . . . . . . . . 10-71
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
PW160-7H 10-1
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTS
1 2
7 6 5
10-2 PW160-7H
RADIATOR OIL COOLER CHARGE AIR
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD COOLER
10
8
12
14 6
4 3 2
13 7 11 1
1. Reservoir tank 6. Oil Cooler inlet tube 11. Charge Air Oil Cooler inlet hose
2. Oil cooler 7. Radiator outlet hose 12. Net
3. Radiator 8. Radiator inlet hose 13. Shroud
4. Charge Air Cooler 9. Fan 14. Radiator Cap
5. Oil Cooler outlet tube 10. Charge Air Oil Cooler outlet hose
SPECIFICATIONS:
Combination Cooler
PW160-7H 10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
10 9
1 13 2
11
12
14
18
15 16 17
10-4 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN
PW160-7H 10-5
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
745Nm 745Nm
(75.9 kgm) (75.9 kgm)
SJP09097A
10-6 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
SPECIFICATIONS
Reduction ratio:
92 = 7.615
13
PW160-7H 10-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY & MOTOR
1. Swing machinery
2. Swing motor
3. Swing pinnion
4. Dipstick
10-8 PW160-7H
12
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY & MOTOR
12
549Nm +/-59Nm
3.3Nm +/-0.49Nm
1150Nm +/-50Nm
86Nm +/-7.5Nm
10-10 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY & MOTOR
12
1. Pinion shaft 16. Toothed ring
2. Spacer 17. Reduction assembly
3. Sealing 18. Sun gear
4. Screw 19 Cover
5. Cover 20. Reduction assembly
6. Bearing 21. Screw
7. Gearbox housing 22. Sun gear
8. Plug 23. Circlip
9. Output assembly 24. Lubrication kit
10. Lubrication kit 25. Lubrication kit
11. Cock 26. Screw
12. Seal ring 27. Washer
13. Bearing 28. O-ring
14. Nut 29. Hydraulic motor
15. O-ring
PW160-7H 10-11
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
MSF 85P
SPECIFICATIONS
A PW160-7H
Service ports
B Model MSF85P
M Anti-cavitation Theoretical displacement 87.3 cm/rev
DB Drain port Safety valve set pressure 19.6 MPa {200 kg/cm}
GA Rated revolving speed 1,553 rpm
Pressure gauge ports
GB Brake release pressure 1.9 MPa {19 kg/cm}
PB Brake port
10-12 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
10-14 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
Kit Ref. No. Description Kit Ref. No. Description
K0 1 Motor housing kit 13 Collar
Base plate assembly 14 Spring
29 Pin K2 15 Collar washer
31 Base plate 16 Circlip
32A Relief valve 27 Valve plate
32B Relief valve K4 6 Motor shaft assembly
K1
43 Anti-cavitation valve assembly K5 4 Motor seal ring
44 Screw Bearings assembly
52 Anti-swing back valve K6 5 Bearing
53 Plug 28 Bearing
54 O-ring Brake assembly
K1.0 31 Base plate 17 Steel disc
Plug assembly 18 Brake disc
2 Plug 20 Brake spacer
K7
3 O-ring 23 Brake piston
K!.4 46 Plug 24 Spring
47 O-ring 25 Spring
53 Plug 30 Pin
54 O-ring Seal assembly
K1.5A 32A Relief valve assembly 3 O-ring
K1.5B 32B Relief valve assembly 19 O-ring
43 Anti-cavitation valve assembly 21 O-ring
39 Check valve 22 O-ring
K1.6 40 Spring 26 O-ring
41 O-ring 33 O-ring
42 Plug 34 Backup ring
52 Anti-swing back valve assembly 35 Backup ring
K8
45 O-ring 36 O-ring
K1.9
51 Anti-swing back valve 37 O-ring
50 Screw 38 O-ring
Cylinder Block Assembly 41 O-ring
7 Thrust plate 45 O-ring
8 Piston 47 O-ring
K2 9 Retainer plate 48 O-ring
10 Spherical bush 49 O-ring
11 Pin 52 O-ring
12 Cylinder block
PW160-7H 10-15
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
AA
Gear pump
AA
10-16 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
Operation
1. When starting swing
When the swing control lever is operated to
swing right, the pressure oil from the pump
passes through the control valve and is sup-
plied to port MA. As a result, the pressure at
port MA rises, the starting torque is generated
in the motor, and the motor starts to rotate.
The oil from the outlet port of the motor
passes from port MA through the control valve
and returns to the tank. (Fig. 1)
2. When stopping swing
When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil from
the outlet port of the motor, the return circuit to
the tank is closed by the control valve, so the
pressure at port MB rises. As a result, rotation
resistance is generated in the motor, so the
braking effect starts.
If the pressure at port MB becomes higher
than the pressure at port MA, it pushes shuttle
valve A (4) and chamber C becomes the same
pressure as port MB. The oil pressure rises
further until it reaches the set pressure of relief
valve (1). As a result, a high braking torque
acts on the motor and stops the motor. (Fig.2)
When relief valve (1) is being actuated, the
relief oil and oil from port S passes through
check valve B (3) and is supplied to port MA.
This prevents cavitation at port MA.
PW160-7H 10-17
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD UNDERCARRIAGE
UNDERCARRIAGE
3 2
14
13
12
11
9
10-18 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD UNDERCARRIAGE
10
4 5
8
6
1. Undercarriage 8. Transmission
2. Step 9. Double Wheel Assy
3. Wheel Chock 10. Steering Cylinder
4. Front Oscillating Steering Axle 11. Suspension
5. Rear Axle 12. Swivel Joint
6. Propshaft 13. Slew Ring
7. Travel motor 14 Axle Oscillation pin
PW160-7H 10-19
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1
Q 4
Engaged
3 2 Disengaged
SPECIFICATIONS:
Type Single motor two speed automatic powershift
Small clutch (High gear) 1.32 : 1.
Gear ratio
Large clutch (Low gear) 4.93 : 1
Pressure required to disengage
clutches (Large & Small) 58 +/- 7 bar.
10-20 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRANSMISSION
FUNCTION
Steering pump
Swivel joint
P Q
Powershift Transmission
Travel motor
Small clutch
Large clutch
PW160-7H 10-21
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRANSMISSION
10 7
6
13
14 4
11 3
2
12
10-22 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
A6VM107 HAXT/63W-VAB380A-SK
U T1
M1
Gext
Y
T2
G1
X MA:MB
B A
G1 X
ViewYY
PW160-7H 10-23
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
Travel Motor
3 1
1. Counterbalance valve
2. Motor
3. Relief valve
10-24 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
12
OPERATION OF TRAVEL MOTOR
1. Travel motor
2. Transmission and clutch
3. Drive shafts 107
Max Angle
4. Main control valve
Displacement
5. Main pump
(cc/rev)
6. Swivel joint
PW160-7H 10-25
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
3 4
1. Counterbalance valve
2. Relief valve
3. Swivel joint
4. Main control valve
10-26 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLUTCH CONTROL CIRCUIT
12
CLUTCH CONTROL CIRCUIT
Gear pump
on Engine
Swivel joint
P Q
Powershift Transmission
Travel motor
Small clutch
Large clutch
PW160-7H 10-27
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLUTCH CONTROL CIRCUIT
12
FUNCTION
10-28 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLE
AXLE
OUTLINE
A trunnion-type axle shaft with a king pin at the
Each axle consists of an axle housing supporting final drive end is used to enable the direction of
the chassis weight, a differential set in the axle the machine to be changed.
housing, a final drive, and a brake provided at
each end.
FRONT AXLE
5 5
2 1 2
4
6 3 7 6
1. Steer cylinder 3. Axle housing 5. Brake line input 7. Oil level plug
2. Track control arms 4. Drive shaft input 6. Wheel hub
10-30 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLE
3 5 7 9 23 25 27 28
2 4 6 8 24 26
1 10 11
29 30
12
13
14 38 37
15 36
35
22 21 16 34
20 17 33
18 32
19
31
PW160-7H 10-31
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLE
12
REAR AXLE
3 3
4 1 4
2
1. Axle housing
2. Drive shaft input
3. Brake line input
4. Wheel hub
5 Oil level plug
10-32 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AXLE
12
13 15 17 19 34 23
1 2 3 4 5 12 18 24
14 16 20 21 22
33 27 25
32 31 29
30 28 26
11 10 9 8 7 6
PW160-7H 10-33
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SUSPENSION LOCK CYLINDER
5
3
4
1. Plunger
2. Cylinder housing
STRUCTURE AND FUNCTION
3. Check valve cartridge
4. Switching cylinder Plunger cylinder with inbuilt check valve.
5. Control spool The check valve is designed as a leak free ball seat
6. Wiper valve which is released by a control spool.
10-34 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SUSPENSION LOCK CYLINDER
12
CIRCUIT through pipelines to the suspension lock solenoid
valve (4).
Purpose When the excavator is being moved on the jobsite,
The undercarriage of wheeled hydraulic excavators the suspension lock solenoid valve should be enger-
has one of the two driven axles oscillating mounted. nised so that the hydraulic oil in the cylinder can be
This makes it possible to fully utilize the excavators returned to tank as the axle is oscillating up and
rimpull in rough terrain - all of the wheels being con- down. Before commencing excavating operations,
stantly in contract with the ground. A suspension cyl- the oscillation lock solenoid valve should be
inder is fitted on each side of the undercarriage to de-energised to pressurise the oil in the cylinders.
block the axle during digging or lifting work. This will lock the axle in the position it is in.
Blocking the axle increases the excavators stability.
The oscillating axle (3) is mounted on axle mount pin
(2) in the middle of the excavator. The two cylinders
(1) which are full of hydraulic oil are connected
4
7
5
1. Cylinder
2. Axle mount pin
3. Oscillating axle
4. Oscillation lock solenoid valve
5. PPC pressure reducing valve
6. Hydraulic tank
7. Swivel joint
8. PPC operated check valve
9. Accumulator
AXLE OSCILLATION
PW160-7H 10-35
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKING SYSTEM
BRAKING SYSTEM
LS Signal from
Steering valve
10-36 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKING SYSTEM
PW160-7H 10-37
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BRAKE/STEER PUMP
BRAKE/STEER PUMP
5 3 4
1 2
FUNCTION
5
5
10-38 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PRIORITY VALVE
PRIORITY VALVE
LS
EF CF
SPECIFICATION
P Pressure port (from pump)
Priority valve control
EF Output port to brake system spring pressure 7 bar
CF Output port to steering system
LS Load sensing port from steering valve
FUNCTION
PW160-7H 10-39
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER BRAKE VALVE
A T1 T2
1
X
3
View A
2
5
6 7
R2 N
8 X1
R1 F R3
9 10 R
P B
T4
N1 T3
1 Brake system support pedal F Accumulator pressure switch P Feed from priority valve
with hook
SPECIFICATIONS
(cut in) = 120 +/- 5 bar
Accumulator charge pressure
(cut out) = 155 +0/-2 bar
Service brake pressure 63 bar
Park brake pressure 58 +/- 7 bar
10-40 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER BRAKE VALVE
FUNCTION
The main function of the power brake valve is to
gradually reduce the machines travelling speed when
the pedal is slowly depressed. The higher the force
applied to depress the pedal, the greater the deceler-
ation of the machine, until the machine is eventually
in a stationary position.
An alternative function of the power brake valve is
the digging brake application, if the machine is to be
used for digging, the power brake valve should be
fully depressed until the pedal is locked and the
latching hook is secured on its location pin. This will
prevent the machine from "Travelling" when it is
being used for digging.
PW160-7H 10-41
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ACCUMULATOR FOR BRAKE SYSTEM
SPECIFICATIONS
10-42 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
STEERING SYSTEM
3
2
6
1
PW160-7H 10-43
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Pedal
4. Hose connections
5. Orbitrol valve
6. Mounting bracket
7. Sunshine sensor
10-44 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ORBITROL VALVE
ORBITROL VALVE
70 CC/REV
PW160-7H 10-45
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC EQUIPMENT LAYOUT DRAWINGS
12
HYDRAULIC EQUIPMENT LAYOUT DRAWINGS
6 7 8 9
10
5
11
4
12
3
2
1
13
10-46 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC EQUIPMENT LAYOUT DRAWINGS
12
15 16
17
14
18
19
20
21
21
22
PW160-7H 10-47
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CIRCUIT DIAGRAM
10-48 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
5
3 2
1. Sight gauge
SPECIFICATIONS
2. Oil filler cap
3. Hydraulic tank Tank 166 l
4. Suction strainer Amount of oil inside tank 120 l
5. Filter element Pressure valve
6. Strainer 16.7 +/-6.9 kPa
Relief cracking pressure
7. Bypass valve {0.17 +/-0.07 kg/cm2}
0 - 0.49 kPa
Suction cracking pressure
{0 - 0.005 kg/cm2}
150 +/- 30 kPa
Bypass valve set pressure
{1.5 +/- 0.3 kg/cm2}
PW160-7H 10-49
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV125
1 Pd1 PB
PEPC PA
PM
PEPC
PSIG
Pen
19.6~27.4Nm
11.8~14.7Nm {2.0~2.8kgm}
{1.2~1.5kgm}
4
Isig
Im
Pd2
PS 58.8~78.4Nm
{6~8kgm}
2 3
PA*
PLS
PLSC
1. Main pump Im :PC mode selector current PLS :Load pressure input port
2. LS valve Isig :S set selector current PLSC :Load pressure detection port
3. PC valve PA :Pump delivery port PS :Pump suction port
4. LS-EPC valve PA* :Pump delivery pressure PLSC:LS set selector pressure detection
5. PC-EPC valve detection port port
PB :Pump pressure input port PM :PC set selector pressure detection
Pd1 :Case drain port
port
Pen :Pump control pressure
PEPC:EPC basic pressure input port
detection port
PEPC :EPC basic pressure checking port
Pd2 :Drain port
PSIG :LS set change pressure checking port
Outline
This pump consists of a variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.
10-50 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
58.8~78.4Nm
{6~8kgm}
1 2 3 4 5 6 7 8 9 10
PW160-7H 10-51
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
1 2 3 4 5 6 7 8 9
SWP
B A
SJP09037AA
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
Structure when it slides.
Cylinder block (7) is supported to shaft (1) by a Piston (6) carries out relative movement in the
spline, and shaft (1) is supported by the front and axial direction inside each cylinder chamber of
rear bearings. cylinder block (7).
The tip of piston (6) is a concave ball, and shoe The cylinder block seals the pressure oil to valve
(5) is caulked to it to form one unit. Piston (6) and plate (8) and carries out relative rotation. This
shoe (5) form a spherical bearing. surface is designed so that the oil pressure bal-
ance is maintained at a suitable level. The oil
inside each cylinder chamber of cylinder block
(7) is sucked in and discharged through valve
plate (8).
10-52 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle is called the swash plate
angle.)
Center line X of rocker cam (4) maintains
swash plate angle 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
cylinder 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-
umes E and F inside cylinder block (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.)
PW160-7H 10-53
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
2. Control of discharge amount
If the swash plate angle becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
Swash plate angle is changed by servo
piston (10).
Servo piston (10) moves in a reciprocal
movement () according to the signal pres-
sure from the PC and LS valves. This
straight line movement is transmitted
through rod (11) 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 (self pres-
sure) PP is always brought to the chamber
receiving the pressure at the small diameter
piston end. A
11
10-54 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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 : LS mode selection pilot port
8) Sleeve
PC VALVE
PA : Pump port
1) Servo piston assembly
PA2 : Pump pressure pilot port( = PA )
2) Plug
PDP : Drain port
3) Pin
PM : PC mode selector pressure pilot port
4) Spool
PPL : PC control pressure output port (to
5) Retainer
LS valve)
6) Seat
PPL2 : PC control pressure output port (to
7) Cover
serve piston)
8) Wiring
PW160-7H 10-55
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
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 dif-
ference between main pump pressure PP and 09142
control valve outlet port pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control valve 0.64 {6.5} 2.1 {21.5}
output, and pressure Psig {called the LS selector A
pressure} from the proportional solenoid valve
enter this valve. The relationship between dis-
charge amount Q and differential pressure
PLS, (the difference between main pump pres-
sure PP and LS pressure PLS) (= PP - PLS)
changes as shown in the diagram at the right
according to LS pressure selector current isig of
the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to this,
and the selector point for the pump discharge
amount changes at the rated central valve
between 0.64 2.1 MPa {6.5 21.5 kg/cm}.
(2) PC valve
When the pump discharge pressure PP1 (self-
pressure) is 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 horsepower
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 A
10-56 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
OPERATION
Control
valve
Control circuit
pressure setting
valve
SDP08884
10
A
(1) LS valve at the small diameter end of the piston, so the swash
1) When control valve is at neutral position plate is moved to the minimum angle by the differ-
The LS valve is a three-way selector valve, with ence in the area of the piston (10).
pressure PLS (LS pressure) from the inlet port of
the control valve brought to spring chamber B, 10
and main pump discharge pressure PP coming
from the control valve output brought to port H of
sleeve (8). The size of this LS pressure PLS +
force Z of spring (4) and the main pump pressure
(self pressure) PP determines the position of
spool (6). However, the size of the output pres-
sure PSIG (the LS selection pressure) of the
EPC valve for the LS valve entering port G also
changes the position of spool (6). (The set pres-
sure of the spring changes).
Before the engine is started, servo piston (ic) is
pushed to the left. (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/cm}. (It is interconnected with the
drain circuit through the control valve spool.)
PW160-7H 10-57
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Control
valve SDP08885
Control circuit
pressure setting
valve
10
AA
2. Operation in increase direction for pump dis- For this reason, the pressure at the large diame-
charge amount ter end of servo piston (10) becomes drain pres-
When the difference between the main pump sure PT, and pump pressure PP enters port J at
pressure PP and LS pressure PLS, in other the small diameter end, so servo piston (10) is
words, LS differential pressure PLS, becomes pushed to the left. Therefore, the swash plate
smaller (for example, when the area of opening moves in the direction to make the discharge
of the control valve becomes larger and pump amount larger. If the output pressure of the EPC
PP drops), spool (6) is pushed to the left by the valve for the LS valve enters port G, this pressure
combined force of LS pressure PLS and the creates a force to move piston (7) to the right. If
force of spring (4). piston (7) is pushed to the right, it acts to make
When spool (6) moves, port D and port E are the set pressure of spring (4) weaker, and the dif-
joined and connected to the PC valve. When this ference between PLS and PP changes when
happens, the PC valve is connected to the drain ports D and E of spool (6) are connected.
port, so circuit D - K becomes drain pressure PT.
(The operation of the PC valve is explained
later).
10-58 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Control
valve
Control circuit
pressure setting
valve
SDP08886
10
AA
3. Operation in decrease direction for pump dis- Main pump pressure PP also enters port J at the
charge amount small diameter end of the piston, but because of
The following explains the situation if the servo the difference in area between the large diameter
piston (10) moves to the right (the discharge end and the small diameter end of servo piston
amount becomes smaller). When LS differential (10), servo piston (10) is pushed to the right.
pressure PLS becomes larger (for example, As a result, the swash plate moves in the direc-
when the area of opening of the control valve tion to make angle smaller.
becomes smaller and pump pressure PP rises), If LS selection pressure PSIG enters port G, it
pump pressure PP pushes spool (6) to the right. acts to make the set pressure of spring (4)
When spool (6) moves, main port pressure PP weaker.
flows from port C and port D and from port K, it
enters the large diameter end of the piston.
PW160-7H 10-59
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Control
valve
Control circuit
pressure setting
valve
SDP08887
10
AA
4. When servo piston is balanced At this point, the relationship between the area
Let us take the area receiving the pressure at the receiving the pressure at both ends of piston (10)
large diameter end of the piston as A1, the area is A0 : A1 = 1:2, so the pressure applied to both
receiving the pressure at the small diameter end ends of the piston when it is balanced becomes
as A0, and the pressure flowing into the large PP : Pen = 2:1.
diameter end of the piston as Pen. If the main The position where spool (6) is balanced and
pump pressure PP of the LS valve and the com- stopped is the standard center, and the force of
bined force of force Z of spring (4) and LS pres- spring (4) is adjusted so that it is determined
sure PLS are balanced, and the relationship is when PP - PLS = 2.1 MPa {21.5 kg/cm}. How-
A0 x PP = A1 x Pen, servo piston (10) will stop in ever, if PSIG (the output pressure of 0 2.9
that position, and the swash plate will be kept at MPa {0 30 kg/cm} of the EPC valve of the LS
an intermediate position. (It will stop at a position valve) is applied to port G, the balance stop posi-
where the opening of the throttle from port D to tion will change in proportion to pressure PSIG
port E and from port C to port D of spool (6) is between PP - PLS = 2.1 0.64 MPa {21.5
approximately the same.) 6.5 kg/cm}.
10-60 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Control
valve
09143
Control circuit
pressure setting
valve
AA
(2) PC Valve
1) When pump controller is normal
a). When the load on the actuator is small and The pressure (pressure of port C) output
pump pressures PP from the PC valve changes according to this
Movement of PC-EPC solenoid (1) position.
The command current from the pump con- The size of command current X is deter-
troller flows to PC-EPC solenoid (1).This mined by the nature of the operation (lever
command current acts on the PC-EPC valve operation), the selection of the working
and outputs the signal pressure. When this mode, and the set value and actual value for
signal pressure is received, the force push- the engine speed.
ing pin (2) is changed.
On the opposite side to the force pushing
this pin (2) is the spring set pressure of
springs (4) and (6) and pump pressure PP
(self pressure) pushing spool (3). Pin (2)
stops at a position where the combined force
pushing spool (3) is balanced, and
PW160-7H 10-61
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Control
valve
09144
Control circuit
pressure setting
valve
AA
10-62 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
When pump pressures PP is small, spool (3) is
on the left relative to servo piston (9). At this
point, port C and D are connected, and the pres-
sure entering the LS valve becomes drain pres-
sure PT. If port E and port G of the LS valve are
connected (see 1. LS valve), the pressure enter-
ing the large diameter end of the piston from port
J becomes drain pressure PT, and servo piston
(9) moves to the left. In this way, the pump dis-
charge amount moves in the direction of
increase.
As servo piston (9) moves further to the left,
springs (4) and (6) expand and the spring force
becomes weaker. When the spring force
becomes weaker, spool (3) moves to the right
relative to servo piston (9), so the connection
between port C and port D is cut, and the pump
discharge pressure ports B and C are con-
nected. As a result, the pressure at port C rises,
and the pressure at the large diameter end of the
piston also rises, so the movement of servo pis-
ton (9) to the left is stopped.
In other words, the stop position for servo 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 PP acting on the spool (3) are in balance.
PW160-7H 10-63
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Control
valve
09145
Control circuit
pressure setting
valve
AA
b). When load on actuator is large and pump dis- servo piston (9), the opening joining port C and
charge pressure is high port D becomes larger. As a result, the pressure
When the load is large and pump discharge at port C (= J) drops, and servo piston (9) stops
pressure PP is high, the force pushing servo pis- moving to the right.
ton (9) to the left becomes larger and spool (3) The position in which servo piston (9) stops when
moves to the position in the diagram above. this happens is further to the right than the posi-
When this happens, as shown in the diagram tion when pump pressure PP is low.
above, part of the pressurized oil from port B
flows out through port C where the LS valve is
actuated to port D, and the pressurized oil flow-
ing from port C to the LS valve becomes approx-
imately half of main pump pressure PP.
When port E and port G of the LS valve are con-
nected (see 1 LS valve), the pressure from port J
enters the large diameter end of servo piston (9),
and servo piston (9) stops.
If main pump pressure PP increases further and
servo piston (9) moves further to the left, main
pump pressure PP flows to port C and acts to
make the discharge amount the minimum. When
servo piston (9) moves to the right, springs (4)
and (6) are compressed and push back spool
(3). When spool (3) moves to the left relative to
10-64 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PW160-7H 10-65
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Control
valve
09146
Control circuit
pressure setting
valve
AA
10-66 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Control
valve
09147
Control circuit
pressure setting
valve
7AA
PW160-7H 10-67
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
LS(PC)-EPC VALVE
10-68 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12O
Function
The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por-
tion.
When it receives signal current i from the reference
reference
(500, 10.5)
reference
(300, 4)
300 500
900
AA
Operation
1. When signal current is 0 (coil de-ener-
gized)
When there is no signal current flowing from
the controller to coil (5), coil (5) is de-ener-
gized.
For this reason, spool (2) is pushed to the left
in the direction of the arrow by spring (3).
As a result, port PEPC closes and the pres-
surized oil from the main pump does not flow
to the LS (PC) valve.
At the same time, the pressurized oil from the
LS (PC) valve passes from port PSIG(PM)
through port PT and is drained to the tank. 08890
Control circuit
pressure setting
valve
AA
PW160-7H 10-69
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
AA
10-70 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PILOT PRESSURE CONTROL (PPC) SYSTEM
361.5 Bar
From orbitrol
valve load
3
sensing signal
To orbitrol valve
OPERATION
1. Gear Pump
The PPC pumpless system utilizes the return line
2. Steering/Braking priority valve oil from the power brake valve, oil is supplied to
3. Power Brake Valve the steering / braking circuits from a gear pump
4. Pressure Reducing Valve driven by the engine. Oil is prioritised to the
Incorporated in Main Solenoid Valve Block steering circuit via the priority valve with the
remaining oil flow feeding the power brake valve.
The return line from the brake valve passes
through a relief valve to maintain a pressure of
FUNCTION
38 1.5 BAR.
The PPC Pump less system discharges pres-
surised oil to operate the PPC circuit and sole-
noid valve assemblies.
PW160-7H 10-71
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
PW160-7H
OUTLINE
A1. To swing motor LH PA1. From swing PPC valve LEFT PP. from main pump
A2. To boom cyl bott PA2. From boom PPC valve RAISE PX. from 2-stage relief sol valve
A3. To travel fwd PA3. From travel PPC valve FORWARD PBP from 2-stage lift check sol valve
A4. To stabilizer cyl bott PA4. From stabilizer PPC valve RAISE P. From pump
A5. To adjust cyl bott PA5. From adjust cyl PPC valve EXTEND BP. from boom RAISE PPC
A6. To arm cyl head PA6. From arm cyl PPC valve OUT SA1. from boom RAISE PPC valve
A7. To bucket cyl head PA7. From bucket cyl PPC valve DUMP SA6. from travel PPC valve
A8. To service PA8. From service PPC valve SA7. from travel PPC valve
A9. To service PA9. From service PPC valve SB1. from boom RAISE PPC
B1. To swing motor RH PB1. From swing PPC valve RIGHT SB2. from travel PPC valve
B2. To boom cyl head PB2. From boom PPC valve LOWER SB6. from travel PPC valve
B3. To travel rev PB3. From travel PPC valve REVERSE SB7. from travel PPC valve
B4. To stabilizer cyl bott PB4. From stabilizer PPC valve LOWER TSW. to swing motor
B5. To adjust cyl head PB5. From adjust cyl PPC valve RETRACT TS1. to tank
B6. To arm cyl bott PB6. From arm cyl PPC valve IN LS. to pump LS valve
B7. To bucket cyl bott PB7. From bucket cyl PPC valve CURL TC. to oil cooler
B8. To service PB8. From service PPC valve TB. to tank
B9. To service PB9. From service PPC valve
10-72 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
F G H J K L M N CC DD AA
A1 A2 A3 A4 A5 A6 A7 A8 A9
D C
TB
B1 B2 B3 B4 B5 B6 B7 B8 B9
P-BP
B
F G H J K L M N CC DD AA
11.8~14.7Nm
{1.2~1.5Kgm} A 11.8~14.7Nm B
{1.2~1.5Kgm}
Arm regeneration valve Tighten bolts in order 1~4
S-B1 S-B2 S-B6 S-B7
Pump pressure
98.1~113Nm checking port
{10~11.5Kgm}
BP 3 1
LS
PP
2 4
27.8~34.3Nm
{2.8~3.5Kgm} LS pressure
Swing bleed valve
checking port
S-A1 S-A6 S-A7
E D C
PW160-7H 10-73
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
20 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16
17 18 19
147~186Nm 147~186Nm 147~186Nm 196~240Nm
{15~19kgm} {15~19kgm} {15~19kgm} {20~24.5kgm}
25 24 23 22 21
1. Pressure compensation valve F (Swing Left) 10. Pressure compensation valve R (Swing Right)
2. Pressure compensation valve F (Boom Raise) 11. Pressure compensation valve R (Boom Lower)
3. Pressure compensation valve F (Travel Forward) 12. Pressure compensation valve R (Travel Reverse)
4. Pressure compensation valve F (Stabilizer Raise) 13. Pressure compensation valve R (Stabilizer Lower)
5. Pressure compensation valve F (2PBoom Raise) 14. Pressure compensation valve R (2PBoom Raise)
6. Pressure compensation valve F (Arm Out) 15. Pressure compensation valve R (Arm Curl)
7. Pressure compensation valve F (Bucket Dump) 16. Pressure compensation valve R (Bucket Dig)
8. Pressure compensation valve F (Service) 17. Variable pressure compensation valve R (Service)
9. Pressure compensation valve F (Service) 18. Variable pressure compensation valve R (Service)
19. Unload valve
The letters F and R refer to the following valves.
F: Flow control valve R: Reducing valve
Unit:mm
No Check Item Criteria Remedy
Standard size Repair limit
Free length x Out- Installed Installed Free Installed
side diameter length load length load
9.8Nm 7.8Nm
20. Flow control valve spring 36.2 x 5.3 32 (1kgm) (0.8kgm)
9.8Nm 7.8Nm
21. Reducing valve spring 24.5 x 15 14.5 (1kgm) (0.8kgm) If damaged or
74.5Nm 59.8Nm deformed, replace
22. Relief valve spring 17.1 x 9 15.5 (7.6kgm) (6.1kgm) spring
17.6Nm 13.7Nm
23. Reducing valve spring 27.5 x 14.2 18 (1.8kgm) (1.4kgm)
66.4Nm 53.1Nm
24. Reducing valve spring 74.8 x 14.2 40 (6.8kgm) (5.4kgm)
17.6Nm 13.7Nm
25. Reducing valve spring 32.5 x 14.2 23 (1.8kgm) (1.4kgm)
10-74 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
1 6 7
10
2 3 4 5 8 9
11 11 11 13 13 12 11 13 13
11 13 11 13 13 13 11 13 13
Unit:mm
No Check Item Criteria Remedy
Standard size Repair limit
Free length x Out- Installed Installed Free Installed
side diameter length load length load
221.5Nm 187.4Nm If damaged or
11. Spool return spring 45.7 x 28 43 (22.6kgm) (19.1kgm) deformed, replace
spring
245Nm 187.4Nm
12. Spool return spring 42.4 x 28 39 (22.kgm) (19.1kgm)
230.Nm 184Nm
13. Spool return spring 45.6 x 28 43 (23.5kgm) (18.8kgm)
PW160-7H 10-75
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
19 8 9
176.6~196.2Nm
{18~20kgm}
1 2 3 4 5 6 7
20
10 11 12 13 14 15 16 17 18
27 137.2~157Nm 34~44Nm
{14~16kgm} {3.5~4.5kgm}
137.2~156.8Nm
108~147Nm
{11~15kgm} {14~16kgm}
21
22
49~63.7Nm
{5~6.5kgm} 23
19.6~27.5Nm
{2~2.8kgm}
49~63.7Nm
{5~6.5kgm} 49~63.7Nm 49~63.7Nm 26 25 28 24
{5~6.5kgm} {5~6.5kgm}
Unit:mm
No Check Item Criteria Remedy
Standard size Repair limit
Free length x Out- Installed Installed Free Installed If damaged or
side diameter length load length load deformed, replace
5.9Nm 4.7Nm spring
28. Check valve spring 41.5 x 8.5 31.5
(0.6kgm) (0.48kgm)
10-76 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
14.7~19.6Nm
{1.5~2kgm}
6 2
1
7
11
12
8
47.1~58.8Nm
{4.8~6.0Kgm}
5
10 M-M 9 4 3
J-J
Unit:mm
No Check Item Criteria Remedy
Standard size Repair limit
Free length x
Installed Installed Free Installed If damaged or
Outside diame- length load length load deformed,
ter replace spring
12 Check valve spring 41.5 x 8.5 26.5 8.8Nm 7Nm
(0.9kgm) (0.7kgm)
PW160-7H 10-77
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
14.7~19.6Nm
14.7~19.6Nm {1.5~2kgm}
{1.5~2kgm}
2 6 7
1
11
5
4 3 8
10
N-N DD-DD 9
10-78 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
14.7~19.6Nm
13 1 {1.5~2kgm}
59~78Nm
{6~8kgm}
59~78Nm
{6~8kgm}
14.7~19.6Nm 4
{1.5~2kgm} 3 G-G
2
6
10
5
14
9
14.7~19.6Nm
{1.5~2kgm} 7
59~78Nm
8 12 11 {6~8kgm}
H-H K-K
Boom control valve Stabilizer control valve
Unit:mm
No Check Item Criteria Remedy
Standard size Repair limit
Free length x
Outside diame- Installed Installed Free Installed If damaged or
ter length load length load deformed,
replace spring
3.9Nm 2.9Nm
13. Bleed spool return spring 23.3 x 12.5 23 (0.4kgm) 0.3kgm)
PW160-7H 10-79
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
4 5
3 1
2 L-L
1. Suction valve
2. Spool (2nd Boom)
3. Pressure compensation valve R
4. Pressure compensation valve F
5. Suction valve
10-80 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
34~44Nm
{3.5~4.5kgm} 4
8
1
7
6
AA-AA
147~186.3Nm 19.6~24.5Nm 5
{15~19kgm} {2.0~2.5kgm} F-F
47~58.8Nm
2 {4.8~6kgm}
Unit:mm
No Check Item Criteria Remedy
Standard size Repair limit
Free length x
Outside diame- Installed Installed Free Installed If damaged or
ter length load length load deformed,
replace spring
135.3Nm 112.7Nm
7. Lift check valve spring 72.7 x 20.6 42.5 (13.8kgm) 11.5(kgm)
135.3Nm 112.7Nm
8. Cooler bypass valve spring 72.7 x 20.6 42.5 (13.8kgm) 11.5(kgm)
PW160-7H 10-81
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
FEATURES STRUCTURE
CLSS is an abreviation for Closed centre Load The CLSS consists of a main pump, control
Sensing System, and has the following features. valve, and actuators for the work equipment.
The main pump body consists of the pump itself,
Fine control not influenced by load the PC valve and LS valve.
Control enabling digging even with fine control
Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
Energy saving using variable pump control
10-82 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
BASIC PRINCIPLE
1. Control of pump swash plate angle
The pump swash plate angle (pump discharge
amount) is controlled so that LS differential pres-
sure PLS (the difference between pump (dis-
charge) pressure PP and control valve outlet port
LS pressure PLS) load pressure of actuator) is
constant.
(LS pressure PLS=Pump discharge pressure
PP-LS pressure PLS)
PW160-7H 10-83
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
When to actuators are operated together, this size of the load (pressure). In this way, the flow of
valve acts to make pressure difference P oil from the pump is divided (compensated) in
between the upstream (inlet port) and down- proportion to the area of openings S1 and S2 of
stream (outlet port) the same, regardless of the each valve when it is operated.
10-84 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
PW160-7H 10-85
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
10-86 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
1. Unload valve
Function
1. When the control valve is at neutral, pump dis-
charge amount Q discharged by the minimum
swash plate angle is released to the tank circuit.
At this time, pump discharge pressure PP is set
at 2.45 MPa {25 kg/cm2} by spring (3) inside the
valve. (LS pressure PLS : 0 MPa {0 kg/cm2})
Operation
PW160-7H 10-87
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
Operation
10-88 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
Operation
PW160-7H 10-89
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
2. Introduction of LS pressure
Work equipment valve
Operation
Function
When spool (1) is operated, pump discharge
The LS pressure is the actuator load pressure at
pressure PP flows from flow control valve (2)
the outlet port end of the control valve.
through notch (a) in the spool and bridge pas-
Actually, pump discharge pressure PP is reduced sage (b) to actuator circuit A.
by reducing valve (3) of the pressure compensa-
At the same time, reducing valve (3) also moves
tion valve to the same pressure as actuator cir-
to the right, so pump discharge pressure PP is
cuit pressure A and sent to LS circuit 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.
10-90 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
3. LS Bypass plug
Outline
1. This releases the residual pressure of LS pres-
sure PLS.
Operation
The pressurized oil for the LS circuit PLS passes 1. LS bypass plug
from the clearance filter a (formed by the clear-
ance between LS plug (1) and the valve body)
PLS: LS circuit (pressure)
through orifice b and flows to the tank circuit T.
T: Tank circuit (pressure)
PW160-7H 10-91
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
10-92 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
Operation
When the load pressure of another actuator side
(the upper side) rises during a compound opera-
tion, the flow in the actuator circuit Aa on this
side (the lower side) is apt to increase.
In this case, the LS pressure PLS of another
actuator is applied to the spring chamber PLS1
and pushes the pressure reducing valve (1) and
the flow control valve (2) to the left side.
The flow control valve (2) throttles the opening
area between the pump circuit PP and the spool
upstream PPA and causes a pressure loss
between PP and PPA.
The flow control valve (2) and the pressure
reducing valve (1) balance each other where the
pressure difference between PA applied to the
both end faces of the pressure reducing valve (1)
and PLS becomes the same as the pressure
loss between PP before and after the flow control
valve and PPA.
So, the pressure differences between the
upstream pressures PPA and the downstream
pressures PA of the both spools under com-
pound operation become the same, and the
pump flow is distributed in proportion to the
opening area of each spool notch a.
PW160-7H 10-93
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
10-94 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
Operation
When the boom is lowered and falls due to its
own weight, the bottom side pressure A in the
boom cylinder (1) will rise above the head side
pressure B.
At the time, part of the return flow on the bottom
side passes through the regeneration passage a
of the boom spool (2), pushes the check valve
(3) to open it and flows to the head side.
This increases the boom lower speed.
PW160-7H 10-95
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
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-
cess, the head side pressure B of the boom cyl-
inder (1) rises above the bottom side pressure A
At the time, the head side pressure B and the
spring (4) close the check valve (3), and the cir-
cuits on the head side and the bottom side are
interrupted.
10-96 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
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.
PW160-7H 10-97
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
2. At arm in process
Function
When the bottom pressure B of the cylinder (1)
rises above the head pressure A and the arm
enters the digging process, the check valve (3)
will be closed and the circuits on the head side
and the bottom side will be interrupted.
Operation
When the arm is in the digging process, the bot-
1. Arm cylinder
tom side pressure B of the arm cylinder (1) will
rise, close the check valve (3) and interrupt the 2. Arm spool
circuits on the head side and the bottom side. 3. Check valve
10-98 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
PA
a 1
b PLS
PP
PW160-7H 10-99
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
10-100 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
Operation
1. Normal operation
Normally,except when boom RAISE is operated,
the pilot pressure does not act on pilot port BP.
In this condition, pump pressure PP pushes
valve (1) open and goes to reducing valve (4) of
the swing valve. When the swing is operated, LS
pressure PLS is generated in accordance with
the load pressure and flows to the pump LS
valve.
PW160-7H 10-101
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTRE SWIVEL JOINT
F 1 3 5 7 9 11 13 B
A
4 4
14
2
A 11
12
8
6 6
A D C
E 2 4 6 10 12 14
8
Unit: mm
Criteria
No. Check Item Remedy
Standard Size Standard clearance Repair limit
-0.02
1 Internal shaft
110-0.06 Max.=0.21 >=0.26 Replace
0.15
Min.=0.12
2 External rotor
110 0.10
10-102 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC PEDAL
P
3
PRESSURE SENSOR
TRAVEL
TRAVEL CONTROL VALVE
NEUTRAL PEDAL F - R SOLENOID TRAVEL SPOOL
SOLENOID
10-104 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC PEDAL
12
MONITOR
TRAVEL PPC TRAVEL
PRESSURE PPC
SENSOR TRAVEL FORWARD
PARK HI PRESSURE SENSOR
F-N-R
BRAKE LO
SWITCH SWITCH
CREEP
F-R
SOL PUMP
PRESSURE
T.R.P.S
SENSOR
GOVERNOR TRAVEL N
MOTOR CONTROLLER SOL
STEERING
PUMP
MAIN
PUMP
TRAVEL
CONTROL
VALVE
CREEP
SOL
PARK BRAKE
SOL
ACCUMULATOR
T/M CLUTCH
SOL UPPER
LOWER
TRAVEL
MOTOR
SPEED PICKUP
SMALL CLUTCH
(ELECTRONIC)
PW160-7H 10-105
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT SWING PPC VALVE
10-106 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT SWING PPC VALVE
12
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
PW160-7H 10-107
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT SWING PPC VALVE
OPERATION
1) At neutral
Ports A and B of the control valve and ports
P1 and P2 of the PPC valve are connected to
drain chamber D through fine control hole f in
spool (1). (Fig. 1)
10-108 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT SWING PPC VALVE
12
4. At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP. Therefore, the pilot pressure oil from
the control circuit 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. (Fig. 4)
PW160-7H 10-109
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE
1. Spool T. To tank
2. Metering spring P. From main pump
3. Centering spring P1. Port
4. Piston P2. Port
5. Lever
6. Plate
7. Retainer
8. Body
Unit: mm
10-110 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE
OPERATION
At neutral
The pressurized oil from the control circuit
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
PW160-7H 10-111
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE
10-112 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE MANIFOLD
2-stage manifold:
Hi-lo (see page 10-222),
2-stage back pressure (see page 10-224) solenoid
valves.
TO. To tank A1. 2 stage relief V01 PPC hyd press lock sol
T1. To tank A2. Swing brake V02 2-stage relief sol
P1. From brake valve A3. Suspension lock valve V03 Swing brake sol
P2. To : main valve,
2 stage back pressure valve, A5. N/A V04 Sus lock sol
EPC valve in main pump
PS. To : accumulator,
manifold valve block, A6. Travel neutral V06 Travel neutral sol
2 stage back pressure lock
P0. PPC hydraluic pressure lock A8. Travel creep (motor volume pilot) V07 Travel creep sol
PW160-7H 10-113
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE MANIFOLD
4
3
5
T
1. Connector
2. Plunger
3. Coil A
4. Spool
5. Spring
OPERATION B
When solenoid is deactivated
Since the signal current does not flow from the
controller, coil (3) is turned off
Accordingly, spool (4) is pressed by spring (5)
against the left side.
By this operation, the passage from P to A is
closed and the hydraulic oil from the control cir-
cuit does not flow into the actuator.
At this time, the oil from the actuator is drained
through ports A and T into the tank.
10-114 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE MANIFOLD
P
T
PW160-7H 10-115
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE MANIFOLD
2 5
3 4
P
1. Connector
2. Plunger T
3. Coil
4. Spool
A
5. Spring
OPERATION B
When solenoid is deactivated
Since the signal current does not flow from the
controller, coil (3) is turned off
Accordingly, spool (4) is pressed by spring (5)
against the left side.
By this operation, the passage from P to A is
closed and the hydraulic oil from the control cir-
cuit does not flow into the actuator.
At this time, the oil from the actuator is drained
through ports A and T into the tank.
10-116 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE MANIFOLD
P
T
PW160-7H 10-117
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE MANIFOLD
12
ATTACHMENT EPC VALVE
A
A
1 2 3 4 5 6
A
1. Body
2. Spool
3. Spring
4. Push pin
5. Coil
6. Plunger
7. Connector
10-118 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE MANIFOLD
12
Function
The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve poertion.
When it receivers signal current i from the pump
controller, it generates EPC output pressure P in
proportion to the size of the signal, and outputs it
to the control valve.
Operation
1) When signal current is 0 (coil deactivated)
There is no signal current flowing from the con- LS VALVE
troller to coil (5), coil (5) is deactivated.
For this reason, spool (2) is pulled to the right in 2 3 5
C
the direction of the arrow by spring (3).
As a result, port P closes and the pressurised oil
from the pressure regulating valve does not flow
to the Att pedal.
T P
PPC pressure
reducing valve
PW160-7H 10-119
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE MANIFOLD
12
3. When signal current is maxium (coil excited)
when the signal current flows to coil (5), coil (5) is
LS VALVE
excited.
When this happens, the signal current is at its
maximum, so the propulsion force of plunger (6) 24 5 6
is also at its maximum.
For this reason spool (2) is pushed to the left in
the direction of the arrow by push pin (4).
As a result, the maximum flow of pressurised oil
from port P flows at its maximum to port C, and
the circuit pressure between EPC valve and Att PPC pressure
reducing valve
pedal becomes the maximum.
At the same time, port T closes and stops the oil
from flowing to the tank.
10-120 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BOOM SAFETY VALVE
Pilot signal
(Pi port)
To cylinder port
(Cy port)
10-122 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BOOM SAFETY VALVE
12
Operation
Boom Raise V port
During boom raising the pilot signal from wrist 2
control operates control valve spool to direct high
pressure oil to port V of hose burst valve.
This pressure lifts check valve (4) from seat and
high pressure oil flows in the bottom of the cylin- To tank
der raising the room.
Boom control
Cylinder valve
Control lever
PPC pressure
reducing valve
Boom Lower
During boom lowering the pilot signal reverses 2
the flow through the control valve spool. High
pressure oil flows to the head side of the cylinder. T port
Oil in the bottom side of the cylinder flows
through the port Cy of the valve. The pilot signal To tank
also opens the spool (2) of the hose burst valve
and allows oil to flow back to tank.
4
Cy port
PPC pressure
reducing valve
To tank
PPC pressure
reducing valve
PW160-7H 10-123
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
Stroke - 1378~2263
58.9 ~ 73.6Nm
(6 ~ 7.5kgm) A
10-124 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CYLINDER
12
ADJUST CYLINDER
Stroke - 1198~1900
Unit: mm
-0.030 +0.190
1 Piece boom 70 -0.100 +0.070 0.100 ~ 0.290 --- Replace
pin or
-0.030 +0.190 bushing
2 piece boom 70 -0.060 +0.070 0.100 ~ 0.250 ---
-0.030 +0.198
Arm 70 -0.100 +0.124 0.154 ~ 0.298 ---
Clearance
between cyl- -0.030 +0.198
3 inder bottom Bucket 70 -0.104 +0.124 0.154 ~ 0.302 ---
support pin
and bushing -0.030 +0.457
Adjust 90 -0.076 +0.370 0.400 ~ 0.533 ---
-0.030 +0.190
1 Piece boom- 70 -0.060 +0.070 0.100 ~ 0.250 ---
PW160-7H 10-125
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD OUTRIGGER CYLINDER
12
OUTRIGGER CYLINDER
1 1
2
12
Left handed screw
I 3
9
4
11
10 5
18
19 6
20
21 10 7
22 11
23 10
17
16
24
8
11
10
25
5
4
9
26
27 3
Attention pos.8 is
125 rotated mounted at the rod side
26
15 H
28 14
29
30
13
1
2
12
10-126 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD OUTRIGGER CYLINDER
12
1. Circlip 16. Backup ring
2. Spherical plain bearing 17. O-ring
3. Screw plug 18. Groove nut
4. Valve seat 19. Piston wear-ring
5. Pressure spring 20. Turcon-glyd-ring
6. Valve poppet 21. O-ring
7. Control spool 22. Backup ring
8. Valve poppet 23. Guide
9. O-ring 24. Cylinder
10. O-ring 25. Piston rod
11. Backup ring 26. Rod wear-ring
12. Grease nipple 27. Cylinder Head
13. Grub screw 28. U-ring
14. Backup ring 29. O-ring
15. O-ring 30. Wiper
Function
Cylinder head (27) guides the piston rod (25) which
is sealed by seal (28). Seal (28) is protected against
dirt by wiper (30).
Important
Depressurising the cylinder
The check valve built into the cylinder prevents any
cylinder movement due to oil leakage within the con-
trol block or sudden loss of hydraulic pressure due to
a hose burst.
PW160-7H 10-127
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DOZER CYLINDER
DOZER CYLINDER
20
3
4
24 23 21 22 21 22 21 5
17
16
25
26
H 8
9
15 6
32 28 31 30 29 28 27
10
14 Caulk spherical plain bearing
four times on both sides
13
12
11
10-128 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DOZER CYLINDER
12
1. O-ring 17. Cylinder
2. Turcon-glyd-ring 18. Piston wear-ring
3. Backup ring 19. Guide
4. O-ring 20. Self locking groove nut
5. Uncut backup ring 21. O-ring
6. Rod wearing 22. Uncut backup ring
7. Cylinder head 23. Valve seat
8. O-ring 24. Throttle bolt
9. Uncut backup ring 25. Valve seat
10. O-ring 26. Control spool
11. Spherical plain bearing 27. Screw plug
12 Grease nipple 28. O-ring
13. Wiper 29. Valve poppet
14. U-ring 30. Pressure spring
15. Grub screw 31. Pressure spring
16. Piston rod 32. Screw plug
Function
Cylinder head (7) guides the piston rod (16) which is
sealed by seal (14). Seal (14) is protected against
dirt by wiper (13).
Important
Depressurising the cylinder
The check valve built into the cylinder prevents any
cylinder movement due to oil leakage within the con-
trol block or sudden loss of hydraulic pressure due to
a hose burst.
PW160-7H 10-129
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
F D
G
L
E
M
J
A
K
B
I
H
L-L M-M
10-130 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT
Work Equipment
Unit: mm
PW160-7H 10-131
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT
1. DIMENSION OF ARM
Unit: mm
PW160-7H Arm Size (M)
Model No.
2.1 2.5 3.0
1 70 +0.1
0
2 81.5 +1.0
0
0.2
3 226 -0.7
-0.03
4 70 -0.06
5 293.9 2 275.7 2 291.8 2
6 199.7 1 199.7 1 219.6 1
7 635.0 0.5 635.0 0.5 631.9 1
8 2,089.8 2,492.2 2,991.9
9 2,100 1.5 2,100.2 1.5 2,100 1.5
10 290 0.5
11 493 0.2
12 422 0.5
13 1,202
14 60
15 261 1
16 60
17 When pressfitting bushing 260
Min. 1,378
18
Max. 2,263
10-132 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT
2.DIMENSION OF BUCKET
Size Size
Model No. (mm) Model No. (mm)
1. 373 10. 85
2. 38 11. 380
3. 95.80 12. 16
4. 374.9 13. 110
5. 1,197 14. 101.5
6. 222 15. 138
7. 60 16. 85
8. 260 17. 85
9. 50
PW160-7H 10-133
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
10-134 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRICAL WIRING DIAGRAM
PW160-7H 10-135
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
A
z
10-136 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
12
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. 08903
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.
PW160-7H 10-137
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
12
2. COMPONENT
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
The fuel control dial is installed near the moni-
tor panel, and a potentiometer is installed
under the knob. The potentiometer shaft is
turned by turning the knob.
As the potentiometer shaft is turned, the resis-
tance of the variable resistor in the potentiom-
eter 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.
Governor motor
10-138 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
1. Potentiometer Function
2. Cover The motor is turned according to the drive signal
from the engine throttle and pump controller to
3. Shaft
control the governor lever of the fuel injection
4. Dust seal pump.
5. Bearing This motor used as the motive power source is a
6. Motor stepping motor.
7. Gear A potentiometer for feedback is installed to moni-
tor the operation of the motor.
8. Connector
Revolution of the motor is transmitted through
the gear to the potentiometer.
Operation
While motor is stopped
Electric power is applied to both phases A and B
of the motor.
PW160-7H 10-139
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL SYSTEM
12
Engine throttle and pump controller
CONTROLLER, GP
PW160-7H
10-140 PW160-7H
12
Input and output signals
1
Control function
Auto-deceleration function
5
10-142 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Wiper position
2
signal
Wiper controller
PPC lock
Susp lock Monitor Panel Swing
Swing position
position
Personal code signal
Swing
signal
sensor
lock
Brake lock Brake
position signal lock
signal
position
Travel forward signal 6
Travel reverse signal
7
Boom raise/Stabiliser
up signal
8
PPC lock selection Boom lower/Stabiliser
Swing lock selection down signal
9
Sus. lock selection
10
11
12
13
14
Service/2PB signal
15
28 31
Battery relay
drive 29 Travel creep
PPC lock 30 sol.
Travel creep signal
RH lever Back press valve signal 32
Relay Travel speed
pick up sensor Back press.
Sus. lock sol. 33
Relay sol.
Relay 34
Travel PPC pressure
Neutral sol 36
Raise Lower
Boom/Stabiliser sol.
Fwd/Rev sol
PPC lock
Relay
35
Outrigger
Monitor
10-144 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
10
11
Attachment
12 Solenoid
13
14
15 2PBoom extend pressure switch
22
23
28
Travel clutch Travel neutral
29 solenoid
solenoid valve
30 valve
34
Travel creep
Back pressure
valve
Travel
Travel PPC pedal
sensor 31
35
Trans-
mission
Speed
sensor
32
33
36
38 Clamshell
Relay
Solenoid
PW160-7H 10-145
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
SJP08754
OR
08908
Travel
Pedal
Monitor Panel
10-146 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
FUNCTION
TRAVEL
SJP08756
OR
08910
AA
SJP08757
OR TRAVEL
08911
AA
PW160-7H 10-147
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) Control method in each mode
Mode A
Matching point in mode A: Rated speed
Model PW160-7H
Mode A SJP08758
2,150 rpm
Working
OR
08913
SJP08760
OR
08914
10-148 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Mode E / Mode B / Mode L
SJP08761
OR
Mode PW160-7H
08915
Mode E 2,010 RPM
08916
SJP08763
OR
08917
OR
08915
Ab
PW160-7H 10-149
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
10-150 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
2. Pump/Valve control function
Stabilizer
Service 1
Service 2
2PBoom
Bucket
Boom
Swing
Travel
Arm
SJP08765
OR
08921
Monitor Panel
SJP09129B B
Function
The machine is matched to various types of work
properly with the 2-stage relief function to
increase the digging force, etc.
PW160-7H 10-151
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) LS control function
The change point (LS set differential pressure) of
the pump discharge in the LS valve is changed
by changing the output pressure from the LS-
EPC valve to the LS valve according to the oper-
ating condition of the actuator.
By this operation, the start-up time of the pump
discharge is optimized and the composite opera- 08922
tion and fine control performance is improved.
2. 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.
550 mA
Operating condition for turning on cut-off function
Condition
The value of the pressure sensors is above
27.9 MPa {285 kg/cm} and the one-touch
power maximizing function is not turned on
The cut-off function does not work, however, while 285 345
the machine is travelling in mode A .
3. 2-stage relief function A
During travel
When swing lock switch is 34.8 MPa
turned on {355 kg/cm}
When boom is lowered
When one-touch power maxi- 37.2 MPa
mizing function is turned on {380 kg/cm}
When L mode is operated
10-152 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
3. One-touch power maximizing function
SJP08766
OR
08923
Monitor Panel
BB
FUNCTION
PW160-7H 10-153
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
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 automati-
cally as shown below.
Software cut-off function
Working Engine/Pump con-
2-stage relief function Operation time
mode trol
34.8 MPa {355 kg/cm}
Matching at rated Automatically
A, E Cancel
output point reset at 8.5 sec
37.2 MPa {380 kg/cm}
10-154 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
4. Auto-deceleration function
SJP08767
OR
08924
Travel
pedal
Monitor Panel
FUNCTION
PW160-7H 10-155
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
OPERATION
10-156 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
5 . Auto-warm-up/Overheat and White Smoke
prevention function
SJP08768
OR
08925
Monitor Panel
FUNCTION
PW160-7H 10-157
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) Auto-warm-up 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.
Resetting condition (Any one) Reset
Water temperature: Above 30C
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 tem-
If the engine cooling water temperature rises too perature rises above 95C.
high during work, the pump load and engine
speed are reduced to prevent overheating.
Work mode: Any mode Fuel control dial: Return to low idle
Water temperature: Engine speed: Low idle position once.
Above 105C Monitor alarm lamp: Lights up Under above condition, controller is set
Alarm buzzer: Sounds to condition before operation of function.
(Manual reset)
Work mode: Mode A, E, OR B Water temperature: Below 102C
Water temperature: Engine speed: Keep as is. Under above condition, controller is set
Above 102C Monitor alarm lamp: Lights up. to condition before operation of function.
Lower pump discharge. (Automatic reset)
Water temperature: Below 100C
Work mode: Mode A
Water temperature: Under above condition, controller is set
Engine speed: Keep as is.
Above 100C to condition before operation of function.
Lower pump discharge.
(Automatic reset)
Water temperature: Below 95C
Work mode: Travel
Water temperature: Under above condition, controller is set
Engine speed: Keep as is.
Above 95C to condition before operation of function.
Lower travel speed.
(Automatic reset)
10-158 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
6 . Swing control function
Pressure
switch
SJP08769
OR Monitor Panel
08926
SJP09133B
FUNCTION
PW160-7H 10-159
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) Swing lock and swing holding brake func- Swing lock operates and
tions machine is locked from swing-
Swing
The swing lock function (manual) is used to lock ON ON ing. Even if swing lever is oper-
lock
machine from swinging at any position. The ated, swing lock is not reset and
swing holding brake function (automatic) is used machine does not swing.
to prevent hydraulic drift after the machine stops
swinging. Operation of swing holding brake release switch
Swing lock switch and swing lock/holding brake If the controller, etc. has a problem, the swing
holding brake does not work normally, and the
Lock Lock machine cannot swing, the swing lock can be
Function Operation
switch lamp reset with the swing holding brake release
switch.
If swing lever is set in neutral,
Swing swing brake operates in about 5
OFF OFF holding sec. If swing lever is operated,
brake brake is released and machine
can swing freely.
10-160 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
7 . Travel control function
SJP08770
OR
08927
FUNCTION
PW160-7H 10-161
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) Pump control function during travel From CREEP to other mode, or from other
If the machine travels in a work mode other than mode to CREEP, travel mode should be
mode A, the work mode and the engine speed changed immediately.
remain unchanged and the pump absorption Default mode should be the last mode when
torque is increased. starter switch was turned off.
For details, see ENGINE/PUMP COMPOSITE Maximum speed 2100 rpm.
CONTROL FUNCTION.
Maximum engine speed:
2. Travel speed change function Max. Engine speed
Manual change with travel speed button on Travel 2450 rpm
the monitor panel.
A Mode 2150 rpm
If the travel speed switch is changed
E Mode 2010 rpm
between CREEP, LO, and HI, the governor/
pump controller controls the pump capacity L Mode 1830 rpm
and motor capacity at each gear speed as B Mode 2040 rpm
shown at right to change the travel speed.
(See engine speed table, right)..
Pump capacity
60 100 100
(%)
Travel speed 0 - 26 0 - 35
2.5 0 ~9.5
(km/h) 0 - 35 0 - 20
10-162 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Monitor Panel
LH
Att. direction
control
RH
PW160-7H 10-163
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
FUNCTION
10-164 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
2. PPC oil pressure switch
1. Plug
2. Switch
3. Connector
SPECIFICATIONS
FUNCTION
PW160-7H 10-165
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
3. Pump pressure sensor
1. Sensor
2. Connector
FUNCTION
10-166 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Release
Lock
To R11
Fuse 3
Brake lights
O: Always work ON
Brake lock SW
O*: Follow the logic below (Proximity SW) OFF
ON ON
OFF
Stop lights
5 min
PW160-7H 10-167
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
SJP08775
OR
08931
10-168 PW160-7H
12
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
MONITOR PANEL
OUTLINE
10-170 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
PW160-7H 10-171
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
MONITOR PORTION 3 2 1 7
8
19 6
11
4 9 12 10 5
13 14
16
15
18
17
10
10
10-172 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
Item
No. Symbol Display item Display method
Displays set mode in top left hand corner of monitor as shown in diagram below.
2. Working mode
3. Travel speed
Travel Direc- Displays the travel direction set by the 3 way switch on the right hand wrist con-
4. tions trol lever.
Engine water
6. temperature See Monitor Gauge Displays on page 175.
gauge
PW160-7H 10-173
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
Hydraulic oil
7. temperature
gauge
8. Fuel gauge
10-174 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
B4 B3 B2 B1 C3 C2 C1
A1
A2
A3
A4 C6
A5
A6
B5 B6 C4 C5
PW160-7H 10-175
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
Item
Symbol Display item Display method Priority
No.
Upper structure When the upper structure is correctly positioned facing forward this dis-
position play is constant. If the position is slightly off this display flashes 3
PPC lock When PPC lock switches in the ON position this display is ON. 1
When displayed:
Automatic sus- Travel pedal operated - suspension lock OFF
pension lock Travel pedal not operated - suspension lock ON
11.
12.
P Parking brake When displayed: Park brake ON
When not displayed: Park brake OFF
10-176 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
When abnormal,
13. Radiator water level Yes Lights up when lights up and buzzer
abnormal sounds
When abnormal,
17. Engine oil pressure Yes -- lights up and buzzer
sounds
PW160-7H 10-177
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
The problems that have occurred are displayed in When the above cautions are displayed, if the
order from the left. hydraulic oil temperature is high or low, only the sym-
bol is displayed.
10-178 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
12
KEYPAD LAYOUT
17 18
16 19
15
14
13
12
10 11
PW160-7H 10-179
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
10-180 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
PW160-7H 10-181
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
10-182 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
PW160-7H 10-183
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
10-184 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
PW160-7H 10-185
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
7 . AUTO-DECELERATION SWITCH
When this auto-deceleration switch (7) is depressed, Monitor display portion
the auto-deceleration is actuated. If the control levers
and foot pedals are in the neutral position, the engine
speed is automatically lowered to reduce fuel con-
sumption.
Monitor display ON: Auto-deceleration actuated.
Monitor display OFF: Auto-deceleration cancelled.
When the auto-deceleration switch is pressed
and the auto-deceleration is actuated, the mode is
displayed in the centre of the monitor display, and the Monitor indicator
screen returns to the normal screen after 2 seconds.
Monitor display portion
2 seconds
10-186 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
12
PW160-7H 10-187
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
10-188 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
ADJUSTMENT SCREENS
(A).Adjusting contrast
1. Use the brightness/contrast screen and press
up switch (14) or down switch (13) to select the
contrast monitor.
(The selected monitor is inverted to black.)
2. When the screen changes to the contrast
adjustment screen, press up switch (14) or down 15
switch (13) to adjust the contrast.
3. After completing adjustment of the contrast, 14
press input confirmation switch (12). This will
store the new setting and return you to the 13
adjustment menu.
As normal, within any menu, press switch (15) to 12
return to the previous screen at any time.
PW160-7H 10-189
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
13
12
10-190 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
PW160-7H 10-191
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
PASSWORD FUNCTION
If the password function is active, the engine will
not start unless the password is input correctly
when starting.
When setting this function or when changing the
password, it is necessary to go from the normal
screen to the setup screen and input the pass
word.
This becomes possible 10 minutes after the
starting switch is turned ON and the monitor
screen has changed to the normal screen.
13
10-192 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
Invalid
PW160-7H 10-193
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
12
SERVICE METER CHECK FUNCTION
When the starting switch is in the OFF position,
press return switch (15) and control switch (14) 15
of the monitor at the same time, and the service
meter will be shown on the display. 14
This display is shown only while the two switches
are being pressed. When the switches are
released, the display goes out.
10-194 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
12
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.
PW160-7H 10-195
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD OVERLOAD WARNING DEVICE
OUTLINE
FUNCTION the operator. When the monitor lamp lights,
This device is installed to warn the operator immediately lower the weight to the ground or
when the machine lifts an excessive weight. bring the arm closer in the operator to prevent
STRUCTURE the machine from tipping over.
When an excessive weight is lifted, the oil pres- NOTE: The overload caution system can only be
sure increases at the bottom side of the boom activated when the lifting mode (L) is activated
cylinders. When this happens, a pressure switch on the monitor panel.
is activated which lights the monitor lamp to warn
Monitor
Lifting mode L
(Must be selected)
Overload warning
monitor lamp
10-196 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
SENSOR
The signals from the sensors are input directly to
the engine controller and pump controller moni-
tor.
The contact type sensors are always connected
at one end to the chassis GND
Sensor name Type of sensor When normal When abnormal Input controller
Coolant level Contact ON (closed) OFF (open)
Monitor
Engine oil level Contact ON (Closed) OFF (Open)
Engine oil pressure Contact ON (Open) OFF (Closed) Engine control-
Coolant temperature Resistance ler
PW160-7H 10-197
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
1. Sub-tank
2. Float
3. Sensor
4. Connector
1. Connector
2. Bracket
3. Float
4. Switch
10-198 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
PW160-7H 10-199
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
Structure of
circuit
1. Thermistor
2. Body
3. Tube
4. Tube
5. Wire
6. Connector
1. Float
2. Connector
3. Cover
4. Variable resistor
10-200 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
Structure of
circuit
PW160-7H 10-201
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
10-202 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
PW160-7H 10-203
1st ATTACHMENT CIRCUIT HYDRAULIC
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PERFORMANCE (MAIN VALVE
The performance of the hydraulic system when oper- The pressure Pb is the pressure observed in the
ating the 1st attachment circuit is shown below. breaker low back pressure return line (back pres-
sure) measured at the attachment outlet connection.
The pressure Pa is that which is observed at the inlet
to the attachment. The figures below show the pressures at points A
and Pb for varying flow through the attachment in A
mode, E mode & B mode.
10-204 PW160-7H
1st ATTACHMENT CIRCUIT HYDRAULIC
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PERFORMANCE (MAIN VALVE
PW160-7H 10-205
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
TRAVEL SYSTEM
TRAVEL CIRCUIT
10-206 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
PW160-7H 10-207
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
1. Travel Motor.
1.1 Shown in the neutral position.
10-208 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
PW160-7H 10-209
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
1. Travel Motor (2) which directs the flow to move the servo and
1.3 Introduction of Creep control: High Torque - Low supply the motor displacement to maximum giv-
Speed. ing creep speed of 2.5kph
It can be seen from the diagram that the spool
moves across on the torque speed control valve
10-210 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
PW160-7H 10-211
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
10-212 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
1. Travel Motor.
1.5 Motor begins to overrun and pressure falls on
supply side: This causes counterbalance valve to
begin to close and throttle return flow from motor.
PW160-7H 10-213
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
1. Travel Motor.
1.6 Motor begins to overrun and pressure falls on
supply side: This causes counterbalance valve to
begin to close and throttle return to flow motor.
Pressure line in return line rises providing a brak-
ing torque.
10-214 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
1. Travel Motor.
1.7 Travel Motor Performance.
1.7.1 High Torque - Low Speed.
PW160-7H 10-215
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
1. Travel Motor.
1.7.2 Low Torque - High Speed.
10-216 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
2. Travel Pedal
PW160-7H 10-217
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
FNR Signal
Status
F N R
0 0 0 N (Error)
0 0 1 N
0 1 0 R
0 1 1 N (Error)
1 0 0 F
1 0 1 N (Error)
1 1 0 N (Error)
1 1 0 N (Error)
10-218 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
PW160-7H 10-219
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
10-220 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
6.2 Travel Creep Solenoid: Located on the 7-stage Travel Mode Travel Speed
Creep Solenoiid Selected (kph)
solenoid manifold in the service compartment at
the rear of the operators cab. When this device is On Creep 0 - 1.5
activated CREEP mode is selected and travel Off Low 0-9
speed, sends PPC pressure to port X on travel
Off High 0 - 35
motor ensure ttravel motor stays at maximum dis-
placement. Off Auto 0 - 35
PW160-7H 10-221
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
7.2 2-Stage Relief Solenoid: Located on the 7- By this operation, the hydraulic force is increased
stage solenoid manifold in the service compart- further
ment at the rear of the operators cab. This device Operating condition for turning on 2-stage relief
is activated when the forward / reverse travel function.
solenoid is selected.
The relief pressure in the normal working mode
is 34.8 Mpa (355 kg/cm2). If the 2-stage relief
function is turned on, however, the relief pres-
sure rises to about 37.2 MPa (380 kg/cm2).
10-222 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
During travel
34.8 Mpa
When swing lock switch is turned on (355 kg/cm2)
When boom is lowered
When one-touch power maximizing 37.2 Mpa
function is turned on. (380 kg/cm2)
When L mode is operated
PW160-7H 10-223
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
Solenoid On Lo 0 - 9 kph
8.2 Hi / Lo Solenoid Valve: Located on the 2-stage Solenoid Off Hi 0 - 35 kph *
solenoid block in the service compartment at the
* : To max speed
rear of the operators cab. This device is activated-
when HI or LO speeds are selected.
10-224 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
PW160-7H 10-225
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
Solenoid Valves
1 Travel Creep (see page 10-221) 4 Swing Brake
2 Travel Neutral (see page 10-220) 5 2 Stage Relief (see page 10-222)
3 Suspension Lock Valve 6 PPC Hyd Pressure Lock
10-226 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL SYSTEM
7 1 2
6
PPC manifold
3 4
9 10 11 12 13 14 15 16 17 18 19 20
PW160-7H 10-227
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
STEERING SYSTEM
OPERATING PRINCIPLES
When the steering wheel is turned the demand for This applies to pressure control valves but also that
fluid at port P of the oorbitrol valve causes the CF of flow control devices incorporating pilot relief valve
signal level to fall. The priority spool is now forced control.
upwards by the spring creating a flow path into the
CF port. Turning the steering wheel also connects
the P port of the orbitrol valve to the service A and
the service port B to tank.
Simultaneously the service port pressure is con-
nected to the priority vavle LS connection on its
spring side. This action causes the priority spool to
take up a modulation condition balanced by the pilot
pressure pp from the CF line on one side and the
service port pressure and spring on the opposite.
This results in a pressure drop across the metering
valve section of the orbit unit equal to the priority
spool spring rating.
Therefore P = pp - LS
= P1 - P2
At this stage the priority valve becomes a pressure
compensator for the steering unit forming a pressure
compensated flow control. This ensures a constant
rate of steering irrespective of changes in steering
cylinder forces.
Dynamic Steering
2 - stage principle
10-228 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
1. Condition 1.
PW160-7H 10-229
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
2. Condition 2.
10-230 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
3. Condition 3.
PW160-7H 10-231
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
4. Condition 4.
10-232 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
5. Condition 5.
PW160-7H 10-233
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
6. Condition 6.
10-234 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
PW160-7H 10-235
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
Technical data
10-236 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
PW160-7H 10-237
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
10-238 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
PW160-7H 10-239
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD STEERING SYSTEM
10-240 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE BRAKE AND SUSPENSION SYSTEM
BRAKING SYSTEM
The hydraulic braking sytem unit contains the follow-
ing services.
Accumulators:
for fluid storage providing a number of brake
operations (usually 5 ~ 8 operations depending
upon accumulator capacity)
Check Valves:
to isolate the inlet supply from the charged accu-
mulators and isolate individually charged accu-
mulators from each other, thereby allowing
individual brake circuits to be controlled.
NOTE: Service brakes1 and 2 are individually
supplied but simultaneously applied.
PW160-7H 10-241
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE BRAKE AND SUSPENSION SYSTEM
10-242 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE BRAKE AND SUSPENSION SYSTEM
PW160-7H 10-243
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE BRAKE AND SUSPENSION SYSTEM
OPERATION
Oil from the steering priority valve passes at a most position, closing off the supply to the auxil-
controlled rate to charge the accumulators. The iary circuit and charging the accumulators once
inlet bypass valve is spring biased into the posi- again.
tionshown and hydraulically balanced.
When the oil pressure in the accumulators reach
the cracking pressure of the pressure limiting
valve it begins to open. The valve in this example
has a pressure overide of 35 bar.
Between 120 and 155 bar the accumulators con-
tinue to charge until the bottom pilot signal on the
inlet bypass valve is diverted to tank, allowing the
inlet bypass valve to move downwards thereby
diverting all the incoming flow to the auxilliary cir-
cuit.
If the break pedal is now operated oil at a con-
trolled pressure will be sent to the service
brakes, the brake force being controlled by the
pre-loading of the valve by the action of the
pedal.
As the brakes are applied the accumulator vol-
umes and associated pressure will fall. This
action will allow the pressure limiting valve to
gradually close as the pressure falls below 155
bar.
Eventually, the flow path through the valve will
close causing the pilot signal on the bottom of
the inlet bypass valve to be re-established. This
in turn will move the inlet bypass in to its upper
10-244 PW160-7H
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE BRAKE AND SUSPENSION SYSTEM
PW160-7H 10-245
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE BRAKE AND SUSPENSION SYSTEM
10-246 PW160-7H
20 TESTING AND ADJUSTING
Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
! When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert 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.
PW160-7H 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Engine
At sudden acceleration
Bosch Max. 4.0 Max. 6.0
Exhaust gas color LO idle - HI idle
index
At high idling Max. 1.5
L/min. 51 102
Blow-by pressure 2500rpm full load with 0.221 inch orifice
{mm H2O} {76.2} {330.2}
20-2 PW160-7H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissible
Item Measurement Condition Unit
value value
PW160-7H 20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
20-4 PW160-7H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissibl
Item Measurement Condition Unit
value e value
Time taken
sec 26.0 2.5 Max. 30
to swing
Hydraulic oil temperature: Within operation range
Engine running at high idling
Working mode: A mode
Time required for 5 more turns after making initial one turn
Swing
15o
Hydraulic
drift of mm 0 0
swing
Hydraulic oil temperature: Within operation range
Engine stopped
Keeping upper structure transverse on slope of 15 degrees
Notching a mating mark on inner and outer races of swing cir-
cle
Mating mark misalignment amount during 5 minutes
Hydraulic oil temperature: Within operation range
leakage
Engine running at high idling
from swing cc/min Max. 21
Swing lock switch: ON
motor
Leakage amount for one minute during swing relief
PW160-7H 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissibl
Item Measurement Condition Unit
value e value
CR 7210%
LO 18 +2 / -0
CR 230 5%
20-6 PW160-7H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissible
Item Measurement Condition Unit
value value
PW160-7H 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissible
Item Measurement Condition Unit
value value
RAISE
3.8 0.4 Max. 4.6
Mono boom
boom lift
Hydraulic oil temperature: Within operation
LOWER
range
Engine running at high idle 2.9 0.5 Max. 3.5
Working mode: A
Time required from raise stroke end till bucket
touches ground
RAISE
4.5 0.4 Max. 5.3
Work equipment speed
Two piece
Work equipment
boom
1st boom lift Hydraulic oil temperature: Within operation
range sec
LOWER
Two piece
boom
2nd boom
adjust
LOWER
20-8 PW160-7H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissible
Item Measurement Condition Unit
value value
RAISE
3.5 0.5 Max. 4.5
Hydraulic oil temperature: Within operation
range
Engine running at high idle
Outrigger
Working mode: A
Time required for 1 outrigger raise stroke end to
LOWER
lower stroke end.
3.9 0.4 Max. 4.7
RAISE
2.1 0.3 Max. 2.7
Hydraulic oil temperature: Within operation
range
Engine running at high idle
Dozer Blade Working mode: A
Time required from raise stroke end to lower
LOWER
sroke end.
2.1 0.3 Max. 2.7
PW160-7H 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissible
Item Measurement Condition Unit
value value
IN
Arm
OUT
range 3.0 0.3 Max. 3.6
Engine running at high idling
Work equipment speed
CURL
2.8 0.3 Max. 3.4
Work equipment
Bucket
DUMP
Monoboom
sec Max. 1.0 Max. 1.2
boom lift
20-10 PW160-7H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissible
Item Measurement Condition Unit
value value
Two piece
Engine running at low idle
boom 1st sec Max. 1.0 Max. 1.2
Operate full boom down from stroke end till bucket touches
boom lift
ground. Measure delay from bucket touching ground to bucket
starting to push the machine up.
PW160-7H 20-11
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Standard Permissible
Item Measurement Condition Unit
value value
Two piece
boom 2nd
Hydraulic oil temperature: Within operation range Max. 1.0 Max. 1.2
boom
adjust Engine running at low idle
Operate full boom adjust down from stroke end till bucket
touches ground. Measure delay from bucket touching ground to
Work equipment
sec
Hydraulic pump
See next page /min See next page
delivery
20-12 PW160-7H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
300
250
200
150
Performance of hydraulic pump
100
50
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
measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PW160-7H 20-13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Mono boom
Time required for turn-
Characteristics of 4.4 0.4
ing from 0 to 90
PC flow control sec Two piece boom
degrees with boom Hydraulic oil temperature: Within operation
valve 5.0 0.4
raised range
Engine at high idling
Working mode: A mode
Rated load applied to bucket
Solid and flat ground
Time required till passing spot of 90 degrees
starting from illustrated posture and with boom
raised
20-14 PW160-7H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
20-16 PW160-7H
20 TESTING AND ADJUSTING
PW160-7H 20-101
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM
A2
Engine RPM may be read off the monitor
panel (special function on the monitor panel).
WARNING! Be careful not to touch the engine by
accident while installing a measure-
ment equipment as the engine can get
extremely hot.
INSPECTION
1. Open up the engine hood.
Slacken off the air conditioner compressor
3. Measure the engine RPM after setting each
and unhook the belt from the pulley wheel.
measurement condition.
(Refer to operation and maintenance manual
NOTE: RPM at low idling:
for adjusting).
Pass the belt over the fan and remove the air A. Set the fuel dial at low idling (MIN).
conditioner compressor belt from machine. B. Move all the control levers of work equip-
Secure the compressor bracket with the fix- ment, swing and travel to the NEUTRAL
ing bolts prior to starting the engine. position.
3.1.RPM at high idling:
A. Turn the auto-decelerator OFF.
B. Set the fuel dial at high idling (MAX).
C. Move all the control levers of work equip-
ment, swing and travel to the NEUTRAL
position.
3.2.RPM at fuel pump relief
A. Set the fuel dial at high idling (MAX)
B. Put the arm in the digging relief position.
3.3.RPM when pump relief and one-touch power
max. switch are set (near rated RPM)
If the fan guard was removed during disas-
sembly then refit this guard correctly prior to A. Set the fuel dial at high idling (MAX).
starting the engine. B. Put the arm in digging relief position and
Use a filter wrench to take off the cover. keep the one-touch max. power switch
depressed.
The one-touch power max. function is auto-
matically released in 8.5 seconds, even if the
1 knob switch is kept depressed. Take mea-
surement during the period.
3.4.RPM when auto-decelerator is set
A. Turn the auto-decelerator ON.
B. Set the fuel dial at high idling (MAX).
C. Move all the control levers of work equip-
ment, swing and travel to the NEUTRAL
position.
20-102 PW160-7H
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM
PW160-7H 20-103
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOUR
20-104 PW160-7H
2.8.Put the polluted filtering paper on non-polluted fil-
tering paper (more than 10 sheets) in the filtering
paper holder, and read the indicated value.
2.9.Detach the measurement tool after the measure-
ment, and make sure that the machine is back to
normal condition.
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOUR
12
20-106 PW160-7H
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
1
3
PW160-7H 20-107
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
20-108 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF COMPRESSION PRESSURE
Nozzle holder:
609 Nm{6.120.92 kgm
PW160-7H 20-109
TESTING AND ADJUSTING MEASUREMENT OF BLOW-BY PRESSURE
1
2. Fit tool E2 to blow-by hose and connect it with
gauge of blow-by kit E1.
20-110 PW160-7H
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
INSPECTION
1. Open up the engine hood, and then detach the
fan guard.
5. Disconnect plug (4) of the fuel injection pump.
2. Take off cover (1) and fit gear F1.
6. Reverse and push in timing pin (5) of the fuel
injection pump, and confirm its cut out portion
matches with protruding portion b inside the
pump.
If timing pin (5) can be pushed in smoothly,
then injection timing is correct.
If timing pin (5) cannot be pushed in
smoothly, 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 assembly F3 may well
be used instead.
3. Locate top dead centre (TDC) for cylinder No. 1
by following procedure described See ADJUST-
MENT OF VALVE CLEARANCE on page 107.
PW160-7H 20-111
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
20-112 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE
PW160-7H 20-113
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE
Threaded portion:
Gasket sealant (LG-6)
ADJUSTMENT
2. Screw back sensor (1) from that position by the 1. Loosen bolts (1) and (2).
prescribed angle.
For monitoring engine speed, refer to the 2. Loosen nut (5) attached to fixed bracket (3), and
section, "Special Function of Monitor Panel". then tighten bolt (6).
20-114 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE
5. Tighten nut.
PW160-7H 20-115
TESTING AND ADJUSTING EMERGENCY SETTING IF FAILURE OCCURS IN ENGINE CONTROL SYSTEM
3
4
10mm
20-116 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
150 ~200MM
the opposite side.
PW160-7H 20-117
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
Hydraulic oil pressure in the hydraulic circuit for 3) Start the engine and keep it running until the
work equipment, swing and travel (hydraulic hydraulic oil temperature rises to the operat-
pump output pressure) may be also confirmed ing range.
with a monitoring function in the monitor panel
(special function of monitor panel). J1
MEASUREMENT
1. Pre-measurement work
Lower the work equipment to the ground, then
release the remaining pressure in the piping by
operating the control lever several times after
stopping the engine, and release the pressure
inside the hydraulic tank by gradually loosening
the oil filler cap. Ignition switch must be in the
ON position.
1) Remove hydraulic oil pressure measuring
plug (1). 2. Measurement of Unload Pressure
1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idling and all the
control levers are moved to the NEUTRAL
position.
20-118 PW160-7H
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
If one-touch power max. switch is mal, adjust the high pressure setting side of
depressed, the oil pressure is turned to high main relief valve (3).
relief pressure, and if released, it is turned to
low relief pressure. The high pressure settinging is the state in
which th 2 stage relief solenoid valve is
Keep the swing lock switch in the OFF posi- turned ON and the pilot pressure is applied.
tion during the inspection. If it is moved to
the ON position, hydraulic oil pressure is
turned to high relief pressure, as the con-
stant 2-stage relief valve is moved to the ON
position.
Hydraulic oil pressure when the swing motor 1) Disconnect the pilot hose.
safety valve is relieved is displayed. 2) Loosen lock nut (5) and adjust the pressure
by turning holder (6).
The swing motor relief pressure is lower than
the main relief pressure. If the holder is turned to the right, the pres-
sure rises.
5. Measurement of travel circuit relief pressure If the holder is turned to the left, the pressure
1) Start the engine and apply service brake to falls.
prevent travel, select forward or reverse
Adjustment amount per turn of holder:
travel.
Approx. 12.5 MPa{approx. 128 kg/cm2}
Hydraulic oil pressure with the main relief 3) Check the pressure again after the adjust-
valve in relief condition is displayed. In the ment, following the aforementioned steps for
travel circuit relief, the pressure is high pres- measurement.
sure relief all the time. When measuring the pressure, connect the
ADJUSTMENT pilot hose.
The unload valve and the safety valve for boom If high pressure setting side is adjusted, low
LOWER cannot be adjusted. pressure setting side is also affected, so
adjust it, too.
1. Adjustment of main relief pressure
(high pressure setting side) 1. Adjustment of main relief pressure (low pressure
setting side)
If relief pressure of the high pressure in the
work equipment and travel circuits is not nor-
PW160-7H 20-119
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
8
Lock nut: 39.2 4.9 Nm {4.0 0.5 kgm}
2. Adjusting swing relief pressure 3) After finishing adjustment, check again that
the pressure is normal according to the pro-
If the relief pressure of the swing circuit is cedure for measurement described above.
abnormal, adjust swing motor safety valves
(9) according to the following procedure.
20-120 PW160-7H
12
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
MEASUREMENT
20-122 PW160-7H
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
1
2
2 3
PW160-7H 20-123
INSPECTION AND ADJUSTMENT OF PUMP PC (VALVE INLET) CONTROL OIL
TESTING AND ADJUSTING PRESSURE
MEASUREMENT
20-124 PW160-7H
INSPECTION AND ADJUSTMENT OF PUMP PC (VALVE INLET) CONTROL OIL
TESTING AND ADJUSTING PRESSURE
3) Start the engine and keep it running until the If there is any abnormality with PC valve or
hydraulic oil temperature rises to the operat- servo piston, the PC valve output pressure
ing range. (servo piston output pressure) equals to the
pump delivery pressure, or approximates to
0 pressure.
1
1. Measurement of PC-EPC output pressure
1) Remove oil pressure measurement plug (5).
Judgement method: J2
When the ratio between the pump delivery
pressure and PC valve output pressure
(servo piston output pressure) reaches the
following values, both pressures are judged J2
normal.
Pressure to be
measured Pressure ratio
Pump delivery
pressure 1
PC valve outlet
pressure Approx. 3/5 3) Start the engine and keep it running until the
hydraulic oil pressure rises to the operating
range.
PW160-7H 20-125
INSPECTION AND ADJUSTMENT OF PUMP PC (VALVE INLET) CONTROL OIL
TESTING AND ADJUSTING PRESSURE
7
B
ADJUSTMENT
6
7
20-126 PW160-7H
12
INSPECTION AND ADJUSTMENT OF PUMP LS VALVE CONTROL OIL
TESTING AND ADJUSTING PRESSURE
MEASUREMENT
1. Measurement of LS valve output pressure 2) Use fitting K2 and connect it to oil pressure
(servo piston inlet pressure) gauge of hydraulic tester K1.
20-128 PW160-7H
INSPECTION AND ADJUSTMENT OF PUMP LS VALVE CONTROL OIL
TESTING AND ADJUSTING PRESSURE
PW160-7H 20-129
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF PUMP LS VALVE CONTROL OIL PRES-
K1
K2
20-130 PW160-7H
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF PUMP LS VALVE CONTROL OIL PRES-
ADJUSTMENT
8
A
PW160-7H 20-131
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
Measure solenoid valve output pressure after Hoses to outlet ports (8 ~ 11) of the 4-station
confirming that control circuit original pressure is manifold in the service area at the rear of
normal. operator's cab.
CAUTION!Lower the work equipment to the ground
and stop the engine. After the engine stops, op-
erate the control lever several times to release
the remaining pressure in the piping. Then loos-
en the oil filler cap to release the pressure inside
the hydraulic tank. Switch must be in the ON po-
sition.
20-132 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
L1
PW160-7H 20-133
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
20-134 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
PW160-7H 20-135
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
20-136 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
PW160-7H 20-137
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
* Pressure switch fitted to this port if 2 attachment fitted 1. Attach fitting of hydraulic tester M and con-
** Pressure switch fitted to this port if 2 piece boom fitted nect oil pressure gauge .
Oil pressure switches (1) through (12) are Use an oil pressure gauge with the capacity
installed in the PPC manifold block installed at of 5.9 MPa{60 kg/cm2}.
the rear of operator's cab.
1
1 2 3 4 5 6 7 8 9 10 11 12
20-138 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
PW160-7H 20-139
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
20-140 PW160-7H
TESTING AND ADJUSTING TESTING TRAVEL MOTOR RELIEF PRESSURE
PW160-7H 20-141
TESTING AND ADJUSTING ADJUSTING TRAVEL MOTOR RELIEF PRESSURE
Tighten locknut.
20-142 PW160-7H
TESTING AND ADJUSTING TESTING PROPSHAFT SPEED
Judgement table
PW160-7H 20-143
TESTING AND ADJUSTING TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT
Judgement table
20-144 PW160-7H
TESTING AND ADJUSTING TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT
X
Y
PW160-7H 20-145
TESTING AND ADJUSTING INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
Fill the bucket with earth or apply the rated If pressure in the accumulator has dropped,
load to the bucket. run the engine for approx. 10 seconds to
charge the accumulator again.
[Reference]If the cause of the hydraulic drift is in the
defective packing, and the above operation is carried
out, downward movement is accelerated for the fol-
lowing reasons.
1) If the work equipment is set to the above posture
(holding pressure applied to the bottom end), the
oil at the bottom end leaks to the head end. How-
ever, the volume at the head end is small than
the volume at the bottom end by the volume of
the rod end, so the internal pressure at the head
end increases because of the oil flowing in from
the bottom end.
2) Operate the control lever to the RAISE posi-
2) When the internal pressure at the head end
tion or the bucket control lever to the CURL
increases, the pressure at the bottom end also
position.
rises in proportion to this. The balance is main-
If the lowering speed increases, the cyl- tained at a certain pressure (this differs accord-
inder packing is defective. ing to the amount of leakage) by repeating this
If there is no change, the control valve is procedure.
defective. 3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
Operate the control lever with the engine
operated according to the procedure given
starting switch in the ON position.
above, the circuit at the head end is opened to
If pressure in the accumulator has dropped, the drain circuit (the bottom end is closed by the
run the engine for approx. 10 seconds to check valve), so the oil at the head end flows to
recharge the accumulator again. the drain circuit and the downward movement
becomes faster.
2. Inspection of arm cylinder
1) Operate the arm cylinder to move the arm to
the position 100 mm before the digging
stroke end, and stop the engine.
20-146 PW160-7H
TESTING AND ADJUSTING INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
PW160-7H 20-147
TESTING AND ADJUSTING INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
20-148 PW160-7H
12
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE AMOUNT
20-150 PW160-7H
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE AMOUNT
4. Measurement of oil leakage amount from 2) Disconnect flushing hose (1) of the travel
swing motor motor and fit a blind plug in the hose end.
1) Disconnect drain hose (4) and fit a blind plug 3) Lock travel pedal so that rotary group cannot
in the hose. rotate.
2) Turn the swing lock switch to the ON posi- 4) Port A or B are set under pressure above the
tion. setting of relief valves (i.e. 380 bar)
3) Start the engine. Apply the swing relief pres- ! In this measurement, an erroneous opera-
sure with the engine running at high idling tion of the control lever will likely lead to a se-
and measure an oil leakage amount under rious accident. Make sure that all the signals
such conditions. and confirmations are followed without fail.
After keeping the conditions in 3) above for After keeping the conditions in 4) above for
30 seconds, measure the oil leakage 30 seconds, measure the oil leakage
amount for one minute. amount for one minute.
After the first measurement, turn the upper Repeat the measurement several times,
structure by 180 degrees and take measure- slightly rotating the motor, i.e. shifting the
ment again in the same way. position of valve plate and cylinder, and the
position of cylinder and piston, and take
measurement several times
4 4
PW160-7H 20-151
TESTING AND ADJUSTING AIR BLEEDING OF VARIOUS PARTS
20-152 PW160-7H
TESTING AND ADJUSTING AIR BLEEDING OF VARIOUS PARTS
PW160-7H 20-153
TESTING AND ADJUSTING INSPECTION PROCEDURES FOR DIODE
7 1
10 5 A
20-154 PW160-7H
12
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
[1] Figure input switch 1 [6] Figure input switch 6 Undo switch
[2] Figure input switch 2 [7] Figure input switch 7 Scroll up switch
[3] Figure input switch 3 [8] Figure input switch 8 Scroll down switch
[4] Figure input switch 4 [9] Figure input switch 9 Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
20-156 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PW160-7H 20-157
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-158 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PW160-7H 20-159
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
12
8. Function for adjusting breaker and attach-
ment flow rate (For machines equipped with
breaker attachment)
When a breaker or other attachments are used, e
hydraulic pump flow rate can be adjusted by
operating the select switch. a
Note that the symbol mark and contents of
display partially differ between the breaker c
b
Select switch (c) is used to select the hydraulic
flow setting in each of the working modes A, E
and B. d
When the working mode is A or E
8.1.Press select switch (c) and normal screen on
monitor display changes to the flow setting
screen shown in the diagram on the right
Press up switch (a) or down switch (b) to adjust
to the desired flow.
20-160 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PW160-7H 20-161
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
User
Code Failed System Action Directed to Operator
Ordinary work may be resumed by turning the emergency pump drive switch ON, but call
E02 PC-EPC Valve for the inspection service immediately.
Release the brake after turning emergency swing and parking brake switch ON. When
applying the swing brake, operate the swing lock switch manually. The swing brake may not
E03 Swing Brake be released depending on the nature of the trouble. In either case, call for the inspection
service immediately.
The governor control has become inoperable. Operate the governor control lever manually.
E05 Governor For fixing the lever at full throttle position, use a fixing bolt provided at the bracket. In this
case, call for the inspection service immediately.
E20 Travel Emergency travel
20-162 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PW160-7H 20-163
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
Classification
Error Code Failure Code
Code No.
Failure
Code Content Code No. Location Phenomenon
User
No.
E01 E132 S-net comm. discontinuity-Hot short DA2SKA Controller Monitor Display
E133 PPC lock sol. discontinuity-Hot short DW2CKA Solenoid Disconnected
E134 PPC lock sol. GND short DW2CKB Solenoid Short Circuit
E01 E135 Sus. lock sol. discontinuity-Hot short DW4AKA Solenoid Disc
E01 E136 Sus. lock sol. GND short DW4AKB Solenoid Short
E137 Working light-F switch discontinuity-Hot short DDW2KA
E138 Working light-F switch GND short DDW2KB
E139 Working light-R switch discontinuity-Hot short DDW2KA
E140 Working light-R switch GND short DDW2KB
E141 Beacon light switch discontinuity-Hot short DDR3KA
E142 Beacon light switch GND short DDR3KB
E143 Wiper switch discontinuity-Hot short DDW1KA
E144 Wiper switch GND short DDW1KB
E145 Seat heater switch discontinuity-Hot short DDH3KA
E146 Seat heater switch GND short DDH3KB
E147 Hazard lamp switch discontinuity-Hot short DDWJKA
E148 Hazard lamp Switch GND short DDWJKB
E149 Outrigger-FR sol. discontinuity-Hot short DWB1KA
Electrical system
E150 Outrigger-FR sol. GND short DWB1KB
E151 Outrigger-FL sol. discontinuity-Hot short DWB1KA
E152 Outrigger-FL sol.GND short DWB1KB
E153 Outrigger-RR sol. discontinuity-Hot short DWB1KA
E154 Outrigger-RR sol. GND short DWB1KB
E155 Outrigger-RL sol. discontinuity-Hot short DWB1KA
E156 Outrigger-RL| sol. GND short DWB1KB
E157 Starter cut switch discontinuity-Hot short D5ZKKA
E158 Starter cut switch GND short D5ZKKB
E20 E201 Travel N sol. DW91KB
E20 E202 Travel FR sol. DW44KB
E03 E203 Swing brake sol. GND short DW45KB
E204 Merge/Flow divider sol. GND short DWJ0KB
E205 2-stage relief solenoid GND short DWK0KB 2-stage relief solenoid valve Short circuit
E20 E206 Transmission clutch sol. DW27KB
E20 E207 Creep sol. DW4MKB
E20 E208 Creep sol. DW4MKA
E20 E211 Travel N sol. DW91KA
E20 E212 Travel FR sol. DW44KA
E03 E213 Swing brake sol. DW45KA
E214 Merge/Flow divider sol. DWJ0KA
E215 2-stage relief sol. discontinuity-Hot short DWK0KA
E20 E216 Transmission clutch sol. DW27KA
20-164 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
Classification
Error Code Failure Code
Code No.
Failure
Code
No. Content Code No. Location Phenomenon
User
Electrical system
E253 Travel PPC press. SW abnormality DDP4KX
E20 E254 Speed sensor discontinuity DLT4KA
E256 Memory error DA20KT
E20 E257 Travel PPC press SW hydraulic abnormality 6B2JMA
E20 E258 Brake lock proximity switch DDB2KX
E261 Service sol. relay PD00KB
E262 Service sol. relay PD00KA
E20 E263 Brake light cut relay DDB2KB
E20 E264 Brake light cut relay DDB2KA
E20 E274 Suspension lock relay DW4AKB
E20 E275 Suspension lock relay DW4AKA
E276 PPC lock relay DW4CKB
E277 PPC lock relay DW4CKA
E301 Engine speed low (under 500 rpm) A000N2
E302 Engine speed is over (travel + 150) rpm A000N1
E306 Gov. motor potentiometer abnormality DK54KZ
E05 E308 Fuel Dial Abnormality DK10KZ
E313 Auto lub. abnormal DA80MA
E315 Battery relay drive GND short D110KB
E316 Governor motor step out DY10K4
E05 E317 Governor motor discontinuity - Hot short DY10KA
E05 E318 Governor motor GND short DY10KB
PW160-7H 20-165
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
Classification
Error Code Failure Code
Code No.
Failure
Code
No. Content Code No. Location Phenomenon
User
Mechanical system
None Radiator water level abnormally low B@BCZK Engine cooling water Cooling water level
lowered
None Hydraulic oil overheated B@HANS Hydraulic oil Overheating
20-166 PW160-7H
12
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
2. Switch operation
Operate the switch as instructed below.
Switch operation: [ ] + [1] [2] [3]
20-168 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PW160-7H 20-169
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
1.3.Monitoring operation
Call the monitoring information display and con-
firm the monitored information, while operating
the machine.
20-170 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PW160-7H 20-171
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-172 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
2.1.Selection of menu
Select 02 Abnormality Record in the initial dis-
play of Service Menu and depress [ ] switch. a
2.2.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
PW160-7H 20-173
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-174 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
3.1.Selection of menu
Select 03 Maintenance Record in Service Menu
and depress [ ] switch.
3.2.Information to be displayed a
PW160-7H 20-175
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-176 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
PW160-7H 20-177
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
5.1.Selection of menu
Select 05 Phone Number Entry menu in the dis-
play of Service Menu, and depress [ ] switch.
20-178 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
6.2.Selection of submenu
Select an item to change from the submenu, and
depress [ ] switch.
No. Default submenu
00 Return (Termination of Default)
01 Key-on Mode
02 Unit
03 With/Without Service Circuit
PW160-7H 20-179
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
12
6.4.Function for unit selection
As the unit to be used in the monitoring function
display of Service Menu, three kinds of unit are
provided.
Unit used for default setting in the monitor
panel is SI, i.e. International System of Units.
20-180 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
7.2.Selection of submenu
Select an item to change from the submenu and
depress [ ] switch.
No. Adjustment submenu
00 Return (termination of adjustment)
01 Governor Motor Adjustment
02 Pump Absorption Torque
03 Low Idle Speed
04 Service Current Adjust.
PW160-7H 20-181
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
20-182 PW160-7H
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
Default
1 2 3 4 5 6 7 8
Adjustment value 370 (Heavy ATT) Adjustment value 372 (Light ATT)
Adjustment value 371 (Medium ATT Adjustment value 373 (Super heavy ATT)
PW160-7H 20-183
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
0 1 2 3 4 5 6 7 8 9 a b c e
Value
Offset current
7.8.Service circuit adjustment (Right hand). Value
(mA)
0 -35
1 -30
2 -25
3 -20
4 -15
5 -10
6 -5
7 (Default) 0
8 5
9 10
Value a 15
b 20
20-184 PW160-7H
12
TESTING AND ADJUSTING PM - TUNE UP SERVICE
PM - TUNE UP SERVICE
( PW160-7 )
PW160
20-186 PW160-7H
1 2 3 4 4 Control circuit source pressure port PEN servo in
PW160-7H
2a 3a
TESTING AND ADJUSTING
20-187
TESTING AND ADJUSTING PM - TUNE UP SERVICE
20-188 PW160-7H
4 Inspection of hydraulic circuit
No Part to be checked Fuel Dial Working Auto One-touch main pump main pump LS Control circuit main pump servo Remarks
Work equipment operation
mode decelerator power max switch pressure
1 PPC circuit Circuit pressure 3.8 +/- 0.2MPa (38 +/- 2.0kg/cm 2)
OFF /- /-
2 Main relief valve Arm dumping relief 34.8 + 0.5MPa (355 + 5kg/cm 2)
/- - 2
3 (When power increased) ON 37.2 + 0.5MPa (380 +/ 5kg/cm )
+
Main - LS = 3.38 /- 1.0MPa (34.5 +/- 10kg/cm 2)
Neutral
LS valve LS differential pressure = Unload pressure
(LS differential Raise road wheels clear of ground using work equipment &
4
pressure valve) Full A OFF chassis attachments. 2
Main - LS = 2.2 +/- 0.1 MPa (22 +/- 1kg/cm )
Select LO travel speed.
OFF
Fully depress travel pedal.
+/-
Right relief 30.9 1.5MPa (315 +/- 15kg/cm 2 )
5 Swing safety valve Swing lock switch ON
Left relief
+/-
Main relief valve, Forward 38.2 1.0MPa (390 +/- 10kg/cm 2)
6 Travel relief
Travel safety valve, Reverse
2
Condition Setting kg/cm 2 kg/cm 2 kg/cm kg/cm 2
No Part to be checked Fuel Dial Working Auto One-touch main pump main pump LS Control circuit main pump servo Remarks
Work equipment operation
mode decelerator power max switch pressure
2
Condition Setting kg/cm 2 kg/cm kg/cm 2
No Part to be checked Fuel Dial Working Auto One-touch main pump PC LS Remarks < Reference value : kg/cm 2 >
Work equipment operation
mode decelerator power max switch EPC EPC
E <14>
8 PC - EPC valve Neutral
Full
OFF OFF
<21>
P
B <16>
2
C02
C01
20-190 PW160-7H
TROUBLESHOOTING
PW160-7H 20-201
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. Use the results of the investigation and in-
spection in Items 2 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1)Start from the simple points.
problems with the machine condition before 2)Start from the most likely points.
this? 3)Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 PW160-7H
TESTING AND ADJUSTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
PW160-7H 20-203
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-204 PW160-7H
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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 solder-
ing may be damaged, or the wiring may be
broken.
PW160-7H 20-205
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
Never pull with one hand.
20-206 PW160-7H
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age 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 connec-
tor, 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.
PW160-7H 20-207
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-208 PW160-7H
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
PW160-7H 20-209
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
20-210 PW160-7H
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PW160-7H 20-211
TESTING AND ADJUSTING 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 hydraulic oil level Add oil
Lubricating oil,
20-212 PW160-7H
TESTING AND ADJUSTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Mode Content
Troubleshooting when Service Code (electrical system) and Failure Code (mechanical
Code display
system) are displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
(Engine) Troubleshooting of engine assembly (refer to the shop manual for engine in 102 series)
1. Troubleshooting steps when calling User Code display in the monitor panel
If User Code display, enter service mode on monitor to display Service 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 Service 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 Service Code or mechanical sys-
tem Failure Code, using the failure history function of the monitor panel.
If Service 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, re-examine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out troubleshooting related to the phe-
nomenon in question.
PW160-7H 20-213
TESTING AND ADJUSTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode (Engine)
display
Action to be taken concerning Service Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
Display Service Code in electrical system after checking failure ing to
2
history dis-
Display Failure Code in mechanical system after checking failure played
3 code
history
Engine-related failure
Engine does not start up easily. (It always takes some time to start
4 S-1
up the engine)
5 Engine does not rotate E-1 S-2
6 Engine rotates, but there is no exhaust gas S-2
Engine does not start
There is exhaust gas, but engine does not
7 S-2
start
8 Engine pickup is poor. (Engine does not follow acceleration) S-3
9 Engine stops while in operation E-2 H-2 S-4
10 Engine rotation is irregular. (There is hunting) E-3 S-5
11 Engine is short of output, or lacks power H-1 S-6
12 Color of exhaust gas is too dark. (Incomplete combustion) S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue S-8
14 Premature engine oil contamination S-9
15 Excessive fuel consumption S-10
Engine cooling water is mixed with engine oil, spurts out or
16 S-11
decreases
17 Engine oil amount increases. (Water or fuel gets in) S-13
18 Abnormal noises are heard S-15
19 Excessive vibrations are caused S-16
20 Engine does not stop E-4
21 Auto-decelerator does not work E-5 H-5
22 Engine auto warming-up device does not work E-6
23 Engine preheater does not work E-7
Failure related to work equipment, swing and travel
Speeds of all work equipment, travel and swing are slow, or they
24 H-1 S-6
lack power
25 Engine rotation drops sharply or stalls H-2 S-4
26 All work equipment, travel and swing do not move E-8 H-3
27 There are abnormal noises from around hydraulic pump H-4
28 Fine control mode function works poorly, or shows slow response H-6
20-214 PW160-7H
TESTING AND ADJUSTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting
No. Failure-looking phenomenon Code User
H mode (Engine)
display code
Work equipment-related failure
29 Boom moves slowly or lacks power E-21, 22 H-7
30 Arm moves slowly or lacks power E-23, 24 H-8
31 Bucket moves slowly or lacks power E-25, 26 H-9
32 Boom, arm or bucket does not move H-10
33 Natural drift of work equipment is too fast H-11
34 Work equipment time lag is too big H-12
Other work equipment moves, when specific work equipment is
35 H-13
relieved
36 One-touch power max. switch does not work E-9, 2126 H-14
Compound operation-related failure
In compound operation, work equipment with larger load moves
37 H-15
slowly
38 In swing + boom RAISE operation, boom moves slowly H-16
39 In swing + travel operation, travel speed drops sharply H-17
Travel-related failure
40 Machine tends to swerve while in travel
41 Travel speed is slow
42 Machine is difficult to steer, or lacks power
43 Travel speed cannot be shifted or is slow or fast
Swing-related failure
44 Machine does not swing E-27 H-23
45 Swing acceleration is poor, or swing speed is slow H-24
46 Upper structure overruns excessively, when stopping swing H-25
47 There is a big shock caused when stopping swing H-26
48 There is abnormal noise generated when stopping swing H-27
49 There is natural drift while in swing H-28
Monitor panel-related failure (Operator's Menu: ordinary display)
50 No display appears in monitor panel at all E-10
51 Part of display is missing in monitor panel E-11
52 Descriptions on monitor panel do not apply to the machine model E-12
In startup inspection, radiator water level caution symbol is dis-
53 B@BCZK
played on the monitor panel, when the engine is running
In startup inspection, engine oil level caution symbol is displayed,
54 when the engine is stopped (with the starting key in the ON posi- B@BAZK
tion)
:
PW160-7H 20-215
TESTING AND ADJUSTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting
No. Failure-looking phenomenon Code User
H mode (Engine)
display code
Refer to Operation and Maintenance
55 In startup inspection, maintenance hour monitor lamp lights up red
Manual
While engine is running, battery charging caution symbol is dis-
56 AB00KE
played on the monitor panel.
57 While engine is running, fuel level monitor lamp lights up red E-13
While engine is running, air cleaner clogging charging caution
58 AA10NX
symbol is displayed on the monitor panel.
While engine is running, engine cooling water temperature gauge
59 B@BCNS
is diplayed in red range
While engine is running, hydraulic oil temperature gauge is
60 B@HANS
diplayed in red range
61 Engine cooling water temperature gauge does not display correctly E-14
62 Hydraulic oil temperature gauge does not display correctly E-15
63 Fuel gauge does not display correctly E-16
64 Swing lock monitor does not display correctly E-17
65 When operating monitor switch, no display appears E-18
66 Windshield wiper does not work E-19
67 Warning buzzer cannot be stopped E-20
Monitor panel-related failure (Service Menu: Special Function Display)
In monitoring function, "Boom RAISE" cannot be displayed cor-
68 E-21
rectly
In monitoring function, "Boom LOWER" cannot be displayed cor-
69 E-22
rectly
In monitoring function, "Arm DIGGING" cannot be displayed cor-
70 E-23
rectly
In monitoring function, "Arm DUMPING" cannot be displayed cor-
71 E-24
rectly
In monitoring function, "Bucket DIGGING" cannot be displayed
72 E-25
correctly
In monitoring function, "Bucket DUMPING" cannot be displayed
73 E-26
correctly
74 In monitoring function, "Swing" cannot be displayed correctly E-27
75 In monitoring function, "Travel" cannot be displayed correctly E-28
76 In monitoring function, "Service" cannot be displayed correctly E-29
Other failure
77 Air conditioner does not work E-301
78 Travel alarm does not sound E-31
20-216 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
O-17 1
A01 X 4 Intermediate Connector
K-2 4
N-18 1
A02 X 4 Intermediate Connector
I-2 4
N-18 1
A03 DT 12 Intermediate Connector
H-2 4
N-20 1
A04 SWP 12 Intermediate Connector
F-2 4
O-11 2
A05 SWP 16 Intermediated connector
G-2 4
N-7 1
A06 SWP 16 Intermediated connector
J-2 4
O-14 2
A07 SWP 16 Intermediated connector
L-2 4
N-8 1
A09 SWP 8 Intermediated connector
D-2 4
O-2 4
A11 DT 3 Swivel Joint Connector
D-2 5
O-2 4
A13 DT 4 Swivel Joint Connector
A-2 5
20-218 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
J-2 1
A99 SWP 8 Intermediated connector
N-2 4
PW160-7H 20-219
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
D-12 2
G72 DT 4 RH F-N-R switch
B-10 1
D-13 2
G73 DT 4 RH console emergency F.N.R switch
B-11 1
E-9 2
G99 Britax 10 Park Brake
B-14 1
20-220 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
P-15 3
H15 090 20 Intermediate Connector
B-18 1
L-22 3
M26 S 12 Air Con Unit
O-5 1
PW160-7H 20-221
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
20-222 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
PW160-7H 20-223
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
20-224 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
PW160-7H 20-225
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
20-226 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
View G
View I
G33
M19
View H
PW160-7H 20-227
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
View G
20-228 PW160-7H
TESTING AND ADJUSTING CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY
View H
View J
P70
P01
P02
P10
K31
PW160-7H 20-229
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
View J
H15
20-230 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
View I
G05 G02
PW160-7H 20-231
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
R22 K19 R51R18 R16 R10 C09 C01 C02 C03 D01
D02
W08
View L
H12
H11 M79
H10 View K
M45
M72
R50
R20
H08
H09
D05
D04
D03
K30
J08
J07
G73
J01 M31
J02
20-232 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
View K
PW160-7H 20-233
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
View L
20-234 PW160-7H
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
Steering Column
G103
G104
P15 G102
G110 G105
G101 G111
G3
G4
G02 G05
PW160-7H 20-235
TESTING AND ADJUSTING CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY
Engine
20-236 PW160-7H
TESTING AND ADJUSTING CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY
Operator Cab
M50
M40
M41 M51
M71
M40
M73
M41
H08
H09
W04 T11
PW160-7H 20-237
TESTING AND ADJUSTING CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY
Work Equipment
20-238 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
PW160-7H 20-239
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
20-240 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
16 799-601-7320
PW160-7H 20-241
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7390
20-242 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
PW160-7H 20-243
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
10
(Blue)
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
20-244 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
5 799-601-2710
Body part No.: 79A-222-2620 (Qty: 5) Body part No.: 79A-222-2610 (Qty: 5)
9 799-601-2950
Body part No.: 79A-222-2660 (Qty: 5) Body part No.: 79A-222-2650 (Qty: 5)
13 799-601-2720
Body part No.: 79A-222-2710 (Qty: 2) Body part No.: 79A-222-2690 (Qty: 2)
PW160-7H 20-245
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
17 799-601-2730
Body part No.: 79A-222-2730 (Qty: 2) Body part No.: 79A-222-2720 (Qty: 2)
21 799-601-2740
Body part No.: 79A-222-2750 (Qty: 2) Body part No.: 79A-222-2740 (Qty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
(Qty: 50) (Qty: 50)
20-246 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
PW160-7H 20-247
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
20-248 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-3460
PW160-7H 20-249
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
20-250 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
6 799-601-7370
PW160-7H 20-251
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
20-252 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
PW160-7H 20-253
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
20-254 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
PW160-7H 20-255
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
20-256 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
PW160-7H 20-257
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
20-258 PW160-7H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)
PW160-7H 20-259
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
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)
20-260 PW160-7H
Miscellaneous connectors
No.of
pins Body (receptacle)
Body (plug)
20
20
20
20
20
PW160-7H 20-303
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
20-304 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Abnormal data in the 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
Cause Standard value in normal and references for troubleshooting
Fuse No. 12 and/or 17
1 If the fuse is blown, there is a big possibility that the circuit has a grounding fault.
defective
Fusible link No. A34 and/
2 If the fusible link is blown, there is a big possibility that the circuit has a grounding fault.
or A35 defective
Presumed cause and standard value in normal
Turn the engine starting switch OFF for the preparations, and hold it in the
OFF position for the troubleshooting.
Disconnection of wiring Resistance
Wiring harness from P01 (female) to FB1-17 outlet Above 1
harness value
3
(Disconnection or Resistance
connector contact fault) Wiring harness between FB1-17 inlet and A35 (male) Above 1
value
Resistance
Wiring harness between A35 (male) and A23 (B terminal) Above 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the
OFF position for the troubleshooting.
Grounding fault of wiring Between wiring harness between P01 (female) to FB1-17 Resistance
Above 1 M
harness outlet and grounding value
4
(Contact with grounding Between wiring harness between FB1-17 inlet and A35 Resistance
circuit) Above 1 M
(male) and grounding value
Between wiring harness between A35 (male) and A23 (B Resistance
Above 1 M
terminal) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the
OFF position for the troubleshooting.
5 Monitor Panel defective
P01 Voltage
Between and 20 30 V
20-306 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
J04 (J-20)
13
14
15
16
(Green)
65A 30A
Monitor panel Fusible link
H10 A02
P01 (070 - 12) (S - 16) (X - 4) A34 (L - 2) A35 (L - 2)
A22
M B A23
J03 (J - 20) Battery
relay
15 A01
FB1 E BR
16 (X - 4) A20 A21
12
17 1 Battery
17 - + - +
18 4
Fuse
19 box
20
(Green)
PW160-7H 20-307
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in S-NET signal
E01 E132 DA2SKA phenomenon (in governor pump controller system)
A failure occurred in S-NET communication between the monitor and controller in the past.
Failure content
(The machine operation returned to normal, 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-deceleration: ON
4. Attachment oil flow rate: Minimum
When the failure cause disappears of itself, the machine operation returns to normal.
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-deceleration 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 Service 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 normal.
Relative
The communication has already returned to normal by the time this Service 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.
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness between P02 (female) and Resistance
circuit) Above 1 M
C01 (female) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
3 harness
(Contact with 24 V circuit) Between wiring harness between P02 (female) and
Voltage Below 1 V
C02 (female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 (male) Voltage
Between and 69V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
20-308 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
Monitor panel controller
H12
P02 (040
40 - 20) (S - 12) C02 (DRC - 40)
N/W GND 20
CAB
PW160-7H 20-309
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Short-circuiting in travel neutral solenoid
E20 E201 DW91KB phenomenon (in governor pump controller system)
Abnormal current flow to the travel neutral solenoid circuit, when power was supplied to the circuit.
Failure content
Power supply to the travel neutral solenoid circuit is switched OFF.
Response from
Even if the failure cause disappears of itself, the solenoid circuit does not return to normal, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on Machine will not drive.
machine
Relative Operation of the travel neutral solenoid (ON or OFF) can be checked in the monitoring function. (Code
information No. 024: Solenoid 2)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Travel neutral solenoid tion during the troubleshooting.
defective V06 (male) Resistance value
1
(Internal short-circuiting or
Between and 27 30 at 20C
grounding fault)
Between and grounding Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Assembled-type relay tion during the troubleshooting.
2 R41 defective
R41 (male) Resistance value
(Internal short-circuiting)
Between and Above 400 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Grounding fault of wiring
harness Between wiring harness from C03 (female) to R41
3
(Contact with grounding (female) and grounding. Resistance
Above 1 M
circuit) Between wiring harness from R41 (female) to A05 to value
V06 (female) and grounding.
20-310 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
EMERGENCY
TRAVEL
SWITCH EMERGENCY
FNR SWITCH
FNR SWITCH
1 2 3 4 5 6
1 3 4 6
EMERGENCY 1 2 3 4
F F
N NORMAL N
R 2 5 R
S23
G72 S25
(DT-4) 1 2 3 4 (090-16) 13 14 15 16 1 2 3 4 G73 (DT-4)
R22
J02 (J-20) (BLACK)
FB1
RELAY FOR
3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 STARTER CUT
1 2 3 5 6
(TRAVEL N)
FUSE BOX
R40 R41
RELAY FOR
TRAVEL F 10 RELAY FOR
EMERGENCY
EMERGENCY
TRAVEL N 20 (TRAVEL N)
(TRAVEL F/R) 1 2 3 5 6 1 2 3 5 6
TRAVEL F/R 28
S0L.
TRAVEL R 30
TRAVEL 38
NEUTRAL S0L.
1
C03 (DRC-40) TRAVEL F/R SOL
2
V08 (DT-2) 7
8
1 A05 (SWP-14)
TRAVEL NEUTRAL SOL J06 (J-20) 3 4 5
2
(PINK)
V06 (DT-2)
3 5 10
J04 (J-20)
(GREEN)
A65
A02
4
(X-4)
A64
PW160-7H 20-311
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Short-circuiting in travel F/R solenoid (in governor
E20 E202 DW44KB phenomenon pump controller system)
Abnormal current flow to the travel F/R solenoid circuit, when power was supplied to the circuit.
Failure content
Power supply to the travel F/R solenoid circuit is switched OFF.
Response from
Even after the failure cause disappears of itself, the solenoid circuit does not return to normal, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on Machine will not reverse.
machine
Relative Operation of the travel F/R solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
information 024: Solenoid 2)
20-312 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
EMERGENCY
TRAVEL
SWITCH EMERGENCY
FNR SWITCH
FNR SWITCH
1 2 3 4 5 6
1 3 4 6
EMERGENCY 1 2 3 4
F F
N NORMAL N
R 2 5 R
S23
G72 S25
(DT-4) 1 2 3 4 (090-16) 13 14 15 16 1 2 3 4 G73 (DT-4)
R22
J02 (J-20) (BLACK)
FB1
RELAY FOR
3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 STARTER CUT
1 2 3 5 6
(TRAVEL N)
FUSE BOX
R40 R41
RELAY FOR
TRAVEL F 10 RELAY FOR
EMERGENCY
EMERGENCY
TRAVEL N 20 (TRAVEL N)
(TRAVEL F/R) 1 2 3 5 6 1 2 3 5 6
TRAVEL F/R 28
S0L.
TRAVEL R 30
TRAVEL 38
NEUTRAL S0L.
1
C03 (DRC-40) TRAVEL F/R SOL
2
V08 (DT-2) 7
8
1 A05 (SWP-14)
TRAVEL NEUTRAL SOL J06 (J-20) 3 4 5
2
(PINK)
V06 (DT-2)
3 5 10
J04 (J-20)
(GREEN)
A65
A02
4
(X-4)
A64
PW160-7H 20-313
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
E205 DWK0KB phenomenon (in governor pump controller system)
Abnormal current flow to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
Failure content
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 normal,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on The one-touch power max. switch does not work.
machine
Relative Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
2-stage relief solenoid tion during the troubleshooting.
defective V02 (male) Resistance value
1
(Internal short-circuiting or
Between and 27 30 at 20C
grounding fault)
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to A05 to Resistance
circuit) Above 1 M
V02 (female) . value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump
3 C03 Working mode Voltage
controller defective
Other than L mode Below 1 V
Between and grounding
L mode 20 30 V
20-314 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
A05 V02 2 - stage relief
C03 (DRC - 40) (SWP - 14) (DT - 2) solenoid valve
(ON) (0FF)
A65
REVOLVING FRAME
PW160-7H 20-315
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Transmission clutch tion during the troubleshooting.
solenoid defective V11 (male) Resistance value
1
(Internal short-circuiting or
Between and 27 30 at 20C
grounding fault)
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to A05 to Resistance
circuit) Above 1 M
V11 (female) . value
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor pump C03 Travel speed Voltage
3
controller defective
Lo Below 1 V
Between and grounding
Hi + Travel operation 20 30 V
20-316 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
A05 V11 Transmission clutch
C03 (DRC - 40) (SWP - 14) (DT-2) solenoid valve
(ON) (OFF)
A65
PW160-7H 20-317
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Short-circuit in creep solenoid
E20 E207 DW4MKB phenomenon (in governor pump controller system)
Abnormal current flow to the creep solenoid, when power was supplied to the circuit.
Failure content
Power supply to the creep solenoid circuit is switched OFF.
Response from
Even after the failure cause disappears of itself, the machine operation does not return to normal,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on The travel speed does not turn to Creep.
machine
Relative Operation of the creep solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
information 023: Solenoid 1)
Cause Standard value in normal and references for troubleshooting
Presumed cause and standard value in normal
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Creep solenoid defective
1 (Internal short-circuiting or V07 (male) Resistance value
grounding fault) Between and 27 30 at 20C
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to A05 to Resistance
circuit) Above 1 M
V07 (female) . value
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor pump C03 Travel speed Voltage
3
controller defective
Lo Below 1 V
Between and grounding
Hi + Travel operation 20 30 V
20-318 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
A05 V07 Creep
CO3 (DRC - 40) (SWP - 14) (D - 2) solenoid valve
Creep SOL 17 9 1
2
(ON) (OFF)
A65
AB
PW160-7H 20-319
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in creep solenoid
E20 E208 DW4MKA phenomenon (in governor pump controller system)
Failure content No current flows to the creep 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 normal.
Phenomenon
occurring on The travel speed does not turn to Creep.
machine
Operation of the creep solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
Relative 023: Solenoid 1)
information The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E208].)
Cause Standard value in normal and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Presumed cause and standard value in normal
20-320 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
A05 V07 Creep
CO3 (DRC - 40) (SWP - 14) (D - 2) solenoid valve
Creep SOL 17 9 1
2
(ON) (OFF)
A65
BB
PW160-7H 20-321
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in travel neutral solenoid
E20 E211 DW91KA phenomenon (in governor pump controller system)
Failure content No current flows to the travel neutral 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 normal.
Phenomenon
occurring on Machine will not travel.
machine
Operation of the travel neutral solenoid (ON or OFF) can be checked in the monitoring function. (Code
Relative No. 024: Solenoid 2)
information The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E211])
Cause Standard value in normal and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Travel neutral tion during the troubleshooting.
1 solenoid defective V06 (male) Resistance value
(Internal disconnection)
Between and 27 30 at 20C
Presumed cause and standard value in normal
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Between wiring harness from C03 (female) to R41 to Resistance
2 (Disconnection or defec- Below 1
A05 to V06 (female) value
tive contact with connec-
tor) Resistance
Wiring harness between V02 (female) and grounding Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
3 harness Between wiring harness from C03 (female) to R41 to
(Contact with 24 V circuit) A05 to V06 (female) , or between wiring harness C03 Voltage Below 1 V
(female)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Governor pump tion during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between and grounding 20 60
20-322 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
EMERGENCY
TRAVEL
SWITCH EMERGENCY
FNR SWITCH
FNR SWITCH
1 2 3 4 5 6
1 3 4 6
EMERGENCY 1 2 3 4
F F
N NORMAL N
R 2 5 R
S23
G72 S25
(DT-4) 1 2 3 4 (090-16) 13 14 15 16 1 2 3 4 G73 (DT-4)
R22
J02 (J-20) (BLACK)
FB1
RELAY FOR
3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 STARTER CUT
1 2 3 5 6
(TRAVEL N)
FUSE BOX
R40 R41
RELAY FOR
TRAVEL F 10 RELAY FOR
EMERGENCY
EMERGENCY
TRAVEL N 20 (TRAVEL N)
(TRAVEL F/R) 1 2 3 5 6 1 2 3 5 6
TRAVEL F/R 28
S0L.
TRAVEL R 30
TRAVEL 38
NEUTRAL S0L.
1
C03 (DRC-40) TRAVEL F/R SOL
2
V08 (DT-2) 7
8
1 A05 (SWP-14)
TRAVEL NEUTRAL SOL J06 (J-20) 3 4 5
2
(PINK)
V06 (DT-2)
3 5 10
J04 (J-20)
(GREEN)
A65
A02
4
(X-4)
A64
PW160-7H 20-323
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in travel F/R solenoid
E20 E212 DW44KA phenomenon (in governor pump controller system)
Failure content No current flows to the travel F/R 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 normal.
Phenomenon
occurring on It is difficult to steer the machine while travelling.
machine
Operation of the travel F/R solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
Relative 024: Solenoid 2)
information The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E212])
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Between wiring harness from C03 (female) to R40 to Resistance
2 (Disconnection or defec- Below 1
A05 to V08 (female) value
tive contact with connec-
tor) Resistance
Wiring harness between V08 (female) and grounding Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
3 harness Between wiring harness from C03 (female) to R40 to
(Contact with 24 V circuit) A05 to V08 (female) , or between wiring harness C03 Voltage Below 1 V
(female)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Governor pump tion during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between and grounding 20 60
20-324 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
EMERGENCY
TRAVEL
SWITCH EMERGENCY
FNR SWITCH
FNR SWITCH
1 2 3 4 5 6
1 3 4 6
EMERGENCY 1 2 3 4
F F
N NORMAL N
R 2 5 R
S23
G72 S25
(DT-4) 1 2 3 4 (090-16) 13 14 15 16 1 2 3 4 G73 (DT-4)
R22
J02 (J-20) (BLACK)
FB1
RELAY FOR
3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 STARTER CUT
1 2 3 5 6
(TRAVEL N)
FUSE BOX
R40 R41
RELAY FOR
TRAVEL F 10 RELAY FOR
EMERGENCY
EMERGENCY
TRAVEL N 20 (TRAVEL N)
(TRAVEL F/R) 1 2 3 5 6 1 2 3 5 6
TRAVEL F/R 28
S0L.
TRAVEL R 30
TRAVEL 38
NEUTRAL S0L.
1
C03 (DRC-40) TRAVEL F/R SOL
2
V08 (DT-2) 7
8
1 A05 (SWP-14)
TRAVEL NEUTRAL SOL J06 (J-20) 3 4 5
2
(PINK)
V06 (DT-2)
3 5 10
J04 (J-20)
(GREEN)
A65
A02
4
(X-4)
A64
PW160-7H 20-325
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in swing and parking brake solenoid
E03 E213 DW45KA phenomenon (in governor pump controller system)
Failure content No current flows to the swing parking brake solenoid circuit, when power is supplied to the circuit.
Response from None in particular (The solenoid does not function as there is no current flowing to it)
controller When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon
occurring on The machine's upper structure does not swing.
machine
Operation of the swing parking brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in
the OFF position.
The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E213])
Cause Standard value in normal and references for troubleshooting
Swing parking brake Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V03 (male) Resistance value
tion) Between and 27 30 at 20C
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Swing lock switch during the troubleshooting.
defective
Presumed cause and standard value in normal
20-326 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
S22
1 2 3 4 5 6 1 2 3 4 5 6
EMERGENCY OFF
NORMAL ON
1 2 3 4
X05
D05
J10
8 9 10 11 2 1 11 12 13 19 20 8 10
S25
H15
1 VB (CONTROLLER PWR)
11 VB (CONTROLLER PWR)
14 KEY_SIG
24 KEY_SIG
P02
17 SWING LOCK
PW160-7H 20-327
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in 2-stage relief solenoid
E215 DWK0KA phenomenon (in governor pump controller system)
Failure content No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from None in particular (The solenoid does not function as there is no current flowing to it)
controller When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon
occurring on The one-touch power max. switch does not work.
machine
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E215].)
Cause Standard value in normal and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
2-stage relief solenoid tion during the troubleshooting.
Presumed cause and standard value in normal
20-328 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
A05 V02 2 - stage relief
C03 (DRC - 40) (SWP - 14) (DT - 2) solenoid valve
(ON) (0FF)
A65
REVOLVING FRAME
PW160-7H 20-329
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in transmission clutch solenoid
E20 E216 DW27KA phenomenon (in governor pump controller system)
Failure content No current flows to the transmission clutch solenoid circuit, when power is supplied to the circuit.
Response from None in particular (The solenoid does not function as there is no current flowing to it)
controller When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon
The travel speed does not shift to Lo. (Machine defaults to Hi)
occurring on
(The display changes normally in the monitor panel)
machine
Operation of the transmission clutch solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E216])
Cause Standard value in normal and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Transmission clutch sole- tion during the troubleshooting.
Presumed cause and standard value in normal
20-330 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
A05 V11 Transmission clutch
C03 (DRC - 40) (SWP - 14) (DT-2) solenoid valve
(ON) (OFF)
A65
PW160-7H 20-331
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Wiring harness between C02 (female) and C09 Resistance
2 (Disconnection or defec- Below 1
(male) value
tive contact with connec-
tor) Resistance
Wiring harness C09 (male) and J05 and grounding. Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Wiring harness between C02 (female) and C09 (male) Resistance
Above 1 M
and grounding value
Grounding fault of wiring
harness Wiring harness C02 (female) and C09 (male) and Resistance
3 Above 1 M
(Contact with grounding grounding value
circuit) Wiring harness between C02 (female) and C09 (male) Resistance
Above 1 M
and grounding value
Resistance
Between wiring harness C02 and C09 and grounding Above 1 M
value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump C02 Voltage
4
controller defective
Between , , or and grounding 20 30 V
Between and grounding Below 1 V
20-332 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Model selection 4 7 1
Model selection 5 13 2
Model selection 3 17 3
Model selection 2 27 4
Model selection 1 37 5
6
7
J05 (J-20) 8
11 A01 (X - 4)
9 3
A64
(Pink)
PW160-7H 20-333
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Disconnection of wiring Wiring harness between C02 (female) and C09 Resistance
harness Below 1
(male) value
2 (Disconnection or defec-
Wiring harness between C02 (female) and C09 Resistance
tive contact with connec- Below 1
tor) (male) value
Between wiring harness C09 (male) and J05 and Resistance
Below 1
grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Grounding fault of wiring Between wiring harness C02 (female) and C09 (male) Resistance
Above 1 M
harness and grounding value
3
(Contact with grounding Between wiring harness C02 (female) and C09 (male) Resistance
circuit) Above 1 M
and grounding value
Resistance
Between wiring harness C02 and C09 and grounding Above 1 M
value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump C02 Voltage
4
controller defective
Between , or and grounding 20 30 V
Between or and grounding Below 1 V
20-334 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Model selection 4 7 1
Model selection 5 13 2
Model selection 3 17 3
Model selection 2 27 4
Model selection 1 37 5
6
7
J05 (J-20) 8
11 A01 (X - 4)
9 3
A64
(Pink)
PW160-7H 20-335
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in S-NET signal
E20 E218 DA2SKA phenomenon (in governor pump controller system)
A failure occurred in S-NET communication between the monitor and controller in the past.
Failure content
(The machine operation returned to normal, 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-deceleration: ON
4. Attachment oil flow rate: Minimum ( )
When the failure cause disappears of itself, the machine operation returns to normal.
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-deceleration 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 Service 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 normal.
Relative
The communication has already returned to normal by the time this Service 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.
: The multi-monitor specification machine only.
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness P02 (female) and C02 Resistance
Above 1 M
circuit) (female) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
3 harness
Between wiring harness P02 (female) and C02
(Contact with 24 V circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 (male) Voltage
Between and 69V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Governor pump during the troubleshooting.
5 C02 (male) Voltage
controller defective
Between and 69V
20-336 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
Monitor panel controller
H12
P02 (040 - 20) (S - 12) C02 (DRC - 40)
S - NET GND 20
CAB
PW160-7H 20-337
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
E222 DXE0KB phenomenon (in governor pump controller system)
Abnormal current flow to the LS-EPC solenoid circuit.
Failure content
The controller reduces the output to the LS-EPC solenoid circuit to 0.
Response from
Even if the failure cause disappears, the current does not return to normal, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
The travel speed is slow at Lo.
occurring on
In L mode, speeds of the work equipment and swing are too fast.
machine
Relative Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
LS-EPC solenoid defec- tion during the troubleshooting.
tive V22 (male) Resistance value
1
(Internal short-circuiting or
Between and 7 14
grounding fault)
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness C03 (female) and V22 (female) Resistance
Above 1 M
circuit) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Governor pump C03 (female) Resistance value
3
controller defective
Between and 7 14
Between and grounding Above 1 M
Governor pump
controller
Solenoid GND 13 5 6 6 2
Solenoid GND 23
20-338 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
E223 DXE0KA phenomenon (in governor pump controller system)
Failure content No current flows to the LS-EPC solenoid circuit.
Response from None in particular (The solenoid does not function as there is no current flowing to it)
controller When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon
The travel speed is slow at Lo.
occurring on
In L mode, speeds of the work equipment and swing are too fast.
machine
Relative Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)
Cause Standard value in normal and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
LS-EPC solenoid defec- tion during the troubleshooting.
Presumed cause and standard value in normal
Governor pump
controller
Solenoid GND 13 5 6 6 2
Solenoid GND 23
PW160-7H 20-339
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Abnormality in pump pressure sensor
E224 DDHPAKP phenomenon (in governor pump controller system)
Failure content Signal voltage from the pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.
Response from The controller controls the pump pressure at 0 MPa{0 kg/cm2}.
controller If the failure cause disappears, the sensor returns to normal of itself.
Phenomenon
occurring on The travel speed does not shift automatically.
machine
Relative Input from the pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 011: pump pressure)
Cause Standard value in normal and references for troubleshooting
1 Sensor power source fault If the Service Code No. [E226] is displayed, troubleshoot the failure first.
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Pump pressure sensor
2 defective A51 Voltage
(Internal failure) Between and 4.5 5.5 V
Between and 0.5 4.5 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Presumed cause and standard value in normal
20-340 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller Pump oil
A06 A51 pressure
C01 (DRC - 24) (SWP - 16) (DT - 3) sensor
8 3 A GND
Pump pressure
sensor signal GND 10 7 B 5V
sensor 5V
22 C SIG
A03
(DT - 12)
PW160-7H 20-341
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Abnormality in pressure sensor power source
E226 DH10KS phenomenon (in governor pump controller system)
Abnormal current flow to the power source circuit (5 V) for the pressure sensors and potentiometer.
Failure content
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 normal, unless the
controller
engine starting switch is once turned OFF.
Phenomenon Signals from the pressure sensors and potentiometer are not inputted correctly.
occurring on The Service Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at
machine the same time.
(Internal short-circuit)
Governor motor potentiometer E10 Connector
Pump pressure sensor A51 Connector
Overload caution sensor G164 Connector
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Between wiring harness from C01 (female) to E06 Resistance
Above 1 M
(female) and grounding [Fuel dial system] value
Grounding fault of wiring Between wiring harness from C01 (female) to E10
Resistance
harness (female) and grounding Above 1 M
2 value
(Contact with grounding [Governor potentiometer system]
circuit) Between wiring harness from C01 (female) to A51
Resistance
(female) and grounding Above 1 M
value
[Pump pressure sensor system]
Between wiring harness C01 (female) to G164 (female) Resistance
Above 1 M
and grounding. value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Governor pump during the troubleshooting.
3
controller defective C01 Voltage
Between and 4.5 5.5 V
20-342 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
Signal GND 10
Governor potentiometer 13
Fuel dial 19
CAB
Sensor GND 21
Sensor 5V 22
A03 3 7 10
A06
(DT - 12) (SWP - 16)
6 7 8
G164 Pump oil
(DT - 3) A51 (DT - 3) press. sensor
A A
O/load
caution B B
sensor
C C
E21
(DT - 12)
Governor 11 12 10
potentiometer E10 (DT - 3)
A
B
C
PW160-7H 20-343
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service 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 normal.
Phenomenon
occurring on The machine lacks power.
machine
Relative Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine RPM)
Cause Standard value in normal and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Engine rotation sensor tion during the troubleshooting.
fault E04 (male) Resistance value
1
(Internal short-circuiting or
500 1,000
Presumed cause and standard value in normal
Between and
disconnection)
Between and grounding Above 1 M
Engine rotation sensor For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation Sen-
2
adjustment improper sor" in this manual.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness Wiring harness between C02 (female) and E04 (female) Resistance
3 (Disconnection or defec- Below 1
value
tive contact with connec-
tor) Wiring harness between C02 (female) and E04 (female) Resistance
Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
4 harness
Between wiring harness C02 (female) and E04 (female)
(Contact with 24 V circuit) Voltage Below 1 V
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump C02 (female) Resistance value
5
controller defective
Between and 500 1,000
Between and grounding Above 1 M
Governor pump
controller
CAB ENGINE
20-344 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (in governor pump controller system)
Abnormal current flow to the PC-EPC solenoid circuit.
Failure content
The controller reduces the output to the PC-EPC solenoid circuit to 0.
Response from
Even if the failure cause disappears, the current does not return to normal, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
occurring on As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
machine
Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information in a working mode equivalent to E mode by turning the emergency drive switch ON.
(At that time the monitor panel continues to display service code No. [E232], but this is not abnormal)
Turn the emergency driving switch ON during the troubleshooting.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
PC-EPC solenoid defec- tion during the troubleshooting.
tive V21 (male) Resistance value
1
(Internal short-circuiting or
Between and 7 14
grounding fault)
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to S25 to Resistance
Above 1 M
circuit) A04 to V21 (female) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Governor pump C03 (female) Resistance value
3
controller defective
Between and 7 14
Between and grounding Above 1 M
20-346 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
FB1
2 1
(30 )
2
Governor pump 3
controller
4
CAB
C03 (DRC - 40) 5
Solenoid GND 3 6
A04 3
(SWP - 12)
1 2 (Green)
A02
(X - 4)
E22 4
HYD PUMP
PC - EPC V21 2 3 (DT - 12)
solenoid valve (DT - 12)
1
2 A64
PW160-7H 20-347
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (in governor pump controller system)
Failure content No current flows to the PC-EPC solenoid circuit.
Response from None in particular (The solenoid does not function as there is no current flowing to it)
controller When the failure cause disappears of itself, the current returns to normal.
Phenomenon
occurring on As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
machine
Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative
If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information
in a working mode equivalent to E mode by turning the emergency driving switch ON. (At that time the
monitor panel continues to display Service Code No. [E233], but this is not abnormal)
Cause Standard value in normal and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
PC-EPC solenoid tion during the troubleshooting.
1 defective
V21 (male) Resistance value
(Internal short-circuiting)
Between and 7 14
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Emergency pump driving S25 Switch Resistance value
2 switch defective OFF Below 1
Presumed cause and standard value in normal
Between and
(Internal disconnection) ON Above 1 M
OFF Below 1
Between and
ON Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Resistance
Disconnection of wiring Wiring harness between C03 (female) and S25 Below 1
value
harness Resistance
3 (Disconnection or defec- Wiring harness between S25 and V21 (female) Below 1
value
tive contact with connec-
Wiring harness between C03 (female) , , and S25 Resistance
tor) Below 1
value
Resistance
Wiring harness between S25 and V21 (female) Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Short-circuiting of wiring
Between wiring harness C03 (female) and S25 and
4 harness Voltage Below 1 V
grounding
(Contact with 24 V circuit)
Between wiring harness S25 and V21 (female) and
Voltage Below 1 V
grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Governor pump tion during the troubleshooting.
5
controller defective C03 (female) Resistance value
Between and , , . 7 14
20-348 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
FB1
2 1
(30 )
2
Governor pump 3
controller
4
CAB
C03 (DRC - 40) 5
Solenoid GND 3 6
A04 3
(SWP - 12)
1 2 (Green)
A02
(X - 4)
E22 4
HYD PUMP
PC - EPC V21 2 3 (DT - 12)
solenoid valve (DT - 12)
1
2 A64
PW160-7H 20-349
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Short circuit of 2-stage back pressure solenoid
E236 DWK2KB phenomenon (in governor pump controller system)
Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
Failure content
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 normal,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on Travel may be uncomfortable due to excessive noise from travel motor.
machine
Operation of the 2-stage back pressure solenoid (ON or OFF) can be checked in the monitoring func-
Relative
tion.
information
(Code No. 024: Solenoid 2)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
2-stage back pressure tion during the troubleshooting.
solenoid defective V15 (male) Resistance value
1
(Internal short-circuiting or
Between and 27 30 at 20C
grounding fault)
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to A05 to Resistance
circuit) Above 1 M
V15 (female) . value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump C03 Working mode Voltage
3
controller defective
Other than L mode Below 1 V
Between and grounding
L mode 20 30 V
20-350 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
A05 V15 2-Stage back pressure
CO3 (DRC - 40) (SWP - 14) (DT - 2) solenoid valve
2-stage back press SOL 36 6 1
2
(ON) (OFF)
A65
PW160-7H 20-351
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in 2-stage back pressure solenoid
E237 DWK2KA phenomenon (in governor pump controller system)
Failure content No current flows to the 2-stage back pressure 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 normal.
Phenomenon
occurring on Travel may be uncomfortable due to excessive noise from travel motor.
machine
Operation of the 2-stage back pressure solenoid (ON or OFF) can be checked in the monitoring func-
tion. (Code No. 024: Solenoid 2)
Relative
The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
information
the repairs. (Operation of the 2 stage back pressure solenoid [ON or OFF] can be checked in the moni-
toring function [code 024: solenoid 2]).
20-352 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
A05 V15 2-Stage back pressure
CO3 (DRC - 40) (SWP - 14) (DT - 2) solenoid valve
2-stage back press SOL 36 6 1
2
(ON) (OFF)
A65
PW160-7H 20-353
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
E245 DXE4KB phenomenon EPC (in governor pump controller system)
Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Failure content
The controller reduces to zero (0) 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 normal, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on The attachments do not move.
machine
Relative It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Attachment oil flow rate tion during the troubleshooting.
adjusting EPC defective V13 (male) Resistance value
1
(Internal short-circuiting or
Between and 7 14
grounding fault)
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness C03 (female) and V13 (female) Resistance
circuit) Above 1 M
and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Governor pump C03 (female) Resistance value
3
controller defective
Between and 7 14
Between and grounding Above 1 M
Governor pump
controller
A04 V13 Service flow
C03 (DRC - 40) (SWP - 12) (X - 2) control valve
solenoid GND 3 7 1
solenoid GND 13 8 2
solenoid GND 23
CAB
20-354 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in attachment oil flow rate adjusting
E246 DXE4KA phenomenon EPC (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 normal of itself.
Phenomenon
occurring on The attachments do not move.
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)
Cause Standard value in normal and references for troubleshooting
Attachment oil flow rate Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Presumed cause and standard value in normal
Governor pump
controller
A04 V13 Service flow
C03 (DRC - 40) (SWP - 12) (X - 2) control valve
solenoid GND 3 7 1
solenoid GND 13 8 2
solenoid GND 23
CAB
PW160-7H 20-355
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in direction control switches (in governor
E20 E247 DDWCKZ phenomenon pump controller system)
Failure content Error code appears on monitor when travel pedal operated.
Response from
Defaults travel mode to N (Neutral).
controller
Phenomenon
occurring on Machine cannot travel
machine
Relative
information
Presumed cause and standard
S09
C01 1
Travel reverse A06 Reverse
12 2
pressure switch (SWP - 16)
16
S10
C02 15
1
Travel forward Forward
6 2
pressure switch
A65
AC
20-356 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Abnormality in overload caution sensor
E251 DHX1MA phenomenon (in governor pump controller system)
Failure content A normal pulse signal is not inputted to the signal circuit in the overload caution 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 normal.
Phenomenon
occurring on Caution may illuminate on monitor
machine
Relative
Warning buzzer may sound
information
20-358 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
A06
(HDP47)
Overload Caution 3
(Analogue Type) C01 - (DRC - 24)
G164
7 10 (DT - 3)
A
Overload
B Caution
Ground
10 Sensor
(Sig.)
C
22
A03
(HDP47)
Potentionmeter Power
PW160-7H 20-359
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Abnormality in the travel PPC sensor in governor
E20 E252 DHS2KX phenomenon pump controller system)
Failure content A normal signal is not inputted to the signal circuit from the travel PPC sensor.
Response from No control of engine speed via throttle pedal during travel operation.
controller If the failure cause disappears of itself, the signal input returns to normal.
Phenomenon
occurring on The machine lacks speed unless engine fuel dial is turned to Hi position.
machine
Relative
information
Travel
GND (SGNL) 10 3 2 PPC
sensor
16 11 3
A99
(DT-8)
20-360 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in transmission speed sensor
E20 E254 DLT4KA phenomenon (in governor pump controller system)
Failure content A normal pulse signal is not inputted to the signal circuit in the transmission speed sensor.
Response from The machine will default to Hi travel speed only.
controller If the failure cause disappears of itself, the signal input returns to normal condition.
Phenomenon
The machine defaults to Hi speed travel.
occurring on
Monitor will not display travel speed.
machine
Relative
Input from the transmission speed sensor (rpm) can be confirmed in the monitor function.
information
Between and
disconnection)
Between and grounding Above 1 M
Transmission speed sen- For the inspection and adjustment, refer to the section of "Adjusting Transmission speed
2
sor adjustment improper Sensor" in this manual.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Wiring harness between C02 (female) and A57 (female) Resistance
3 (Disconnection or defec- Below 1
value
tive contact with connec-
tor) Resistance
Between C02 (female) and A57 . Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
4 harness
Wiring harness between C02 (female) and A57 (female)
(Contact with 24 V circuit) Voltage Below 1 V
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump C02 (female) Resistance value
5
controller defective
Between C02 and C02 500 1,000
Between C02 and grounding Above 1 M
20-362 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
C01 (DRC-24)
4 GND (Sig.)
C02(DRC-40)
29 GND (Pulse)
A04
12 11 10 (SWP-12)
N S
1 2
A57
(DT-2)
1 2
A14 A11
(DT-3) (DT-3)
1 1
2
Swivel 2
Joint
3 3
PW160-7H 20-363
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Incorrect non-volatile memory data
E256 DA20KT phenomenon (in governor pump controller)
Failure content The data in the non-volatile memory in the controller cannot be updated.
None in particular
Response from
Even if the failure cause disappears, the non-volatile memory does not return to normal, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
In some cases control parameters of the machines change, resulting in increase or decrease of the
occurring on
machine's power.
machine
Relative
Recorded in the non-volatile memory are part of the machine control parameters
information
20-364 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Incorrect non-volatile memory data
E257 6B2JMA phenomenon (in governor pump controller)
Hydraulic signal activates one pressure switch (Either forward or reverse but R.H PPC work lever
Failure content
switch selects opposite travel direction.
Response from
Error code is displayed on the monitor panel.
controller
Phenomenon
occurring on Engine speed raises when travel pedal is operated but machine does not travel.
machine
Relative This error ocurs when hydraulic PPC travel hoses are connected to incorrect ports.
information Countermeasure - Swap hoses.
PW160-7H 20-365
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Abnormality in governor potentiometer
E306 DK54KZ phenomenon (in governor pump controller)
Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
Failure content
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 normal,
unless the engine starting switch is once turned OFF.
The engine cannot attain the specified rotation at high idling. (Lower than normal operation)
The engine cannot attain the specified rotation at low idling (Higher than normal operation)
Phenomenon
The auto-deceleration 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)
Cause Standard value in normal and references for troubleshooting
Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Governor potentiometer E10 (male) Resistance value
2 defective Between and 4.0 6.0 k
(Internal failure)
Between and 0.25 5.0 k
Between and 0.25 5.0 k
Presumed cause and standard value in normal
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Disconnection of wiring Wiring harness between C01 (female) to E10 (female) Resistance
harness Below 1
value
3 (Disconnection or defec-
Wiring harness between C01 (female) and E10 (female) Resistance
tive contact with connec- Below 1
value
tor)
Wiring harness between C01 (female) and E10 (female) Resistance
Below 1
value
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
4
(Contact with grounding Wiring harness between C01 (female) and E10 (female) Resistance
Above 1 M
circuit) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Short-circuiting of wiring Between wiring harness from C01 (female) to E10
5 harness Voltage Below 1 V
(female) and grounding
(Contact with 24 V circuit)
Between wiring harness between C01 (female) and E10
Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump C01 Resistance value
6
controller defective
Between and 4.5 5.5 V
Between and 0.5 4.5 V
20-366 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
CAB ENGINE
PW160-7H 20-367
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Abnormality in governor fuel dial
E05 E308 DK10KZ phenomenon (in governor pump controller)
Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
Failure content
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 normal.
If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL.
Phenomenon
If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL.
occurring on
There is hunting while the engine is running.
machine
The engine cannot attain the specified rotation at high idling and lacks power.
Relative Input from the fuel dial (voltage) can be confirmed in the monitor function.
information (Code No. 030: Fuel dial voltage)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Disconnection of wiring Wiring harness between C01 (female) to E06 (female) Resistance
harness Below 1
value
3 (Disconnection or defec-
Wiring harness between C01 (female) and E06 (female) Resistance
tive contact with connec- Below 1
tor) value
Wiring harness between C01 (female) and E06 (female) Resistance
Below 1
value
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
4
(Contact with grounding Wiring harness between C01 (female) and E06 (female) Resistance
Above 1 M
circuit) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Short-circuiting of wiring Between wiring harness from C01 (female) to E06
5 harness Voltage Below 1 V
(female) and grounding
(Contact with 24 V circuit)
Wiring harness between C01 (female) and E06 (female)
Voltage Below 1 V
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump C01 Resistance value
6
controller defective
Between and 4.5 5.5 V
Between and 0.5 4.5 V
20-368 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Governor pump
controller
H15 E06
C01 (DRC - 24) (090 - 20) (M - 3)
Fuel dial
Fuel dial 19 14 1
Sensor GND 21 15 2
Sensor 5V 22 16 3
CAB
PW160-7H 20-369
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Short-circuiting in battery relay
E315 D110KB phenomenon (in governor pump controller)
Abnormal current flow to the battery relay drive circuit, when power was supplied to the circuit.
Failure content
The controller turns OFF power to the battery drive circuit.
Response from
Even when the failure cause disappears, the relay does not return to normal, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
occurring on The engine does not stop.
machine
Relative It can be confirmed in the monitor function how the battery relay works (ON or OFF).
information (Code No. 037: Controller output)
Cause Standard value in normal and references for troubleshooting
Presumed cause and standard value in normal
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Battery relay defective Battery relay Continuity & Resistance value
1
(Internal failure) Between A21 (BR terminal) and A20 (E ter-
100
minal)
Between A21 (BR terminal) and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to D01 to Resistance
Above 1 M
circuit) J01 to A02 to A21 (BR terminal) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump
3 C03 (female) Engine starting switch OFF Voltage
controller defective
20 30 V
Between and grounding ON OFF
(for 4 to 7 seconds)
20-370 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
CAB
3
D01 (SWP - 8) 4
1
2
5
6 11
12
13
14
A07
(SWP - 16) (Black)
9
Alternator E12
A02
Battery relay (X - 4) B
E21
A20 A21 (DT -12)
E BR
2
A65 1 D
A22 M B A23
BATTERY ROOM ENGINE
PW160-7H 20-371
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code
Service 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 normal, unless the
controller
engine starting switch is once turned OFF.
Phenomenon The engine rotation cannot be controlled.
occurring on There is hunting in the rotation.
machine The engine does not stop.
1 Fuel dial defective If Service Code [E308] is displayed, troubleshoot that failure first.
2 Governor potentiometer defective If Service Code [E306] is displayed, troubleshoot that failure first.
value in normal
3 Governor motor defective (disconnection) If Service Code [E317] is displayed, troubleshoot that failure first.
4 Governor motor defective (short-circuiting) If Service Code [E318] is displayed, troubleshoot that failure first.
Refer to the section of "Inspection and Adjustment - Special Function
5 Governor lever adjustment improper
of Monitor Panel" in this manual.
6 Engine fuel control system defective Refer to Engine Shop Manual.
As this is an internal failure, no troubleshooting can be carried out. (If
7 Governor pump controller defective there is none of the failures listed above, the controller is judged as
defective)
20-372 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and B
E05 E317 DY10KA phenomenon (in governor pump controller)
Failure content No current flow 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 normal.
The engine rotation drops to low idling.
Phenomenon
There is hunting in the rotation
occurring on
The engine does not stop.
machine
The governor motor steps out.
Relative Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
(Internal disconnection)
Between and 2.5 7.5
Between and 2.5 7.5
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Wiring harness between C03 (female) and E11 (female) Resistance
Below 1
Disconnection of wiring value
harness Wiring harness between C03 (female) and E11 (female) Resistance
2 (Disconnection or defec- Below 1
value
tive contact with connec-
tor) Wiring harness between C03 (female) and E11 (female) Resistance
Below 1
value
Wiring harness between C03 (female) and E11 (female) Resistance
Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Governor pump C03 (female) Resistance value
3
controller defective
Between and 2.5 7.5
Between and 2.5 7.5
20-374 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
CAB ENGINE
PW160-7H 20-375
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and Phase
E05 E318 DY10KB phenomenon B (in governor pump controller system)
Failure content Abnormal current flow to the governor motor, when power is supplied to the motor.
Response from None in particular
controller If the failure cause disappears, the governor motor returns to normal.
The engine rotation cannot be controlled.
Phenomenon
The engine rotation drops to low idling.
occurring on
There is hunting in the rotation.
machine
The engine does not stop.
Relative Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
20-376 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
CAB ENGINE
PW160-7H 20-377
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Engine rotation at high idling out of rate
A000N1 phenomenon (in mechanical system)
Engine rotation above 2,450 rpm was detected for more than 10 seconds, while the engine was run-
Failure content
ning.
Response from None in particular
controller If the failure cause disappears of itself, the engine rotation returns to normal.
Phenomenon
occurring on There is a possibility that the engine is damaged, if it is used continuously without adjustment.
machine
Relative Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)
User Code Service Code Failure Code Failure Out-of-rate engine rotation at low idling
A000N2 phenomenon (in mechanical system)
Failure content Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
Response from None in particular
controller If the failure cause disappears of itself, the rotation returns to normal.
Phenomenon
occurring on There is a possibility that the engine is damaged, if it is used continuously without adjustment.
machine
Relative Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)
20-378 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Air cleaner clogged
AA10NX phenomenon (in mechanical system)
While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
None in particular
controller
Phenomenon
occurring on There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative panel while the engine is running.
information Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)
Cause Standard value in normal and references for troubleshooting
Air cleaner clogged (when
1 the system is in normal Check the air cleaner for clogging. If it is clogged, clean or replace it with new one.
Presumed cause and standard value in normal
condition)
Turn the engine starting switch OFF for the preparations, and keep the engine running
Monitor
panel
H10 A06 A31 Air cleaner
P02 (040 - 20) (S - 16) (SWP - 16) (DT-2) clogging switch
Air cleaner
5 11 9 1
clogging switch
2
A65
CAB ENGINE
PW160-7H 20-379
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Charging voltage abnormally lowered
AB00KE phenomenon (in mechanical system)
Failure content Generation signal from the alternator is not inputted, while the engine is running.
Response from
None in particular
controller
Phenomenon
There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while
Relative the engine is running.
information Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)
Cause Standard value in normal and references for troubleshooting
Turn the engine starting switch OFF for the preparations, and hold it running during the
Presumed cause and standard value in normal
20-380 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
H11
P02 (040-20) (S - 16)
Battery
11 3
Charge level
J01 (J-20)
11
12
13
14
A07
(SWP - 16) (Black)
9
Alternator E12
E21 B
(DT - 12)
1 D
AC
PW160-7H 20-381
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service Code Failure Code Failure Engine oil pressure abnormally lowered
B@BAZG phenomenon (in mechanical system)
The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
Failure content
engine was running.
Response from
None in particular
controller
Phenomenon
occurring on There is a possibility that the engine may seize, if the engine is kept running without corrective action.
machine
This Failure Code is recorded, if the engine oil pressure caution symbol is displayed in the monitor
Relative panel, while the engine is running.
information Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 046: Monitor input 2)
Cause Standard value in normal and references for troubleshooting
Engine oil pressure low-
Presumed cause and standard value in normal
1 ered (the system in nor- Check the failure cause and damage to the engine, and then make repairs.
mal condition)
Turn the engine starting switch OFF for the preparations, and keep the engine running
Engine oil pressure switch during the troubleshooting.
2 defective E02 (on switch side) Engine oil pressure Resistance value
(Internal short-circuiting) Between terminal and When in normal condition Above 1 M
grounding When lowered Below 1
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
3
(Contact with grounding Wiring harness between P02 (female) and E02 (termi- Resistance
Above 1 M
circuit) nal) and grounding value
Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition 20 30 V
Between and grounding
When lowered Below 1 V
Monitor panel
H10 A03 E21 Engine oil
P02 (040 - 20) (S - 16) (DT - 12) (DT - 12) pressure switch
Engine oil E02
7 13 11 7
pressure switch
CAB ENGINE
20-382 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code Service Code Failure Code Failure Engine oil level abnormally lowered
B@BAZK phenomenon (in mechanical system)
The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when
Failure content
the engine is stopped (with the starting switch in the ON position).
Response from
None in particular
controller
Phenomenon
occurring on There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is
Relative stopped (with the starting key in the ON position).
information Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)
Cause Standard value in normal and references for troubleshooting
Engine oil level lowered
Check the engine oil level, and refill oil.
Presumed cause and standard value in normal
CAB ENGINE
PW160-7H 20-383
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
User Code Service 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 102C, 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
This Failure Code is recorded, if the engine cooling water temperature gauge is displayed in the red
Relative range, when the engine is running.
information Input from the engine cooling water temperature sensor (temperature) can be confirmed in the monitor
function. (Code No. 041: Engine cooling water temperature)
Monitor panel
A06 Engine water
H - 10 (SWP - 16) E21 E05
P02 (040 -20) (S - 16) (DT - 12) (DT - 2) temperature sensor
Engine water 12
1 7 4 2
temperature sensor
Sensor GND 13 16 3 1
4
CAB ENGINE
20-384 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
A65
PW160-7H 20-385
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
1 (system in normal condi- Check the cause and damage to the hydraulic equipment, and repair it.
tion)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Hydraulic oil temperature tion during the troubleshooting.
2 sensor defective A55 (male) Hydraulic oil temperature Resistance value
(Internal short-circuiting) Between and 90 3.5k
10 100 C
Between and grounding Above 1 M
Grounding fault of wiring Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
3
(Contact with grounding Wiring harness between P02 (female) and A55 (female) Resistance
Above 1 M
circuit) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
4 Monitor panel defective P02 (female) Engine water temperature Resistance value
Between and 90 3.5k
10 100 C
Between and grounding Above 1 M
H11 A06
Monitor panel
(S - 16) (SWP - 16)
A55 Hydraulic oil
P02 (040 - 20) 4 5 1 (DT - 2) temperature sensor
Hydraulic oil
temperature sensor 12 2
Sensor GND 13 16 4 3 1
H10 E21
(S - 16) (DT - 12)
20-386 PW160-7H
TESTING AND ADJUSTING
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
PW160-7H 20-501
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
The standard values in normal by which to judge "good" or "no good" about presumed
1 causes.
References for making judgement of "good" or "no good"
Presumed cause and standard value in normal
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
20-502 PW160-7H
TESTING AND ADJUSTING E-1
Failure
The engine does not start (the engine does not rotate).
information
The following two engine start locking mechanisms are provided in the engine starting circuit.
Relative
1) Engine start locking by means of password in the monitor panel ( )
information
2) Engine start locking by means of safety lock lever
short-circuiting) Release
Between and
LOCK Below 1 M
Engine starting + Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
R22 motor cut relay, during the troubleshooting.
R11 and R13 defec- R11 (female) & R13 (male) + R22 Resistance value
5 tive 100 500
Between and
(Internal
disconnection or Between and Above 1 M
short-circuiting) Between and Below 1
Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting. (If all of the power source, grounding (GND), generation signal and
engine start input are normal and yet the engine start output is not normal, the engine start-
ing motor relay is defective)
Engine start-
Engine starting Safety relay Voltage
ing switch
motor fault
Power source: Between B terminal and grounding 20 30 V
6 (Internal
disconnection or GND (grounding): Between E terminal and grounding Connected
short-circuiting) Generation signal: Between R terminal (A27 ) and
Below 1 V
grounding Start
Engine start input: Between C terminal and grounding 20 30 V
Engine start output: Between S terminal (A27 ) and
20 30 V
grounding
Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting. (If all of the power source, grounding (GND), generation signal and
engine start input are normal and yet the engine start output is not normal, the engine start-
Engine starting
ing motor relay is defective)
motor fault
7 Engine start-
(Internal disconnec- Engine starting motor (E13) Voltage
tion or damage) ing switch
Power source: B terminal and grounding 20 30 V
Start
Engine start input: C terminal and grounding 20 30 V
PW160-7H 20-503
TESTING AND ADJUSTING E-1
Resistance
Wiring harness between S14 (male) and R11 (female) Below 1
value
Wiring harness between R11 (female) and R13 (female) Resistance
Below 1
value
Resistance
Wiring harness from R13 (female) to J04 to grounding Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness from battery relay B terminal (A23) Resistance
Above 1 M
to A35 to A01 to FB1-18 and grounding value
Wiring harness between FB1-18 outlet and H15 (female) Resistance
Above 1 M
and grounding value
Between wiring harness from H15 (female) to J01 to R11 Resistance
Above 1 M
(female) and grounding value
Grounding fault of Wiring harness between R11 (female) and R22 (female) Resistance
Above 1 M
wiring harness and grounding value
10
(Contact with Wiring harness between R22 (female) to A07 to A27 Resistance
grounding circuit) Above 1 M
(female) . value
Wiring harness between engine starting motor relay C termi- Resistance
Above 1 M
nal and engine starting motor C terminal and grounding value
Wiring harness between FB1-3 and S14 (female) and Resistance
Above 1 M
grounding value
Wiring harness between S14 (female) and R11 (female) Resistance
Above 1 M
and grounding value
Between wiring harness from R13 (female) to J06 to H11 Resistance
Above 1 M
to P02 (female) and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of during the troubleshooting.
wiring harness Wiring harness between A27 (female) and E08 (female)
11
(Contact with 24 V , or wiring harness from A27 (female) to A07 to J01 to
circuit) Voltage Below 1 V
D01 (female) , or between wiring harness between A27
(female) to J01 to H11 to P02 (female) and grounding.
20-504 PW160-7H
TESTING AND ADJUSTING E-1
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
Controller
DO2
Starting switch PPC hydraulic (safety) (SWP-8)
CO1 (DRC-24)
B BR R1 R2 C ACC lock switch
KEY SW. C 17 R1 1
OFF Free
KEY SW. ACC. 23 ACC 2
ST Lock
5
CO2 (DRC-4O)
6
S14
PPC LOCK (Out) 9
(M-3)
R45 6
6
(PPC lock)
7
5
8
3
9
2
11
1
12
R13
6 13
Relay starter
cut 5 15
(Personal code) 16
3
2 19
1 2O
DO1 (SWP-8)
R11 6
Starter cut 1
5
2
3
5
2
6
1
15
16
JO4 3 5 9 17
(J-20)
JO6 18
(Green)
(J-2O) 19
(Pink)
2O
18 19 FB1
Monitor 10A
1
PO1 (O7O-12) H1O
3
10A
(S-16)
KEY SW. 1 20A
12
1
KEY SW. 2 10A
17
KEY SW. C 4 2 18
10A
VB + (24V) 8
H11
PO2 (O4O-2O) (S-16)
BATTERY CHARGE 11 3
PERSONEL CODE
14 5
RELAY
PREHEAT 18 9
PPC AO7
VO1 AO2 AO1
pressure (SWP-16)
(DT-2) AO5 (X-4) (X-4)
lock
(SWP-14) 5 6 9
2 3 2 4 1 2 4
SOL.
1
A34 (L-2)
1
2 1 A27 Starting motor
2
(X-2) B
E21 E13
Fusible 2 1 (DT-12)
1
links A35 (L-2)
C
1
S5 S3
2
Alternator
B E12
E A28
S B
D
R C
A29
Starter safety
A26 relay
A24
A2O A22
A25 E M
+ -
Grid B
BR
relay EO1 A21 A23
- +
heater Grid Battery
heater relay
A65
A64
BWP1O435C
PW160-7H 20-505
TESTING AND ADJUSTING E-2
Failure
The engine suddenly stopped 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)
1 eter fault
Between A and C 4.0 6.0 k
(Internal failure)
Between B and A 0.25 5.0 k
Between B and C 0.25 5.0 k
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) to A03 to E10 Resistance
defective contact Below 1
with connector) (female) 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 Wiring harness between C01 (female) and E10 (female) Resistance
grounding circuit) Above 1 M
and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump C01 Voltage
4
controller defective
Between and 4.5 5.5 V
Between and 0.5 4.5 V
Governor 9
15 2 2 A (-)
Motor (A-)
Governor
25 3 10 3 B (+)
Motor (B+)
Governor
35 4 11 4 B (-)
Motor (B-)
20-506 PW160-7H
TESTING AND ADJUSTING E-3
Governor lever
2 Refer to the section "Special Function of Monitor Panel" in this manual.
improperly adjusted
If the governor motor lever moves smoothly in the following operations, it is judged as nor-
Governor motor mal.
3
improperly working The fuel dial is operated between low idling and high idling.
The engine is stopped with the fuel dial.
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
6
(Contact with Wiring harness between C01 (female) to J03 and H15 Resistance
grounding circuit) Above 1 M
(female) and grounding value
Governor pump As this is an internal failure, troubleshooting cannot be conducted.
7
controller defective (If there is none of the causes from Item 1 to 6 above, the controller is judged as defective)
20-508 PW160-7H
TESTING AND ADJUSTING E-3
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
Controller
DO2
Starting switch PPC hydraulic (safety) (SWP-8)
CO1 (DRC-24)
B BR R1 R2 C ACC lock switch
KEY SW. C 17 R1 1
OFF Free
KEY SW. ACC. 23 ACC 2
ST Lock
5
CO2 (DRC-4O)
6
S14
PPC LOCK (Out) 9
(M-3)
R45 6
6
(PPC lock)
7
5
8
3
9
2
11
1
12
R13
6 13
Relay starter
cut 5 15
(Personal code) 16
3
2 19
1 2O
DO1 (SWP-8)
R11 6
Starter cut 1
5
2
3
5
2
6
1
15
16
JO4 3 5 9 17
(J-20)
JO6 18
(Green)
(J-2O) 19
(Pink)
2O
18 19 FB1
Monitor 10A
1
PO1 (O7O-12) H1O
3
10A
(S-16)
KEY SW. 1 20A
12
1
KEY SW. 2 10A
17
KEY SW. C 4 2 18
10A
VB + (24V) 8
H11
PO2 (O4O-2O) (S-16)
BATTERY CHARGE 11 3
PERSONEL CODE
14 5
RELAY
PREHEAT 18 9
PPC AO7
VO1 AO2 AO1
pressure (SWP-16)
(DT-2) AO5 (X-4) (X-4)
lock
(SWP-14) 5 6 9
2 3 2 4 1 2 4
SOL.
1
A34 (L-2)
1
2 1 A27 Starting motor
2
(X-2) B
E21 E13
Fusible 2 1 (DT-12)
1
links A35 (L-2)
C
1
S5 S3
2
Alternator
B E12
E A28
S B
D
R C
A29
Starter safety
A26 relay
A24
A2O A22
A25 E M
+ -
Grid B
BR
relay EO1 A21 A23
- +
heater Grid Battery
heater relay
A65
A64
BWP1O435C
PW160-7H 20-509
TESTING AND ADJUSTING E-4
Failure
The engine does not stop.
information
The Governor pump controller drives the battery relay for the min. 4 seconds and max. 7 seconds from
Relative the moment the engine starting switch is turned OFF to the moment the engine completely stops.
information It can be confirmed in the monitor function how the battery relay works (ON or OFF)
(Code No. 037: Controller output)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type
during the troubleshooting.
diode D01 fault
2
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Diode mode Continued
Between and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Resistance
ing harness Wiring harness between C03 (female) and D01 (female) Below 1
value
3 (Disconnection or
Wiring harness from D01 (female) to J01 to A02 to battery Resistance
defective contact Below 1
with connector) relay BR terminal (A21) value
Wiring harness between battery relay E terminal (A20) and Resistance
Below 1
grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump
4 C03 Engine starting switch Voltage
controller defective
20 30 V
Between and grounding ONOFF
(for 4 to 7 seconds)
20-510 PW160-7H
TESTING AND ADJUSTING E-4
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
Controller
DO2
Starting switch PPC hydraulic (safety) (SWP-8)
CO1 (DRC-24)
B BR R1 R2 C ACC lock switch
KEY SW. C 17 R1 1
OFF Free
KEY SW. ACC. 23 ACC 2
ST Lock
5
CO2 (DRC-4O)
6
S14
PPC LOCK (Out) 9
(M-3)
R45 6
6
(PPC lock)
7
5
8
3
9
2
11
1
12
R13
6 13
Relay starter
cut 5 15
(Personal code) 16
3
2 19
1 2O
DO1 (SWP-8)
R11 6
Starter cut 1
5
2
3
5
2
6
1
15
16
JO4 3 5 9 17
(J-20)
JO6 18
(Green)
(J-2O) 19
(Pink)
2O
18 19 FB1
Monitor 10A
1
PO1 (O7O-12) H1O
3
10A
(S-16)
KEY SW. 1 20A
12
1
KEY SW. 2 10A
17
KEY SW. C 4 2 18
10A
VB + (24V) 8
H11
PO2 (O4O-2O) (S-16)
BATTERY CHARGE 11 3
PERSONEL CODE
14 5
RELAY
PREHEAT 18 9
PPC AO7
VO1 AO2 AO1
pressure (SWP-16)
(DT-2) AO5 (X-4) (X-4)
lock
(SWP-14) 5 6 9
2 3 2 4 1 2 4
SOL.
1
A34 (L-2)
1
2 1 A27 Starting motor
2
(X-2) B
E21 E13
Fusible 2 1 (DT-12)
1
links A35 (L-2)
C
1
S5 S3
2
Alternator
B E12
E A28
S B
D
R C
A29
Starter safety
A26 relay
A24
A2O A22
A25 E M
+ -
Grid B
BR
relay EO1 A21 A23
- +
heater Grid Battery
heater relay
A65
A64
BWP1O435C
PW160-7H 20-511
TESTING AND ADJUSTING E-5
Failure
The auto-deceleration does not work.
information
Rotation of the auto-deceleration is set at 1,400 rpm. If the fuel dial is not adjusted above this level, the
Relative
auto-deceleration does not work.
information
Confirm the display on the monitor panel, when the engine is running.
If the display on the monitor panel is not normal, proceed to No. E-24 Troubleshooting.
Arm DUMPING Monitoring code Item Normal display
4
signal fault Lever operation: ON
019 Arm DUMPING
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-25 Troubleshooting.
Bucket DIGGING Monitoring code Item Normal display
5
signal fault Lever operation: ON
021 Bucket DIGGING
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-26 Troubleshooting.
Bucket DUMPING Monitoring code Item Normal display
6
signal fault Lever operation: ON
021 Bucket DUMPING
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-27 Troubleshooting.
Monitoring code Item Normal display
7 Swing signal fault
Lever operation: ON
019 Swing
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-28 Troubleshooting.
Monitoring code Item Normal display
8 Travel signal fault
Lever operation: ON
019 Travel
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-29 Troubleshooting.
Attachment signal Monitoring code Item Normal display
9
fault Lever operation: ON
021 Service
Lever NEUTRAL: OFF
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.
20-512 PW160-7H
TESTING AND ADJUSTING E-6
Failure
The auto engine warm-up device does not work.
information
The auto engine warm-up device is activated, when the engine cooling water temperature is below 30C,
Relative and the engine speed is below 1,200 rpm.
information The auto engine warm-up device is canceled 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.
If the display on the monitor panel is not normal, proceed to No. E-14
Troubleshooting.
value in normal
PW160-7H 20-513
TESTING AND ADJUSTING E-7
Failure Even if the pre heater switch is turned to the PREHEAT position, the pre heating monitor lamp does not
information (1) light up.
Relative Input of the pre heating signal (ON or OFF) can be confirmed in the monitor function.
information (Code No. 045: Monitor input 1)
1
switch fault non (2) below.
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
value in normal
Failure
Even if the pre heater switch is turned to the PREHEAT position, the pre heater does not become warm.
information (2)
Relative In low cooling water temperature (lower than 30C), the governor pump controller drives the heater
information relay for 100 seconds after the engine is started and automatically warms up the engine.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Heater relay fault
Heater relay Continuity and resistance value
value in normal
2 (Internal disconnec-
tion) Between coil terminal and grounding Continued
Between contact terminals Above 1 M
Electrical intake air Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
heater tion during the troubleshooting.
3
(Internal disconnec-
tion) Between heater terminals Normal if continuity is established.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wir- tion during the troubleshooting.
ing harness
Wiring harness from H15 (female) to J01 to heater Resistance
4 (Disconnection or Below 1
relay terminal (A25) value
defective contact
with connector) Wiring harness between battery relay M terminal (A22) Resistance
Below 1
and heater relay terminal value
20-514 PW160-7H
TESTING AND ADJUSTING E-7
J01
(J - 20) (Black)
15 Starting switch
16 B BR R1 R2 C ACC
R1
OFF
17 ACC
ST
18
19
20 Fuse box H15
FB1 (090 - 20)
D02 (SWP - 8) 10A 18
1 3
1
2
Governor pump
CAB
5 controller
6
C03 (DRC - 40)
Pre-heater 18 9
A01
(X - 4)
A07 3
(SWP - 16)
5
A64
Battery relay
A21 A20
BR E REV FRAME
PW160-7H 20-515
TESTING AND ADJUSTING E-8
Failure
All the work equipment, swing and travel do not move.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
PPC lock solenoid during the troubleshooting.
fault
3 (Internal disconnec- V01 (male) Resistance value
tion or short-circuit- Between and 20 60
ing)
Between and grounding Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Resistance
ing harness Wiring harness between FB1 outlet and S14 (male) Below 1
value
4 (Disconnection or
Wiring harness from S14 (male) to R45 to A05 to V01 Resistance
defective contact Below 1
with connector) (female) value
Resistance
Wiring harness between V01 (female) and grounding Below 1
value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness Wiring harness between FB1 outlet and S14 (male) and Resistance
Above 1 M
5 (Contact with grounding value
grounding (GND) Wiring harness from C02 (male) to R45 to V01 (female)
circuit) Resistance
, or between wiring harness between C02 (male) and Above 1 M
value
R45 (female) and grounding.
20-516 PW160-7H
TESTING AND ADJUSTING E-8
Starter cut
PPC hydraulic R-11
lock switch
Free
Lock
S14 1 2 3 5 6
(M - 3) FB1
3 10A
1 Fuse box
2
3
Note:
Monitor communicates
with controller through
the CAN network A05 V01 PPC lock
(SWP - 14) (DT - 2) solenoid valve
3 1
2
C02 (DRC-40) (ON) (OFF)
PPC lock (OUT) 9 A65
C03 (DRC-40)
PPC lock (IN) 29
R45
PPC lock
1 2 3 5 6
PW160-7H 20-517
TESTING AND ADJUSTING E-9
Failure
The one-touch power max. switch does not work.
information
If the one touch-power max. switch is pressed while the engine is running, the symbol mark is displayed
Relative in 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)
FBI
Governor pump
controller Fuse box 10A 5 G70 Power Max
(DT - 4)
knob switch
C01 (DRC - 24) 1
Power Max 11 2
Cab
20-518 PW160-7H
TESTING AND ADJUSTING E-10
Failure
When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness from P01 (female) to H10 to J03 to Resistance
2 (Disconnection or Below 1
FB1 value
defect contact with
connector) Resistance
Wiring harness between P01 (female) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness from P01 (female) to FB1 Resistance
Above 1 M
circuit) outlet and grounding value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor pump P01 Voltage and resistance value
4
controller defective
Between and grounding Voltage: 20 30 V
Between and grounding Resistance value: Below 1
60A 30A
Monitor panel Fusible link
H10
P01 (070 - 12) (S - 16) A34 (L - 2) A35 (L - 2)
PW160-7H 20-519
TESTING AND ADJUSTING E-11, E-12
Failure
Part of the display in the monitor panel is missing.
information
Relative
information
If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the
Monitor panel LCD
1 following switching operation, then the monitor panel is normal.
fault
Switching operation: [ ] + [A] (simultaneous switching operation)
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
Failure
The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
information
If the display on the monitor panel is normal, proceed to Service Code [E217].
Model code signal
Monitoring code Item Normal display
1 fault
(Internal failure) 002
Controller model code 200
003
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
20-520 PW160-7H
TESTING AND ADJUSTING E-13
E-13 Fuel level monitor red lamp lights up while engine is running
Failure
The fuel level monitor red lamp lighted up while the engine was running.
information
If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
Relative
(5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
information
(Code No. 042: Fuel level sensor)
condition)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Fuel level sensor during the troubleshooting.
fault A54 (male) Fuel level Resistance value
2
(Internal
disconnection) FULL (Upper limit) Approx. 12
Between and grounding
EMPTY (Lower limit) 85 110
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
Wiring harness between P02 (female) and A54 (female) Resistance
grounding (GND) Below 1
circuit) value
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor pump P02 (female) Fuel level Resistance value
4
controller defective
FULL (Upper limit) Approx. 12
Between and grounding
EMPTY (Lower limit) 85 110
Monitor panel
Fuel level
H10 A06 A54 sensor
P02 (070 - 20) (DT - 12) (HDP - 47) (X - 1)
PW160-7H 20-521
TESTING AND ADJUSTING E-14
E-14 Engine cooling water temperature gauge does not indicate correctly
Failure The engine cooling water rises normally, but the display does not exceed the white range (C).
information 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)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and E05 (female) Below 1
value
defective contact
with connector) Resistance
Wiring harness between P02 (female) and E05 (female) Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between P02 (female) and E05 (female) Resistance
Above 1 M
circuit) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) and E05
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel
A06 E21 Engine water
H - 10 (SWP - 16) (DT - 12) E05
P02 (040 -20) (S - 16) (DT - 2) temperature sensor
Engine water 4 3
1 16 1
temperature sensor
Sensor GND 13 7 4 2
12
CAB ENGINE
20-522 PW160-7H
TESTING AND ADJUSTING E-15
Failure Hydraulic oil temperature rises normally, but the display does not exceed the white range (C).
information 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)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and A55 (female) Below 1
value
defective contact
with connector) Resistance Between 1.9
Wiring harness between P02 (female) and A55 (female)
value and 38.2K
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between P02 (female) and A55 (female) Resistance
Above 1 M
circuit) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) and A55
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Sensor GND 13 16 4 3 1
H10 E21
(S - 16) (DT - 12)
PW160-7H 20-523
TESTING AND ADJUSTING E-16
Failure Though fuel was refilled, the display does not exceed the red range (E).
information Though the remaining fuel level is low, the display 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)
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) and A54 Resistance
Above 1 M
circuit) (female) 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) and A54
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor pump P01 Fuel level Resistance value
5
controller defective
FULL (Upper limit) Approx. 12
Between and grounding
EMPTY (Lower limit) 85 110
Monitor panel
Fuel level
H10 A06 A54 sensor
P02 (070 - 20) (DT - 12) (SWP - 16) (X - 1)
20-524 PW160-7H
TESTING AND ADJUSTING E16
PW160-7H 20-525
TESTING AND ADJUSTING E-17
Failure Though the swing lock switch was turned ON, the swing lock monitor does not light up.
information 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.
information (Code No. 049: Monitor input 3)
Between and
ON Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness from P02 (female) to H11 to H15 to X05 Resistance
2 (Disconnection or Below 1
(female) value
defective contact
with connector) Resistance
Wiring harness from X05 (female) to grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness from P02 (female) to H11 to H15 Resistance
Above 1 M
circuit) to X05 (male) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness from P02 (female) to H11 to H15
circuit) Voltage Below 1 V
to X05 (male) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel P02 Swing lock switch Voltage
5
defective
OFF 20 30 V
Between and grounding
ON Below 1 V
20-526 PW160-7H
TESTING AND ADJUSTING E-17
1 2 3 4 5 6 S22 1 2 3 4 5 6
EMERGENCY ON
NORMAL OFF
3 4
8 19 20 H15
(090-20)
C02 (DRC-40)
H11 (S-16) 2 Swing Emergency Switch
P02 (040-20)
Swing Lock 17 8 38 Swing Lock Switch
11 12 13 J10
(J-20) C03 (DRC-40)
(Orange)
11 VB (Controller Power)
A05
5 (SWP-14)
V03 (DT-2) Swing
Brake Sol.
1
Sol.
2
4 A02
(X-4)
A64 A65
PW160-7H 20-527
TESTING AND ADJUSTING E-18
Failure
When operating the working mode changing switch, the working mode monitor does not appear.
information (1)
Relative
information
Failure
When operating the auto-deceleration switch, the auto-deceleration monitor does not appear.
information (2)
Relative
If the auto-deceleration itself does not work, either, carry out No. E-5 Troubleshooting.
information
Failure
When operating the travel speed shifting switch, the travel speed monitor does not appear.
information (3)
Relative
If the travel speed does not actually change, carry out No. H-21 Troubleshooting.
information
Failure
When operating the windshield wiper switch, the windshield wiper monitor does not appear.
information (4)
Relative
If the windshield wiper itself does not work, either, carry out No. E-19 Troubleshooting.
information
When operating the select switch, the adjustment display does not appear.
Failure
When operating the LCD monitor adjusting switch, the adjustment display does not appear.
information (5)
When operating the maintenance switch, the item display does not appear.
Relative
information
20-528 PW160-7H
TESTING AND ADJUSTING E-18
PW160-7H 20-529
TESTING AND ADJUSTING E-19
Failure
The windshield wiper does not work.
information
Relative
information
ing)
Between and grounding Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness Wiring harness between W08 (female) to H11 to W04 Resistance
3 (Disconnection or Below 1
(female) value
defective contact
with connector) Wiring harness between W08 (female) to H11 to W04 Resistance
Below 1
(female) value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with
grounding (GND) cir- Wiring harness between W08 (female) Resistance
and H08 Above 1 M
cuit) value
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel fault
(Rear limit switch W08 Front window Voltage
system) When installed at front 20 30 V
Between and grounding
When retracted at rear Below 1 V
5 Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel fault W08 Windshield wiper switch Resistance value
(Windshield wiper
motor system) OFF Below 3 V
Between and grounding
Below 3 V 20 30 V
Between and grounding ON
(Constant cycle)
20-530 PW160-7H
TESTING AND ADJUSTING E-19
Wiper
Washer Switch
Switch 15 J 53 31B
15 53C Off
Off I
On II
Wiper Motor
W04
(M-6)
1 2 3 4 5 6
6 6 7 1
G4 G3
Rear
Limit
1 2 13 14 15 H11
Switch
(S-16)
1 2
1 2 3 8 G02
(DT-12)
1 2 W03 J04 (J-20)
(M-2) (Green)
1 11 12
5 6 H08
(M-8)
A64
A05
(SWP-14) A50
13 1 Washer
M Motor
14 1
A59
PW160-7H 20-531
TESTING AND ADJUSTING E-21
Failure
"Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C02 (female) and S13 (female) Below 1
value
defective contact
with connector) Resistance
Wiring harness between S13 (female) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C02 (female) and S13 Resistance
Above 1 M
circuit) (female) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C02 (female) and S13
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump C02 Boom control lever Voltage
5
controller defective
NEUTRAL 20 30 V
Between and grounding
RAISE Below 1 V
Governor pump
controller
A09 S13 Boom RAISE
C02 (DRC - 40) (SWP - 8) (X- 2) pressure switch
Boom RAISE
35 1 2
pressure switch
1
A65
20-532 PW160-7H
TESTING AND ADJUSTING E-22
Failure
"Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C02 (female) and S12 (female) Below 1
value
defective contact
with connector) Resistance
Wiring harness between S12 (female) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C02 (female) and S12 Resistance
Above 1 M
circuit) (female) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C02 (female) and S12
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump C02 Boom control lever Voltage
5
controller defective
NEUTRAL 20 30 V
Between and grounding
LOWER Below 1 V
Governor pump
controller
A09 S12 Boom LOWER
C02 (DRC - 40) (SWP - 8) (X - 2) pressure switch
Boom LOWER
pressure switch 25 2 1
2
A65
PW160-7H 20-533
TESTING AND ADJUSTING E-23
Failure
"Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C02 (female) and S06 (female) Below 1
value
defective contact
with connector) Resistance
Wiring harness between S06 (female) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C02 (female) and S06 Resistance
Above 1 M
circuit) (female) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C02 (female) and S06
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump C02 Arm control lever Voltage
5
controller defective
NEUTRAL 20 30 V
Between and grounding
DIGGING Below 1 V
Governor pump
controller
A09 S06 Arm CURL
C02 (DRC - 40) (SWP - 8) (X - 2) pressure switch
Arm CURL
pressure switch 15 3 2
1
A65
20-534 PW160-7H
TESTING AND ADJUSTING E-24
Failure
"Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C02 (female) and S05 (female) Below 1
value
defective contact
with connector) Resistance
Wiring harness between S05 (female) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C02 (female) and S05 Resistance
Above 1 M
circuit) (female) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C02 (female) and S05
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump C02 Arm control lever Voltage
5
controller defective
NEUTRAL 20 30 V
Between and grounding
DUMPING Below 1 V
Governor pump
controller
A09 S05 Arm DUMP
C02 (DRC - 40) (SWP - 8) (X - 2) pressure switch
Arm DUMP
pressure switch 5 4 2
1
A65
PW160-7H 20-535
TESTING AND ADJUSTING E-25
Failure
"Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C02 (female) and S04 (female) Below 1
value
defective contact
with connector) Resistance
Wiring harness between S04 (female) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C02 (female) and S04 Resistance
Above 1 M
circuit) (female) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C02 (female) and S04
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump C02 Bucket control lever Voltage
5
controller defective
NEUTRAL 20 30 V
Between and grounding
DIGGING Below 1 V
Governor pump
controller
A09 S04 Bucket CURL
C02 (DRC - 40) (SWP - 8) (X - 2) pressure switch
Bucket CURL
36 5 2
pressure switch
1
A65
20-536 PW160-7H
TESTING AND ADJUSTING E-26
Failure
"Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C02 (female) and S03 (female) Below 1
value
defective contact
with connector) Resistance
Wiring harness between S03 (female) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C02 (female) and S03 Resistance
Above 1 M
circuit) (female) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C02 (female) and S06
circuit) Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump C02 Bucket control lever Voltage
5
controller defective
NEUTRAL 20 30 V
Between and grounding
DUMPING Below 1 V
Governor pump
controller
A09 S03 Bucket DUMP
C02 (DRC - 40) (SWP - 8) (X - 2) pressure switch
Bucket DUMP
26 6 2
pressure switch
1
A65
PW160-7H 20-537
TESTING AND ADJUSTING E-27
Failure
"SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Wiring harness between C02 (female) and S02 (female) , Resistance
ing harness or wiring harness between C02 (female) and S01 (female) Below 1
value
3 (Disconnection or
defective contact Resistance
with connector) Wiring harness between S02 (female) and grounding Below 1
value
Resistance
Wiring harness between S01 (female) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with Wiring harness between C02 (female) and S02 (female) ,
grounding (GND) Resistance
or wiring harness between C02 (female) and S01 (female) Above 1 M
circuit) value
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness
5 Wiring harness between C02 (female) and S02 (female) ,
(Contact with 24 V
circuit) or wiring harness between C02 (female) and S01 (female) Voltage Below 1 V
and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump C02 Swing control lever Voltage
6
controller defective
NEUTRAL 20 30 V
Between and grounding
Right or left Below 1 V
20-538 PW160-7H
TESTING AND ADJUSTING E-27
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
Swing RIGHT
S01 (X - 2) pressure switch
2
Governor pump 1
controller
A09 Swing LEFT
C02 (DRC - 40) (SWP - 8) S02 (X - 2) pressure switch
Swing pressure
16 7 2
switch
1
A65
PW160-7H 20-539
TESTING AND ADJUSTING E-28
Failure
"TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
Default travel indication is neutral
information
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Resistance
ing harness Wiring harness from C03 (female) to G72 (female) Below 1
value
2 (Disconnection or
Resistance
defective contact Wiring harness from C03 (female) to G72 (female) Below 1
with connector) value
Resistance
Wiring harness from C03 (female) to G72 Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Wiring harness from C03 (female) , or C03 , or between Resistance
Above 1 M
circuit) wiring harness between C03 (female) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Wiring harness from C03 (female) , or C03 , or between
circuit) Voltage Below 1 V
wiring harness between C03 (female) and grounding.
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
C03 Travel control lever Voltage
Governor pump
5
controller defective Between and grounding
NEUTRAL 20 30 V
Between and grounding
Between and grounding Forward or backward Below 1 V
20-540 PW160-7H
TESTING AND ADJUSTING E-28
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
FNR SWITCH
S23 1 2 3 4 5 6 F
NORMAL N
EMERGENCY R
S25
(090-16)
14 13 FB1 G72
3 10A
(DT-4) 1 2 3 4
J02 (J-20) (Black)
1 4 11 12 13
C03 (DRC-40)
TRAVEL F 10
TRAVEL N 20
TRAVEL R 30
A07
A53 (SWP-16)
BACKUP
1 3
ALARM
PW160-7H 20-541
TESTING AND ADJUSTING E-29
Failure
"Service" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
information
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with Wiring harness between C01 (female) and S21 (female) ,
grounding (GND) Resistance
or between wiring harness between C01 (female) and S20 Above 1 M
circuit) value
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness
5 Wiring harness between C01 (female) and S21 (female) ,
(Contact with 24 V
circuit) or between wiring harness between C01 (female) and S20 Voltage Below 1 V
(female) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor pump C01 Service pedal Voltage
6
controller defective
NEUTRAL 20 30 V
Between and grounding
Front or rear Below 1 V
20-542 PW160-7H
TESTING AND ADJUSTING E-29
2
Governor pump 1
controller
A09 S21 Rear service
C01 (DRC - 40) (SWP - 8) (X - 2) pressure switch
Service
6 8 2
pressure switch
1
A65
PW160-7H 20-543
TESTING AND ADJUSTING E-30
Failure
The air conditioner does not work.
information
Relative For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND
information FUNCTION - Air Conditioner in this manual.
Turn the engine starting switch OFF for the preparations, and hold it in the
Disconnection of wir- OFF position during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between FB1 outlet and M26 (male) Below 1
value
defective contact
with connector) Resistance
Wiring harness between M26 (male) and grounding Below 1
value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the
wiring harness OFF position during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between FB1 outlet and M26
Voltage Above 1 M
circuit) (male) and grounding
Turn the engine starting switch OFF for the preparations, and hold it in the ON
Air conditioner unit position during the troubleshooting.
4
defective M26 Voltage
Between and 20 30 V
20-544 PW160-7H
TESTING AND ADJUSTING E-30
Air Conditioner
Hi/Lo
Pressure 1 2
P15
Switch (Yoso-2)
G05
J04 (DT-12)
(J-20) 3
(Green) P17
2 1 4
1 2 11 12
Air Conditioner
FB1 A07 E21 E06 Compressor
20A (SWP-16) (DT-12) (X-1)
11
7 2 1
A64
M26
(S-12)
2 5 7 8 10 12
M29 (AMP-20)
Compressor Clutch Relay 2
Blower Main Relay 3
Terminal A Air Mix Damper 4
Terminal B Air Mix Damper 5
Terminal B In/Ex Damper 6
Terminal A In/Ex Damper 7
Terminal B Blow Damper 8
Sensor GND 11
GND 12
M27
(Yazaki-18)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
M33
(Sumitomo-4)
1 2 3 4
PW160-7H 20-545
E-31 Travel reverse alarm does not sound
Failure The travel alarm does not sound while the machine is travelling.
information The alarm begins to sound when the machine is at a standstill.
Relative
information
If the monitor display is not correct, proceed to section E-21 of this troubleshooting chapter.
Monitoring code Item Normal display
2 Travel signal fault
Control lever operation: ON
021 Travel Reverse
Control lever NEUTRAL: OFF
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
3 (Disconnection or
Wiring harness between FB1-3 outlet to S25 to S23 to G72 Resistance
defective contact Below 1
with connector) to J02 to A07 and A53 (female) value
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with Between wiring harness between FB1-3 outlet to S25 to
grounding (GND) Resistance
S23 to G72 to J02 to A07 and A53 (female) and ground- Above 1 M
circuit) value
ing
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)
Electrical Circuit Diagram for Travel Alarm System
F.N.R Switch
1 2 3 4 5 6
F
N
R
1 3 G72
(DT-4)
FB1
11 12 13 J02
10A 3 (J-20)
(Black)
C03
(DRC-40)
30 Travel R
A07
(SWP-16) A53
S25 Reverse
3 1
13 14 (090-016) Alarm
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
The standard values in normal by which to judge "good" or "no good" about pre-
1 sumed causes.
References for making judgement of "good" or "no good"
20-602 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
PW160-7H 20-603
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
Does M72
Pin 2 have good NO
Correct poor
connection to ground
ground?
YES
Does M72 NO
Pin 4 have good Replace DC/DC
connection to converter
ground?
YES
Defective
connector or
Does M79 disconnection in
NO
Pin 2 have good wiring between
connection to M79 Pin 2 &
ground? J09 Pin 13 and
J09 Pin 11
YES CN-M72 Pin 4
Is voltage NO
between Replace DC/DC
M72 Pin 3 & converter
Chassis normal?
YES
Defective
Is voltage NO connector or
between disconnection in
M79 Pin 1 & wiring between
Chassis normal? M72 Pin 3 &
M79 Pin 1
YES
Is voltage NO
between Replace socket
M79 Pin 2 & M79
Chassis normal?
YES
Defective
Is voltage NO connector or
between disconnection in
M40 Pin 8 & wiring between
Chassis normal? M40 Pin 8 & M79
Pin 2
Defective
YES connector or
disconnection in
Is voltage NO wiring between
between M72 Pin 30 & J10
M40 Pin 4 & Pin 20 & J10
Chassis normal? Pin 18 & H08
Pin 1 & M50 Pin 4
YES
Defective
Is voltage NO connector or
between disconnection in
M40 Pin 7 & wiring between
Chassis normal? M72 Pin 3 & J10
Pin 17 & J10
Pin 19 & H08
YES Pin 3 & M50 Pin 7
& M40 Pin 7
YES Is voltage NO
Replace Defective
between
damaged radio connector or
M40 Pin 8 &
unit disconnection in
Chassis normal?
wiring between
M72 Pin 4 & J09
Pin 11 & J09
Pin 12 & H08
Pin 2 & M50 Pin 8
& M40 Pin 8
20-604 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
LEFT RIGHT
SPEAKER SPEAKER
M72 (M-4)
DC / DC RADIO CASSETTE
CONVERTER
(AMP-8)
1 2 3 4 M40 4 7 8 1 2 7 8 M73 1 2 1 2 M13
M41
(AMP-8) (M-2) (M-2)
M50 4 7 8 3 4 5 6 M51
FB1 (AMP-8) (AMP-8)
10A M79
(M-2)
1 2
6
TELEPHONE
SOCKET
3 10 11 12 13 14 15
J09 T11 (Cab GND)
(J-20) J10
(Pink) 17 18 19 20 1 2 3 8 H08
(J-20) (M-8)
(Orange)
PW160-7H 20-605
*When Fuse No.3 is not blown
*When bulbs are fitted correctly & fully functional
20-606
START
damaged lamp between R51 damaged relay between S14 YES disconnection in
unit Pin 6 & Chassis R45 Pin 2 & Chassis wiring between
normal? Defective
normal? R45 Pin 3 &
YES connector or
S14 Pin 2
Defective NO disconnection in NO
connector or wiring between
disconnection in Defective R45 Pin 2 & Defective
Is voltage connector or P01 Pin 7 Is voltage
wiring between NO connector or
between disconnection in between S14 NO
R51 Pin 5 & disconnection in
R51 Pin 3 & wiring between Pin 1 & Chassis
G7 Pin 4 wiring between
Chassis R45 Pin 5 & normal?
normal? S14 Pin 1 &
R51 Pin 3 FB1 Pin 3 (fuse)
Is voltage NO YES
between R51
YES
Pin 6 & Chassis Replace
normal? damaged
interlock switch
YES
PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Replay For
PPC Lock (2)
R46
1 2 3 5 6 1 2 3 5 6 FREE
1 2 3 5 6 1 2 3 5 6 1 2 S14
(M-3) C02 (DRC - 40)
FB1 9 PPC Lock (OUT)
10A 3
C03 (DRC - 40)
29 PPC Lock (IN)
A07
(SWP - 16)
15
G8 (DT - 4)
2
S19
A05 (DT-2)
(SWP - 14) 4
3 1
V01 BRAKE
PPC Pressure (DT-2) G7 (DT - 4) LIGHTS
2
Lock Solenoid
1 2
SOL
4
2
A65 A65
A01 (X-4)
1
A64
PW160-7H 20-607
20-608
*When Fuse No.2 is not blown
*When Fuse No.15 is not blown
START 1
Correct poor Correct poor
ground ground
NO NO
YES Pin 2 have good YES between CN-V09 between V10 Pin 2 have good
damaged damaged
connection to Pin 1 & Chassis Pin 1 & Chassis connection to
solenoid valve solenoid valve
ground? normal? normal? ground?
NO NO
Defective
connector or Is voltage
YES between P10
disconnection in
wiring between Pin 2 & Chassis
Ensure monitor V09 Pin 1 & normal?
panel is clear of P10 Pin 2
START 2 error codes NO START 3
YES
Is voltage
Replace outrigger YES between P10
Is attachment Is voltage Is voltage Defective Is voltage Ensure monitor
YES NO YES switch P10 Pin 1 & Chassis YES
interlock icon between C03 between G71 connector or between C03 panel is clear of
normal?
display on Pin 9 & Chassis Pin 4 & Chassis disconnection in Pin 40 & Chassis error codes
monitor panel? normal? normal? wiring between normal?
C03 Pin 9 & NO
NO G71 Pin 4 Defective connector NO
NO or disconnection in
Defective YES Is voltage Between Defective
wiring between P10 C03 Pin 2 & Pin 12
Is voltage YES connector or Is voltage connector or
Pin 1 & C03 Pin 2 & & chassis Normal YES
between G71 disconnection in between G71 disconnection in
wiring between Pin 12 wiring between
Pin 3 & Chassis Pin 3 & Chassis
NO Defective
normal? C03 Pin 40 & normal? C03 Pin 40 &
G71 Pin 3 connector or G71 Pin 3
Undercarriage Attachments - Mode Selection
Is voltage disconnection in
NO wiring between NO
between G71 YES
Pin 4 & Chassis C03 Pin 9 &
normal? G71 Pin 4
NO
Is voltage
between G71 YES Replace
Pin 1 & Chassis damaged PPC
normal? Lever
(Right Hand)
NO
Defective
connector or
disconnection in
wiring between
G71 Pin 1 &
Fuse No. 15
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
OUTRIGGER SWITCH
FB1
20A 2
H10 15
(S-16) 3 4 15A
P10
(DT-8)
J04
1 2 3 4 5 6 7 8
(J-20) 14 16
13
(Green)
BOOM / UNDERCARRIAGE SELECT UNDERCARRIAGE
(RH PPC LEVER)
BOOM
1 3 4 G71
(DT-6)
H12
(S-12)
3 4 5 6 7 12
C03 (DRC-40)
A02 3
(X-4)
VIS (SOL. POWER) 2
V09 (DT-2)
1
BOOM/STABLISER
SOL DOWN SOLENOID
4 5 6 7 A05 10
A99 2
(SWP-8) (SWP-14)
V10 (DT-2)
1
BOOM/STABLISER
SOL UP SOLENOID
A12 2
(DT-4)
1 2 3 4
CN-P01 A65
GND 6 SWIVEL JOINT
V16 (DT-2)
1
FRONT R.H STABLISER
SOL SOLENOID
2
V17 (DT-2)
1
REAR L.H STABLISER
SOL SOLENOID
2
V18 (DT-2)
1
REAR R.H STABLISER
SOL SOLENOID
2
UNDERCARRIAGE ATTACHMENTS
PW160-7H 20-609
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
Refer to Is voltage
Undercarriage NO between P10
Attachments - Pin 1 & Chassis
Mode Selection normal?
page
YES
Replace outrigger
switch P10
20-610 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
OUTRIGGER SWITCH
FB1
20A 2
H10 15
(S-16) 3 4 15A
P10
(DT-8)
J04
(J-20)
1 2 3 4 5 6 7 8
13 14 16
(Green)
BOOM / UNDERCARRIAGE SELECT UNDERCARRIAGE
(RH PPC LEVER)
BOOM
1 3 4 G71
(DT-6)
H12
(S-12)
3 4 5 6 7 12
C03 (DRC-40)
A02 3
(X-4)
VIS (SOL. POWER) 2
V09 (DT-2)
1
BOOM/STABLISER
SOL DOWN SOLENOID
4 5 6 7 A05 10
A99 2
(SWP-8) (SWP-14)
V10 (DT-2)
1
BOOM/STABLISER
SOL UP SOLENOID
A12 2
(DT-4)
1 2 3 4
CN-P01 A65
GND 6 SWIVEL JOINT
V16 (DT-2)
1
FRONT R.H STABLISER
SOL SOLENOID
2
V17 (DT-2)
1
REAR L.H STABLISER
SOL SOLENOID
2
V18 (DT-2)
1
REAR R.H STABLISER
SOL SOLENOID
2
UNDERCARRIAGE ATTACHMENTS
PW160-7H 20-611
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
Refer to Is voltage
Undercarriage NO between P10
Attachments - Pin 1 & Chassis
Mode Selection normal?
page
YES
Replace outrigger
switch P10
20-612 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
OUTRIGGER SWITCH
FB1
20A 2
H10 15
(S-16) 3 4 15A
P10
(DT-8)
J04
(J-20)
1 2 3 4 5 6 7 8
13 14 16
(Green)
BOOM / UNDERCARRIAGE SELECT UNDERCARRIAGE
(RH PPC LEVER)
BOOM
1 3 4 G71
(DT-6)
H12
(S-12)
3 4 5 6 7 12
C03 (DRC-40)
A02 3
(X-4)
VIS (SOL. POWER) 2
V09 (DT-2)
1
BOOM/STABLISER
SOL DOWN SOLENOID
4 5 6 7 A05 10
A99 2
(SWP-8) (SWP-14)
V10 (DT-2)
1
BOOM/STABLISER
SOL UP SOLENOID
A12 2
(DT-4)
1 2 3 4
CN-P01 A65
GND 6 SWIVEL JOINT
V16 (DT-2)
1
FRONT R.H STABLISER
SOL SOLENOID
2
V17 (DT-2)
1
REAR L.H STABLISER
SOL SOLENOID
2
V18 (DT-2)
1
REAR R.H STABLISER
SOL SOLENOID
2
UNDERCARRIAGE ATTACHMENTS
PW160-7H 20-613
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
Refer to Is voltage
Undercarriage NO between P10
Attachments - Pin 1 & Chassis
Mode Selection normal?
page
YES
Replace outrigger
switch P10
20-614 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
OUTRIGGER SWITCH
FB1
20A 2
H10 15
(S-16) 3 4 15A
P10
(DT-8)
J04
(J-20)
1 2 3 4 5 6 7 8
13 14 16
(Green)
BOOM / UNDERCARRIAGE SELECT UNDERCARRIAGE
(RH PPC LEVER)
BOOM
1 3 4 G71
(DT-6)
H12
(S-12)
3 4 5 6 7 12
C03 (DRC-40)
A02 3
(X-4)
VIS (SOL. POWER) 2
V09 (DT-2)
1
BOOM/STABLISER
SOL DOWN SOLENOID
4 5 6 7 A05 10
A99 2
(SWP-8) (SWP-14)
V10 (DT-2)
1
BOOM/STABLISER
SOL UP SOLENOID
A12 2
(DT-4)
1 2 3 4
CN-P01 A65
GND 6 SWIVEL JOINT
V16 (DT-2)
1
FRONT R.H STABLISER
SOL SOLENOID
2
V17 (DT-2)
1
REAR L.H STABLISER
SOL SOLENOID
2
V18 (DT-2)
1
REAR R.H STABLISER
SOL SOLENOID
2
UNDERCARRIAGE ATTACHMENTS
PW160-7H 20-615
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
Refer to Is voltage
Undercarriage NO between P10
Attachments - Pin 1 & Chassis
Mode Selection normal?
page
YES
Replace outrigger
switch P10
20-616 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
OUTRIGGER SWITCH
FB1
20A 2
H10 15
(S-16) 3 4 15A
P10
(DT-8)
J04
(J-20)
1 2 3 4 5 6 7 8
13 14 16
(Green)
BOOM / UNDERCARRIAGE SELECT UNDERCARRIAGE
(RH PPC LEVER)
BOOM
1 3 4 G71
(DT-6)
H12
(S-12)
3 4 5 6 7 12
C03 (DRC-40)
A02 3
(X-4)
VIS (SOL. POWER) 2
V09 (DT-2)
1
BOOM/STABLISER
SOL DOWN SOLENOID
4 5 6 7 A05 10
A99 2
(SWP-8) (SWP-14)
V10 (DT-2)
1
BOOM/STABLISER
SOL UP SOLENOID
A12 2
(DT-4)
1 2 3 4
CN-P01 A65
GND 6 SWIVEL JOINT
V16 (DT-2)
1
FRONT R.H STABLISER
SOL SOLENOID
2
V17 (DT-2)
1
REAR L.H STABLISER
SOL SOLENOID
2
V18 (DT-2)
1
REAR R.H STABLISER
SOL SOLENOID
2
UNDERCARRIAGE ATTACHMENTS
PW160-7H 20-617
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Defective connector or
NO disconnection in wiring
between M33 Pin 2
& FB1 Pin 14
Is voltage between
YES M33 Pin 2 & chassis
normal
Is voltage
between M33
NO Pin 1 & Chassis
normal?
Is voltage
between G33
Pin 3 & Chassis
normal? YES Replace seat heater
switch M33
Defective connector or
YES disconnection in wiring
between M33 Pin 1 &
G33 Pin 3
YES
Replace heating
element
20-618 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
M33 (M-2)
L V
HEATED
OFF SEAT
1
1 2
FB1
10A 14 G33
J09 (Pink)
(J-20)
6
3
T05
PW160-7H 20-619
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Suspension Lock
20-620 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
R47
1 2 3 5 6
1 2 3 5 6
FB1
3
10A
A05
(SWP-14)
C02 12
(DRC-40) V04 (DT-2) Suspension lock
solenoid
SUSPENSION LOCK 19 1
SOL
2
A65
SUSPENSION LOCK
PW160-7H 20-621
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
NO
NO
YES
Defective connector or
Is voltage
NO disconnection in wiring
between R18
between R18 Pin 5
Pin 5 & Chassis
& FB1 Pin 6
normal?
YES
Is voltage Defective connector or
Is voltage
NO between R18 YES disconnection in wiring
between R18
Pin 3 & Chassis between R18 Pin 3
Pin 1 & Chassis
normal? & G52 Pin 1
normal?
NO NO
Defective connector or
Is voltage Is voltage Defective connector Is voltage Between P06 YES
NO NO disconnection in wiring
between G52 between J09 or disconnection in Pin 2 & chassis normal between R18 Pin 1
Pin 3 & Chassis Pin 9 & Chassis wiring between G52
& P06 Pin 2
normal? normal? Pin 3 & FB1 Pin 6 NO
YES YES
Defective connector or
Is voltage Between P06 NO disconnection in wiring
Pin 1 & chassis normal between R18 Pin 1
Defective connector & FB1 Pin 6
or disconnection in YES
wiring between G52
Pin 3 & J10 Pin 9 Change defective switch
P06
Is voltage
between G52 NO
Pin 1 & Chassis
normal?
YES YES
NO Poor connection
to Chassis
ground
20-622 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
LOWER
WIPER
L V
1 2
Off
1
1 2 P06 LOWER WIPER
M
R18
1 2 3 5 6
LW
LB
B
L
1 2 3 4
G52
1 2 3 5 6
A07
(SWP-16)
12
16
W08 (070-18)
VB 5
A64
1 2 3 4 5 6 7 8 9 10 J10
D02 (J-20)
(SWP-8) (Orange)
3 2 7 J09 3
(J-20)
(Pink) 7
T05
FB1
10A 6
PW160-7H 20-623
20-624
*When Fuse No.13 is not blown
*When all bulbs are fully functional & fitted correctly
*With lamp switch M07 switched on
Defective connector
or disconnected
wiring between H09
Pin 3 & M40B Pin 1
& M40 Pin 1
TESTING AND ADJUSTING
NO
Defective connector Defective connector Is voltage between NO Is voltage between NO Is voltage between NO Is voltage between NO
Is voltage between Is voltage between
NO YES or disconnection in or disconnection in R10 Pin 1 & chassis M07 Pin 2 & chassis M07 Pin 1 & chassis J03 Pin 1 & chassis
H09 Pin 5 & chassis R16 Pin 5 & chassis
wiring between R16 wiring between R10 normal normal normal normal
normal normal
Pin 5 & H09 Pin 5 Pin 5 & H09 Pin 3
YES YES YES YES
NO
Defective connector
Is voltage between NO Is voltage between NO Defective connector Defective connector
or disconnection in Replace damaged Replace damaged
R16 Pin 3 & chassis J03 Pin 1 & chassis or disconnection in or disconnection in
wiring between J03 relay R10 switch M07
normal normal wiring between M07 wiring between J03
Pin 1 & FB1 Pin 13
Pin 2 & R10 Pin 1 Pin 1 & M07 Pin 1
YES
YES
Defective connector
Is voltage between YES Replace damaged or disconnection in
R16 Pin 2 & chassis relay R16 wiring between J03
normal
Pin 1 & R16 Pin 3
NO
PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
40A 40B
(M-2) (M-2)
1 1
CAB REAR
WORKLAMP
2 2
M40
(M-2)
1
J09 CAB FRONT LEFT
(J-20) WORKLAMP
3 8 9 2
(Pink)
M41
(M-2)
1
CAB FRONT RIGHT
R16 R10 WORKLAMP
2
1 2 3 5 6 1 2 3 5 6
H09
(S-8)
1 2 3 5 6 1 2 3 5 6
3
6
T05
A99 A89
(SWP-8) A86 (DT-2) (KES1-1)
1 2 1
BOOM (RH)
A90
(KES1-1)
A84 (X-4)
1
BOOM (LH)
1
A85 (X-1)
1
COUNTERWEIGHT
WORKLAMP
J07
1 2 3 5 6 8 9 10 18 19 20
(J-20)
(Black)
A07
D01 H11 (SWP-16)
(SWP-8) (S-16)
2
4 10
8
P02 (040-20)
19 Lamps Switch
J03
1 2 3 4 (J-20) FB1
(Green) 13
20A
H15 M07
(090-20)
L V
7
1 2
6
OFF
1 2
WORK LIGHTS
PW160-7H 20-625
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
NO Defective
NO Is voltage Is voltage between
Replace damaged YES between M07 NO YES connector or
Correct poor M07 Pin 2 &
switch M07 Pin 1 & Chassis disconnection in
ground Chassis normal?
normal? wiring between
A86 Pin 2 &
NO M07 Pin 2
Defective
connector or Is voltage Defective
YES Is voltage Defective connector
disconnection in between R16 connector or
NO between J03 YES or disconection in
wiring between Pin 5 & Chassis disconnection in
Pin 1 & Chassis wiring between J03
A85 Pin 1 & OK? wiring between
normal? Pin 1 & M07 Pin1
R16 Pin 5 J03 Pin 1 &
FB1 Pin 13
NO
Defective connector
Is voltage between NO Is voltage between NO or disconnection in
R16 Pin 3 & chassis J03 Pin 1 & chassis
wiring between J03
normal normal
Pin 1 & FB1 Pin 13
YES
YES
Defective connector
Is voltage between YES Replace damaged or disconnection in
R16 Pin 2 & chassis relay R16 wiring between J03
normal
Pin 1 & R16 Pin 3
NO
20-626 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
40A 40B
(M-2) (M-2)
1 1
CAB REAR
WORKLAMP
2 2
M40
(M-2)
1
J09 CAB FRONT LEFT
(J-20) WORKLAMP
3 8 9 2
(Pink)
M41
(M-2)
1
CAB FRONT RIGHT
R16 R10 WORKLAMP
2
1 2 3 5 6 1 2 3 5 6
H09
(S-8)
1 2 3 5 6 1 2 3 5 6
3
6
T05
A99 A89
(SWP-8) A86 (DT-2) (KES1-1)
1 2 1
BOOM (RH)
A90
(KES1-1)
A84 (X-4)
1
BOOM (LH)
1
A85 (X-1)
1
COUNTERWEIGHT
WORKLAMP
J07
1 2 3 5 6 8 9 10 18 19 20
(J-20)
(Black)
A07
D01 H11 (SWP-16)
(SWP-8) (S-16)
2
4 10
8
P02 (040-20)
19 Lamps Switch
J03
1 2 3 4 (J-20) FB1
(Green) 13
20A
H15 M07
(090-20)
L V
7
1 2
6
OFF
1 2
WORK LIGHTS
PW160-7H 20-627
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Defective connector
or disconnection in Correct poor Is voltage
START 2 YES
wiring between F02B ground between P05 Replace switch P05
Pin 2 & H09 Pin 7 Pin 1 & Chassis
normal?
NO
Is voltage Defective
NO
between A84 connector or
Pin 4 & Chassis disconnection in
normal? wiring between
P05 Pin 1 &
YES FB1 Pin 7
Does A84
Change Is the voltage
YES YES Pin 3 Have good NO
counterweight between G53 Pin 1 Correct poor ground
beacon lamp connection to
& chassis Normal
ground
NO
Defective
connector or
disconnection in
wiring between
A84 Pin 4 &
G53 Pin 1
Defective connector
Is the voltage Is the voltage NO
NO or disconnection in
between P05 Pin 2 between P05 Pin 1
wiring between P05
& chassis Normal & chassis Normal
Pin 1 & FB1 Pin 7
YES YES
20-628 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
F02B
1 2 (DT-2)
F02
1 2 (M-2)
H09
(S-8)
7
A07
8
T05
4
COUNTERWEIGHT
BEACON LAMP
P05
(M-2)
L V
1 2
Off
1
1 2 FB1 G53
A84 1 2 (DT-2)
7 10A
(X-4)
3
4
A65
BEACON LIGHT
PW160-7H 20-629
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
Is voltage Defective
NO
between G33 connector or
Pin 1 & Chassis disconnection in
normal? wiring between
G33 Pin 1 &
YES FB1 Pin 16
Does G33
NO
Pin 2 have good Correct poor
connection to ground
ground?
YES
Change
defective seat
20-630 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
FB1
G33 16
1
M 2
10A
T05
PW160-7H 20-631
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
Is voltage Defective
NO
between connector or
M71 Pin 2 & disconnection in
Chassis normal? wiring between
M71 Pin 2 &
YES FB1 Pin 16
Disconnect lamp
NO
unit & check if good
Correct poor
ground connection
ground
to cab frame
YES
Change
defective lamp
unit
20-632 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
LAMP UNIT
H11
11
M71
ON
1 A64
OFF
2
FB1
H12
16 10A
11
PW160-7H 20-633
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Cigar Lighter
NO
NO
20-634 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
6 5 J03
(J-20)
CIGAR (Green)
LIGHTER
FB1
4 10A
M19 H11
(YAZAKI-2) (S-16)
1 12
2 11
A64
PW160-7H 20-635
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
NO NO
Is voltage NO
between G99 Defective
Pin 8 & Chassis connector or
normal? disconnection in
wiring between
YES G99 Pin 8 &
FB1 Pin 3
Replace
damaged park
brake switch
20-636 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
G99
6 8 2 4 1 3 5 7 10 9
OFF
ON
PRESSURE
V12 H15 S17 SWITCH
Brake Valve (DT-2) (090-20) (DT-2)
Solenoid
1 9 2
(BRAKE
SOL 10 VALVE)
2
12 1
FB1
10A C03 (DRC-40)
3
19 PARK BRAKE PRESSURE SW.
J06 J04
3
(J-20) 1 1 3 10 (J-20)
(Pink) (Green)
A06 1 4 A02
(SWP-16) (X-4)
A64
PARK BRAKE
PW160-7H 20-637
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
START
Is voltage
between C03 YES Replace
Pin 19 & Chassis damaged
normal? controller
NO
Defective
Is voltage connector or
between S17 YES disconnection in
Pin 1 & Chassis wiring between
normal? S17 Pin 1 &
C03 Pin 19
NO
Is voltage
between S17 YES Replace
Pin 2 & Chassis damaged
normal? pressure switch
NO
Defective
Is voltage connector or
between G99 YES disconnection in
Pin 2 & Chassis wiring between
normal? S17 Pin 2 &
G99 Pin 2
NO
Is voltage Defective
between G99 NO connector or
Pin 4 & Chassis disconnection in
normal? wiring between
G99 Pin 4 &
YES FB1 Pin 3
Change
damaged park
brake switch
20-638 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
G99
6 8 2 4 1 3 5 7 10 9
OFF
ON
PRESSURE
V12 H15 S17 SWITCH
Brake Valve (DT-2) (090-20) (DT-2)
Solenoid
1 9 2
(BRAKE
SOL 10 VALVE)
2
12 1
FB1
10A C03 (DRC-40)
3
19 PARK BRAKE PRESSURE SW.
J06 J04
3
(J-20) 1 1 3 10 (J-20)
(Pink) (Green)
A06 1 4 A02
(SWP-16) (X-4)
A64
PARK BRAKE
PW160-7H 20-639
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
YES
20-640 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
EPC
Solenoid
2 1 V13
(DT-2)
A04
8 7 (SWP-12)
RIGHT HAND PPC LEVER
Main Controller
TOP TOP C01 (DRC-24)
LEFT RIGHT R48 Clamshell L.H
18
24 Clamshell R.H
C02 (DRC-40)
1 2 3 5 6
18 Clamshell Sol. Relay
2 5 6
G71 1 2 3 5 6
C03 (DRC-40)
(DT-6) 3 Ground
13 Ground
23 Ground
26 EPC Service
FB1
15A
15
A05
(SWP-14)
11
J05
13 15 (J-20)
(Pink)
V14 (DT-2)
1
2 SOL
A65
A64
CLAMSHELL CONTROL
PW160-7H 20-641
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Defective connector
Is voltage between or disconnection in
NO
R48 Pin 1 and wiring between
chassis normal? R48 Pin 1 & FB1
Pin 15.
YES
NO
NO
YES
Change
damaged work
lever
20-642 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
EPC
Solenoid
2 1 V13
(DT-2)
A04
8 7 (SWP-12)
RIGHT HAND PPC LEVER
Main Controller
TOP TOP C01 (DRC-24)
LEFT RIGHT R48 Clamshell L.H
18
24 Clamshell R.H
C02 (DRC-40)
1 2 3 5 6
18 Clamshell Sol. Relay
2 5 6
G71 1 2 3 5 6
C03 (DRC-40)
(DT-6) 3 Ground
13 Ground
23 Ground
26 EPC Service
FB1
15A
15
A05
(SWP-14)
11
J05
13 15 (J-20)
(Pink)
V14 (DT-2)
1
2 SOL
A65
A64
CLAMSHELL CONTROL
PW160-7H 20-643
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Is voltage between
G71 Pin 5 and Defective connector
C01 Pin 24 NO or disconnection in
normal when lever wiring between
G71 Pin 5 and
switch is C01 Pin 24.
depressed
YES
Is voltage at C03
Pin 26 correct when NO Replace damaged
lever button switches controller
depressed?
YES
YES
YES
YES
EPC circuit OK
20-644 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
EPC
Solenoid
2 1 V13
(DT-2)
A04
8 7 (SWP-12)
RIGHT HAND PPC LEVER
Main Controller
TOP TOP C01 (DRC-24)
LEFT RIGHT R48 Clamshell L.H
18
24 Clamshell R.H
C02 (DRC-40)
1 2 3 5 6
18 Clamshell Sol. Relay
2 5 6
G71 1 2 3 5 6
C03 (DRC-40)
(DT-6) 3 Ground
13 Ground
23 Ground
26 EPC Service
FB1
15A
15
A05
(SWP-14)
11
J05
13 15 (J-20)
(Pink)
V14 (DT-2)
1
2 SOL
A65
A64
CLAMSHELL CONTROL
PW160-7H 20-645
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Horns
START
NO
Defective
Is voltage connector or
between R44 NO disconnection in
Pin 1 & Chassis wiring between
normal? R44 Pin 1 &
FB1 Pin 5
YES
Defective
Is voltage NO connector or
between R44 disconnection in
Pin 3 & Chassis wiring between
normal? R44 Pin 3 &
FB1 Pin 5
YES
Does G70 NO
Pin 4 have good Correct poor
connection to ground
ground?
YES
Does G70
Pin 3 have good
connection to NO Change
ground when damaged PPC
PPC lever horn lever
switch is
depressed?
YES
Does G4 Pin 1
have good
Change NO connection to
damaged ground when
steering column steering column
switch horn switch is
depressed
YES
YES
YES
YES
Replace
damaged relay
R44
20-646 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
R44
1 2 3 5 6
FB1 1 2 3 5 6
A07
5 (SWP-16) A40
10A 1 1
Indicator stalk
J09
(J-20) 1 3 18 19 20 3 4 G70
(Pink) (DT-6)
6 1
G3 G4
G02
(DT-12)
1
7 T05
W08 (070-18)
Wiper Switch Common 12
PW160-7H 20-647
*Emergency swing switch is in Normal position
START
20-648
Does P02 Pin 17 Does V03
Does C02 Pin 38 Is voltage Change
Change YES YES Replace YES Pin 2 have good YES
have good connection have good connection between V03 damaged
damaged to ground with C02 damaged connection to
to ground with P02 Pin 1 & Chassis solenoid
monitor panel Pin 38 Disconnected controller ground?
Pin 17 disconnected normal?
NO NO NO NO
Does H15 Pin Defective Does H15 Pin Defective Defective
YES connector or YES connector or connector or YES Is voltage Correct poor
8 have good 8 have good
disconnection in disconnection in disconnection in between X05 ground
connection to connection to Pin 4 & Chassis
ground? wiring between ground? wiring between wiring between
P02 Pin 17 & C02 Pin 38 V03 Pin 1 & normal?
TESTING AND ADJUSTING
Is voltage Replace
YES
between X05 damaged swing
Pin 3 & Chassis lock switch
normal?
NO
Does X05
Is voltage Change
Pin 2 have good NO YES
Correct poor ground between J10 damaged splice
connection to
Pin 11 & Chassis header J10
ground?
normal?
YES
NO
Is voltage between Defective
X05 Pin 1 & Pin 2 Replace damaged connector or YES Is voltage
YES
normal when switch swing lock switch disconnection in between D05
is ON & not normal X05 wiring between Pin 1 & Chassis
when OFF J10 Pin 11 & normal?
D05 Pin 1
YES NO
Circuit OK Is voltage
YES Change
between D05
Pin 2 & Chassis defective diode
normal? block D05
NO
Defective
connector or Is voltage
YES
disconnection in between C03
wiring between Pin 37 & Chassis
D05 Pin 2 & normal?
C03 Pin 37
NO
Replace
damaged
controller
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Emergency Swing
Parking Brake Release Swing Lock Switch
1 2 3 4 5 6 1 2 3 4 5 6
S22
EMERGENCY ON (Swing Lock)
1 2 3 4
X05
(M-4)
D05
(KES1-2)
J10 (J-20)
(Orange)
(090-16)
(090-20)
8 9 10 11 1 2 11 12 13 8 9 10 19 20 1 3 4 10 J05
(J-20)
S25
H15
(Pink)
H11 P02
5 17 Swing Lock Display
A65
J04
3 4 7 A02 3 4
C03 (DRC-40)
(J-20) (X-4)
1 VB (Controller PWR)
11 VB (Controller PWR)
FB1
1 A64 14 Key Sig.
SWING LOCK
PW160-7H 20-649
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
NO NO NO
Defective Defective
connector or Does S22 Pin 6 have connector or Is voltage Correct poor
YES good connection to
disconnection in disconnection in YES between X05 ground
wiring between ground with wiring between Pin 4 & Chassis
C02 Pin 2 & emergency switch in V03 Pin 1 & normal?
S22 Pin 6 normal position. X05 Pin 4
NO
NO
Defective
Is voltage YES connector or
between S22 disconnection in
Pin 3 & Chassis wiring between
normal? J10 Pin 12 &
S22 Pin 3
NO
NO
Defective
connector or
disconnection in
wiring between
S22 Pin 2 &
FB Pin 1
20-650 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Emergency Swing
Parking Brake Release Swing Lock Switch
1 2 3 4 5 6 1 2 3 4 5 6
S22
EMERGENCY ON (Swing Lock)
1 2 3 4
X05
(M-4)
D05
(KES1-2)
J10 (J-20)
(Orange)
(090-16)
(090-20)
8 9 10 11 1 2 11 12 13 8 9 10 19 20 1 3 4 10 J05
(J-20)
S25
H15
(Pink)
H11 P02
5 17 Swing Lock Display
A65
J04
3 4 7 A02 3 4
C03 (DRC-40)
(J-20) (X-4)
1 VB (Controller PWR)
11 VB (Controller PWR)
FB1
1 A64 14 Key Sig.
SWING LOCK
PW160-7H 20-651
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
NO
Defective
Is voltage between YES connector or
R11 Pin 3 & disconnection in
chassis normal? wiring between
R22 Pin 3 &
NO R11 Pin 3
YES
Is voltage between
2 R11 Pin 5 &
chassis normal?
NO
Defective
Is voltage between YES connector or
J01 Pin 7 & disconnection in
chassis normal? wiring between
R11 Pin 2 &
NO J01 Pin 7
NO
Defective
connector or
Is voltage between YES
disconnection in
H15 Pin 4 &
wiring between
chassis normal?
J01 Pin 5 &
NO H15 Pin 4
Is voltage between
YES H15 Pin 1 & Pin 4 YES Is voltage between
Replace Starter switch
normal with starter H15 Pin 1 &
switch in off position chassis normal?
NO NO
Circuit OK Defective
connector or
disconnection in
wiring between
H15 Pin 1 & FB1
Pin 18
20-652 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
YES
NO
Defective
connector or
Is voltage between YES disconnection in
J02 Pin 3 & wiring between
chassis normal? R22 Pin 1 &
J02 Pin 3
NO
NO
Defective
connector or
Is voltage between YES disconnection in
G72 Pin 4 &
wiring between
chassis normal?
J02 Pin 1 &
NO G72 Pin 4
NO
Defective
connector or
Is voltage between YES disconnection in
S23 Pin 3 & wiring between
chassis normal? G72 Pin 1 &
S23 Pin 3
NO
NO
Defective
connector or
disconnection in
wiring between
S23 Pin 2 & FB1
Pin 3
PW160-7H 20-653
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
YES NO
Defective Defective
connector or Does R13 Pin 6 connector or
NO Is voltage between YES
disconnection in have good disconnection in
wiring between connection to S20 Pin 3 &
wiring between
R11 Pin 2 & ground? chassis normal?
R11 Pin 1 &
R13 Pin 6 S20 Pin 3
YES NO
YES NO
Defective
connector or Defective
disconnection in NO connector or
Is voltage between
wiring between disconnection in
R13 Pin 1 &
R13 Pin 2 & wiring between
chassis normal?
P02 Pin 14 R13 Pin 6 & FB1
Pin 12
YES
Replace damaged
relay R13
20-654 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
J06 15 16 17
J03
(J-20) 18 19
(J-20)
(Pink)
STARTER SWITCH
B BR R1 R2 C ACC
R1
RELAY FOR STARTER CUT RELAY FOR STARTER CUT RELAY FOR STARTER CUT OFF
(PERSONAL CODE) (TRAVEL NEUTRAL)
R13 R11 R22 ACC
ST
J01
(J-20) FB1
(Black)
3
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 10A
H15
2 4 5 7 11 12 1 2 4
(090-20)
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 FB1 12
20A
18
10A
P02 (040-20) H11
PERSONAL CODE 14 5
A07
FNR SWITCH
(SWP-16)
PPC HYDRAULIC LOCK SWITCH 6 9 1 2 3 4 5 6
FREE F
LOCK N
A27 R
(X-2)
1 2
S14
(M-3) J02
1 2 3 R S 1 2 3 4 12 13 (J-20) EMERGENCY TRAVEL SWITCH
STARTER (Black) 1 2 3 4
S23 5 6
SAFETY
RELAY
E NORMAL
G72
(DT-4)
1 2 3 4 EMERGENCY
S25
(090-16)
12
13
14
15
C03 (DRC-40) 16
D01
3 5 9 (SWP-8)
J04 10 TRAVEL F
(J-20) 2
6 20 TRAVEL N
30 TRAVEL R
4
A02
A64
PW160-7H 20-655
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Is voltage
Replace Yes between J02
damaged splice
Pin 16 & Chassis
head J02
normal?
No
Defective
Is voltage connector or
No between R42 Yes disconnection in
3 Pin 5 & Chassis wiring between
normal? R41 Pin 5 &
No J02 Pin 16
Is voltage
Replace Yes between R42
damaged relay
Pin 3 & Chassis
R42
normal?
No
Defective
Is voltage connector or
No between J02 Yes disconnection in
4 Pin 8 & Chassis wiring between
normal? J02 Pin 8 &
R42 Pin 3
20-656 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Defective connector
Is voltage between Yes
or disconnection
J06 Pin 5 & chassis
wiring between J06
normal
Pin 5 & R41 Pin 2
No
No
Defective connector
Is voltage between Yes
or disconnection in
R42 Pin 2 & chassis
wiring between R42
normal
Pin 2 & J06 Pin 6
No
No
Defective connector
Is voltage between
or disconnection in
G73 Pin 2 & chassis Yes
wiring between G73
normal
Pin 2 & R42 Pin 1
No
No
Defective connector
Is voltage between Yes
or disconnection in
S23 Pin 4 & chassis
wiring between S23
normal
Pin 4 & G73 Pin 1
No
No
Defective connector
or disconnection in
wiring between S23
Pin 5 & FB1 Pin 3
PW160-7H 20-657
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Defective connector
Is voltage between Yes
or disconnection
J02 Pin 7 & chassis
wiring between J02
normal
Pin 7 & R41 Pin 1
No
No
Defective connector
Is voltage between Yes
or disconnection in
S23 Pin 1 & chassis
wiring between S23
normal
Pin 1 & J02 Pin 5
No
No
Defective connector
or disconnection in
wiring between S23
Pin 2 & FB1 Pin 3
20-658 PW160-7H
EMERGENCY
FNR SWITCH EMERGENCY
FNR SWITCH trol
TRAVEL
1 2 3 4 5 6 1 2 3 4
SWITCH
F F
S23
PW160-7H
N 1 2 3 4 5 6 N
R EMERGENCY R
NORMAL
R22
RELAY FOR
STARTER CUT
G72 S25 G73 1 2 3 5 6
(TRAVEL N)
(DT-4) 1 2 3 4 12 13 14 15 16 1 2 3 4
(090-16) (DT-4)
TESTING AND ADJUSTING
RELAY FOR
R42 R43
J02 (J-20) (BLACK) EMERGENCY
FB1 (DRIVE F) RELAY FOR
10A EMERGENCY
3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 5 6 1 2 3 5 6 (DRIVE R)
FUSE BOX
Circuit Diagram for Travel Direction Con-
R40 R41
C03 (DRC-40) RELAY FOR
TRAVEL F 10 RELAY FOR
EMERGENCY
EMERGENCY
TRAVEL N 20 (TRAVEL N)
(TRAVEL F/R) 1 2 3 5 6 1 2 3 5 6
TRAVEL F/R 28
S0L.
TRAVEL R 30
TRAVEL 38
NEUTRAL S0L.
TRAVEL 1
D02 (SWP-8)
F/R SOL
4 2 A05 (SWP-14)
V08 (DT-2) 7
8 8
A07
A53 (SWP-16) 1
BACKUP
1 3 TRAVEL
ALARM SOL J06 (J-20) 3 4 5 6 7
NEUTRAL 2
(PINK)
V06 (DT-2)
3 5 10
J04 (J-20)
(GREEN)
A65
A02
4
(X-4)
A64
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-659
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Is voltage
Go to Neutral Yes between R22
Start section on
Pin 1 & Chassis
fault finding
normal?
No
Defective
Is voltage connector or
between J02 Yes disconnection in
Pin 3 & Chassis wiring between
normal? R22 Pin 1 &
No J02 Pin 3
Is voltage
Replace Yes between J02
damaged splice
Pin 2 & Chassis
head J02
normal?
No
Defective
Is voltage connector or
between G73 Yes disconnection in
Pin 3 & Chassis wiring between
normal? J02 Pin 2 &
No G73 Pin 3
Replace Is voltage
damaged Yes between G73
emergency FNR Pin 1 & Chassis
switch normal?
No
Defective
Is voltage connector or
between S23 Yes disconnection in
Pin 4 & Chassis wiring between
normal? S23 Pin 4 &
No G73 Pin 1
Is voltage
Replace Yes between S23
damaged switch
Pin 5 & Chassis
S23
normal?
No
Defective
connector or
disconnection in
wiring between
S23 Pin 5 &
FB1 Pin 3
20-660 PW160-7H
EMERGENCY
FNR SWITCH EMERGENCY
FNR SWITCH trol
TRAVEL
1 2 3 4 5 6 1 2 3 4
SWITCH
F F
S23
PW160-7H
N 1 2 3 4 5 6 N
R EMERGENCY R
NORMAL
R22
RELAY FOR
STARTER CUT
G72 S25 G73 1 2 3 5 6
(TRAVEL N)
(DT-4) 1 2 3 4 12 13 14 15 16 1 2 3 4
(090-16) (DT-4)
TESTING AND ADJUSTING
RELAY FOR
R42 R43
J02 (J-20) (BLACK) EMERGENCY
FB1 (DRIVE F) RELAY FOR
10A EMERGENCY
3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 5 6 1 2 3 5 6 (DRIVE R)
FUSE BOX
Circuit Diagram for Travel Direction Con-
R40 R41
C03 (DRC-40) RELAY FOR
TRAVEL F 10 RELAY FOR
EMERGENCY
EMERGENCY
TRAVEL N 20 (TRAVEL N)
(TRAVEL F/R) 1 2 3 5 6 1 2 3 5 6
TRAVEL F/R 28
S0L.
TRAVEL R 30
TRAVEL 38
NEUTRAL S0L.
TRAVEL 1
D02 (SWP-8)
F/R SOL
4 2 A05 (SWP-14)
V08 (DT-2) 7
8 8
A07
A53 (SWP-16) 1
BACKUP
1 3 TRAVEL
ALARM SOL J06 (J-20) 3 4 5 6 7
NEUTRAL 2
(PINK)
V06 (DT-2)
3 5 10
J04 (J-20)
(GREEN)
A65
A02
4
(X-4)
A64
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-661
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
No
20-662 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Is voltage
between R41 Yes
C
Pin 2 & Chassis
normal?
No
Defective
Is voltage connector or
between J06 Yes disconnection in
Pin 5 & Chassis wiring between
normal? J06 Pin 5 &
R41 Pin 2
No
Is voltage
between J06 Yes Replace damaged
Pin 7 & Chassis splice head J06
normal?
No
Defective connector
Is voltage
Yes or disconnection in
between R43
wiring between
Pin 2 & Chassis
R43 Pin 2 & J06
normal?
Pin 7
No
Is voltage
Yes Replace
between R43
damaged relay
Pin 1 & Chassis
R43
normal?
No
Defective
Is voltage connector or
between G73 Yes disconnection in
Pin 4 & Chassis wiring between
normal? G73 Pin 4 &
R43 Pin 1
No
Is voltage
between G73 Yes Replace damaged
emergency FNR
Pin 1 & Chassis
switch
normal?
No
Defective
Is voltage connector or
Yes disconnection in
between S23
Pin 4 & Chassis wiring between
normal? S23 Pin 4 &
G73 Pin 1
No
Is voltage
Yes Replace damaged
between S23 emergency travel
Pin 5 & Chassis switch S23
normal?
No
Defective
connector or
disconnection in
wiring between
S23 Pin 5 &
FB1 Pin 3
PW160-7H 20-663
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Is voltage
between R41 Yes Replace damaged
Pin 1 & Chassis relay R41
normal?
No
Defective
Is voltage connector or
between J02 Yes disconnection in
Pin 7 & Chassis wiring between
normal? J02 Pin 7 &
R41 Pin 1
No
Is voltage
between J02 Yes Replace damaged
B
Pin 5 & Chassis splice head J02
normal?
No
Defective connector
Is voltage
Yes or disconnection in
between S23
wiring between
Pin 1 & Chassis
S23 Pin 1 & J02
normal?
Pin 5
No
Is voltage
between S23 Yes Replace emergency
Pin 2 & Chassis travel switch S23
normal?
No
Defective
connector or
disconnection in
wiring between
S23 Pin 2 &
FB1 Pin 3
20-664 PW160-7H
EMERGENCY
FNR SWITCH EMERGENCY
FNR SWITCH trol
TRAVEL
1 2 3 4 5 6 1 2 3 4
SWITCH
F F
S23
PW160-7H
N 1 2 3 4 5 6 N
R EMERGENCY R
NORMAL
R22
RELAY FOR
STARTER CUT
G72 S25 G73 1 2 3 5 6
(TRAVEL N)
(DT-4) 1 2 3 4 12 13 14 15 16 1 2 3 4
(090-16) (DT-4)
TESTING AND ADJUSTING
RELAY FOR
R42 R43
J02 (J-20) (BLACK) EMERGENCY
FB1 (DRIVE F) RELAY FOR
10A EMERGENCY
3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 5 6 1 2 3 5 6 (DRIVE R)
FUSE BOX
Circuit Diagram for Travel Direction Con-
R40 R41
C03 (DRC-40) RELAY FOR
TRAVEL F 10 RELAY FOR
EMERGENCY
EMERGENCY
TRAVEL N 20 (TRAVEL N)
(TRAVEL F/R) 1 2 3 5 6 1 2 3 5 6
TRAVEL F/R 28
S0L.
TRAVEL R 30
TRAVEL 38
NEUTRAL S0L.
TRAVEL 1
D02 (SWP-8)
F/R SOL
4 2 A05 (SWP-14)
V08 (DT-2) 7
8 8
A07
A53 (SWP-16) 1
BACKUP
1 3 TRAVEL
ALARM SOL J06 (J-20) 3 4 5 6 7
NEUTRAL 2
(PINK)
V06 (DT-2)
3 5 10
J04 (J-20)
(GREEN)
A65
A02
4
(X-4)
A64
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-665
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
*Standard notes
*When fuse No.20 is not blown
*When bulbs are fitted correctly and fully functional
Correct poor
Start
ground
No
No
Defective
connector or
Yes Is voltage between
disconnection in
G105 Pin 3 &
wiring between
chassis normal?
G105 Pin 3 &
G4 Pin 3
No
No
Defective
connector or
Yes Is voltage between
disconnection in
J07 Pin 17 &
wiring between
chassis normal?
J07 Pin 17 &
G105 Pin 5
No
No
Defective
connector or
disconnection in
wiring between
J07 Pin 15 &
FB1 Pin 20
20-666 PW160-7H
HIGH BEAM
INDICATOR
1 2
G103
PW160-7H
R10
ROAD LIGHTS MAIN BEAMS
J09 + 1 2 3 4 30 56 56B 56A
(J-20) G105
3 8 (Pink) OFF DIPPED BEAM
1 2 3 5 6
POSITION MAIN BEAM
DIPPED FLASH
T05 1 2 3 5 6
5 1 2 3 4
TESTING AND ADJUSTING
2 3 4 5
G4
D01 3 4 8 9 12 13 14 15 16 17 J07 6 9 10 11 9 10 11 12
Circuit Diagram for Driving Lights
(SWP-8) (J-20)
G02
(DT-12)
G05
(DT-12)
(Black)
3
7
8
3 13 14
A99
(SWP-8)
A07
(SWP-16)
J03
(J-20)
(Green) 1 2
G51
FB1 ENGINE ROOM LAMP
1
20A
13 A86
G8
1
(DT-4)
20A G12
20 2
(DT-6)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91 A84
3
(DT-2) (X-4) G10
1 2 3 1
RIGHT
MAIN BEAM LICENCE PLATE LIGHT
2 1 2 2
ARM DIPPED BEAM
G7
MARKER
(DT-4)
LAMPS G13
(DT-6) 3
DIPPED BEAM LH REAR SIDE LIGHT
1 2
MAIN BEAM
2
LEFT
3
SIDE LIGHT A65
4 DRIVING LIGHTS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-667
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
*Standard notes
*When fuse No.20 is not blown
*When bulbs are fitted correctly and fully functional
Correct poor
Start
ground
No
No
Defective
connector or
Yes Is voltage between
disconnection in
J07 Pin 16 &
wiring between
chassis normal?
J07 Pin 16 &
G4 Pin 2
No
No
Defective
connector or
disconnection in
wiring between
J07 Pin 15 &
FB1 Pin 20
20-668 PW160-7H
HIGH BEAM
INDICATOR
1 2
G103
PW160-7H
R10
ROAD LIGHTS MAIN BEAMS
J09 + 1 2 3 4 30 56 56B 56A
(J-20) G105
3 8 (Pink) OFF DIPPED BEAM
1 2 3 5 6
POSITION MAIN BEAM
DIPPED FLASH
T05 1 2 3 5 6
5 1 2 3 4
TESTING AND ADJUSTING
2 3 4 5
G4
D01 3 4 8 9 12 13 14 15 16 17 J07 6 9 10 11 9 10 11 12
Circuit Diagram for Driving Lights
(SWP-8) (J-20)
G02
(DT-12)
G05
(DT-12)
(Black)
3
7
8
3 13 14
A99
(SWP-8)
A07
(SWP-16)
J03
(J-20)
(Green) 1 2
G51
FB1 ENGINE ROOM LAMP
1
20A
13 A86
G8
1
(DT-4)
20A G12
20 2
(DT-6)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91 A84
3
(DT-2) (X-4) G10
1 2 3 1
RIGHT
MAIN BEAM LICENCE PLATE LIGHT
2 1 2 2
ARM DIPPED BEAM
G7
MARKER
(DT-4)
LAMPS G13
(DT-6) 3
DIPPED BEAM LH REAR SIDE LIGHT
1 2
MAIN BEAM
2
LEFT
3
SIDE LIGHT A65
4 DRIVING LIGHTS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-669
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Correct poor
ground
No
No No
Defective connector or
disconnection in wiring Yes Is voltage between
between 12 Pin 2 & G4 Pin 4 &
G4 Pin 4 chassis normal?
2
No
No
Yes Defective connector
Is voltage between or disconnection in
G105 Pin 3 & wiring between
chassis normal? G4 Pin 3 &
G105 Pin 3
No
Yes
Is voltage between Replace damaged
G105 Pin 5 & road lights switch
chassis normal? G105
No
Defective connector
Yes
Is voltage between or disconnection in
J07 Pin 17 & wiring between
chassis normal? G105 Pin 5 &
J07 Pin 17
No
Yes
Is voltage between Replace damaged
J07 Pin 15 & splice head J07
chassis normal?
No
Defective connector
or disconnection in
wiring between
J07 Pin 15 & FB1
Pin 20
20-670 PW160-7H
HIGH BEAM
INDICATOR
1 2
G103
PW160-7H
R10
ROAD LIGHTS MAIN BEAMS
J09 + 1 2 3 4 30 56 56B 56A
(J-20) G105
3 8 (Pink) OFF DIPPED BEAM
1 2 3 5 6
POSITION MAIN BEAM
DIPPED FLASH
T05 1 2 3 5 6
5 1 2 3 4
TESTING AND ADJUSTING
2 3 4 5
G4
D01 3 4 8 9 12 13 14 15 16 17 J07 6 9 10 11 9 10 11 12
Circuit Diagram for Driving Lights
(SWP-8) (J-20)
G02
(DT-12)
G05
(DT-12)
(Black)
3
7
8
3 13 14
A99
(SWP-8)
A07
(SWP-16)
J03
(J-20)
(Green) 1 2
G51
FB1 ENGINE ROOM LAMP
1
20A
13 A86
G8
1
(DT-4)
20A G12
20 2
(DT-6)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91 A84
3
(DT-2) (X-4) G10
1 2 3 1
RIGHT
MAIN BEAM LICENCE PLATE LIGHT
2 1 2 2
ARM DIPPED BEAM
G7
MARKER
(DT-4)
LAMPS G13
(DT-6) 3
DIPPED BEAM LH REAR SIDE LIGHT
1 2
MAIN BEAM
2
LEFT
3
SIDE LIGHT A65
4 DRIVING LIGHTS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-671
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Correct poor
Start ground
No
Defective
connector or Yes Is voltage between
disconnection in 1
J07 Pin 14 &
wiring between
chassis normal?
G12 Pin 4 &
J07 Pin 14
No
Correct poor
ground
1 No
No
No
Correct poor
ground
1 No
Does G51
No Is voltage between Yes have good Yes
Does engine room connection to Replace damaged
G51 Pin 1 &
lamp work? ground when lamp unit
Correct poor chassis normal?
switched on?
ground Yes
No
No
Defective
Yes Does G10 Pin 1 have Yes Is voltage between No
Replace damaged connector or
good connection to G10 Pin 2 & Does license plate Yes disconnection in
lamp unit Is voltage between
ground chassis normal? light work? wiring between
J07 Pin 14 &
chassis normal? G51 Pin 1 &
No Yes J07 Pin 14
No
Defective
connector or Yes Is voltage between
disconnection in
J07 Pin 14 &
wiring between
chassis normal? 1
G10 Pin 2 &
J07 Pin 14
No
1 A
20-672 PW160-7H
HIGH BEAM
INDICATOR
1 2
G103
PW160-7H
R10
ROAD LIGHTS MAIN BEAMS
J09 + 1 2 3 4 30 56 56B 56A
(J-20) G105
3 8 (Pink) OFF DIPPED BEAM
1 2 3 5 6
POSITION MAIN BEAM
DIPPED FLASH
T05 1 2 3 5 6
5 1 2 3 4
TESTING AND ADJUSTING
2 3 4 5
G4
D01 3 4 8 9 12 13 14 15 16 17 J07 6 9 10 11 9 10 11 12
Circuit Diagram for Driving Lights
(SWP-8) (J-20)
G02
(DT-12)
G05
(DT-12)
(Black)
3
7
8
3 13 14
A99
(SWP-8)
A07
(SWP-16)
J03
(J-20)
(Green) 1 2
G51
FB1 ENGINE ROOM LAMP
1
20A
13 A86
G8
1
(DT-4)
20A G12
20 2
(DT-6)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91 A84
3
(DT-2) (X-4) G10
1 2 3 1
RIGHT
MAIN BEAM LICENCE PLATE LIGHT
2 1 2 2
ARM DIPPED BEAM
G7
MARKER
(DT-4)
LAMPS G13
(DT-6) 3
DIPPED BEAM LH REAR SIDE LIGHT
1 2
MAIN BEAM
2
LEFT
3
SIDE LIGHT A65
4 DRIVING LIGHTS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-673
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
A
Correct poor
ground
No
Defective
Yes Yes Is voltage between No connector or
Replace damaged Does lamp unit have Does right arm
A91 Pin 1 & Yes disconnection in
lamp unit good body ground? Is voltage between
chassis normal? marker light work? wiring between
J07 Pin 14 &
chassis normal? A91 Pin 2 &
No J07 Pin 14
No
Defective
connector or Yes Is voltage between
disconnection in
J07 Pin 14 &
wiring between
chassis normal? 1
A91 Pin 1 &
J07 Pin 14
No
No
Defective
connector or
Yes disconnection in
Is voltage between
G105 Pin 1 & wiring between
chassis normal? J07 Pin 12 &
G105 Pin 1
No
No
Defective
connector or
Is voltage between Yes
disconnection in
J07 Pin 17 & wiring between CN-
chassis normal? J07 Pin 17 &
G105 Pin 5
No
No
Defective
connector or
disconnection in
wiring between
J07 Pin 15 &
FB1 Pin 20
20-674 PW160-7H
HIGH BEAM
INDICATOR
1 2
G103
PW160-7H
R10
ROAD LIGHTS MAIN BEAMS
J09 + 1 2 3 4 30 56 56B 56A
(J-20) G105
3 8 (Pink) OFF DIPPED BEAM
1 2 3 5 6
POSITION MAIN BEAM
DIPPED FLASH
T05 1 2 3 5 6
5 1 2 3 4
TESTING AND ADJUSTING
2 3 4 5
G4
D01 3 4 8 9 12 13 14 15 16 17 J07 6 9 10 11 9 10 11 12
Circuit Diagram for Driving Lights
(SWP-8) (J-20)
G02
(DT-12)
G05
(DT-12)
(Black)
3
7
8
3 13 14
A99
(SWP-8)
A07
(SWP-16)
J03
(J-20)
(Green) 1 2
G51
FB1 ENGINE ROOM LAMP
1
20A
13 A86
G8
1
(DT-4)
20A G12
20 2
(DT-6)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91 A84
3
(DT-2) (X-4) G10
1 2 3 1
RIGHT
MAIN BEAM LICENCE PLATE LIGHT
2 1 2 2
ARM DIPPED BEAM
G7
MARKER
(DT-4)
LAMPS G13
(DT-6) 3
DIPPED BEAM LH REAR SIDE LIGHT
1 2
MAIN BEAM
2
LEFT
3
SIDE LIGHT A65
4 DRIVING LIGHTS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-675
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
1 2
Replace Replace
Is voltage between CN- Yes Is voltage between
damaged Yes damaged
J08 Pin 13 & Chassis G3 Pin 5 &
splice head indicator stalk
normal? Chassis normal?
J08 switch
No
No Defective connector
Defective
connector or Is voltage between Yes or disconnection in
Is voltage between Yes J08 Pin 8 & wiring between
disconnection in
G3 Pin 2 & Chassis Chassis normal? J08 Pin 8 & G3
wiring between
normal? Pin 5
J08 Pin 13 &
G3 Pin 2
No No
2 Is voltage between Yes Replace damaged slice
J08 Pin 5 &
head J08
Chassis normal?
No
Defective connector
Is voltage between Yes or disconnection in
F01 Pin 4 & wiring between
Chassis normal? G3 Pin 5 & F01
Pin 4
No
Is voltage between Yes Replace damaged
F01 Pin 3 &
flasher unit
Chassis normal?
No
Defective connector
or disconnection in Yes Is voltage between
wiring between J08 Pin 17 &
F01 Pin 3 & J08 Chassis normal?
Pin 17
No
No
Defective connector
or disconnection in
wiring between
D04 Pin 2 & FB1
Pin 9
20-676 PW160-7H
Hazard Switch R50
F01 (KES1-4) INDICATOR STALK
1 2 3
Warning
PW160-7H
FLASHER UNIT 45A L R
5 3 2
G3
1 2 1 2
G101 G102
TESTING AND ADJUSTING
G02 4 5 6
FB1 (DT-12)
19
20A 1 2 5 6 8
J05 (J-20) G05
(Pink) (DT-12)
16 17 18 19 20
15A
D04 (KES1)
1
Circuit Diagram for Indicators & Hazard
D03 (KES1-2)
1
A07
2 (SWP-16) 11 10
G12 G8
(DT-6) (DT-4)
6 2
A01 A02
(X-4) (X-4) 5 1
3 4
FRONT REAR
G13 G7
INDICATOR INDICATOR
(DT-6) (DT-4)
LIGHTS LIGHTS
5 1
6 2
A64
A65
J08 (J-20) 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20
(Black)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-677
INDICATORS & HAZARD WARNING
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
1 2
Replace
Yes Is voltage between
Replace damaged
Is voltage between G3 Pin 5 &
Yes indicator stalk
damaged Chassis normal?
J08 Pin 3 & Chassis switch
splice head No
normal?
J08 Defective connector
Is voltage between Yes or disconnection in
No J08 Pin 8 & wiring between
Defective
Chassis normal? J08 Pin 8 & G3
connector or Pin 5
Is voltage between Yes
disconnection in
G3 Pin 3 & Chassis
wiring between No
normal?
J08 Pin 3 & Is voltage between Yes
No Replace damaged slice
G3 Pin 3 J08 Pin 5 &
head J08
Chassis normal?
2
No
Defective connector
Is voltage between Yes or disconnection in
F01 Pin 4 & wiring between
Chassis normal? G3 Pin 5 & F01
Pin 4
No
Is voltage between Yes Replace damaged
F01 Pin 3 &
flasher unit
Chassis normal?
No
Defective connector
or disconnection in Yes Is voltage between
wiring between J08 Pin 17 &
F01 Pin 3 & J08 Chassis normal?
Pin 17
No
No
Defective connector
or disconnection in
wiring between
D04 Pin 2 & FB1
Pin 9
20-678 PW160-7H
Hazard Switch R50
F01 (KES1-4) INDICATOR STALK
Warning
1 2 3
PW160-7H
FLASHER UNIT 45A L R
5 3 2
G3
1 2 1 2
G101 G102
TESTING AND ADJUSTING
G02 4 5 6
FB1 (DT-12)
19
20A 1 2 5 6 8
J05 (J-20) G05
(Pink) (DT-12)
16 17 18 19 20
15A
D04 (KES1)
1
Circuit Diagram for Indicators & Hazard
D03 (KES1-2)
1
A07
2 (SWP-16) 11 10
G12 G8
(DT-6) (DT-4)
6 2
A01 A02
(X-4) (X-4) 5 1
3 4
FRONT REAR
G13 G7
INDICATOR INDICATOR
(DT-6) (DT-4)
LIGHTS LIGHTS
5 1
6 2
A64
A65
J08 (J-20) 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20
(Black)
20-679
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
No
Is voltage
Yes between
Replace damaged
J08 Pin 11 &
splice head J08 Yes
Chassis
normal?
No
Defective
Is voltage
connector or
Yes between
disconnection in
R50 Pin 4 &
wiring between
Chassis
R50 Pin 4 &
normal?
J08 Pin 11
No
Defective
Is voltage Is voltage
connector or
Yes between No between
disconnection in
J08 Pin 7 & R50 Pin 3 &
wiring between
Chassis Chassis
J08 Pin 7 &
normal? normal?
R50 Pin 3
Correct poor
No Yes ground
B A No
Is voltage Does G13
Correct poor Does front left No between Yes Pin 6 have Yes Replace
ground indicator G13 Pin 5 & good damaged
work? Chassis connection to lamp unit
No normal? ground?
Yes
Does G7 Is voltage No
Replace Yes Pin 2 have Yes between CN- No Does rear left
damaged good G7 Pin 1 & indicator Is voltage Defective connector
lamp unit connection to Chassis work? between or disconnection in
Yes
ground? normal? J08 Pin 4 & wiring between
Chassis G13 Pin 5 & J08
No normal? Pin 4
Defective connector Is voltage No
or disconnection in Yes between
wiring between J08 Pin 4 &
G7 Pin 1 & J08 Chassis
Pin 4 normal?
No
Is voltage
between Yes Replace damaged splice
J08 Pin 1 & head J08
Chassis
normal?
No
Is voltage
between Yes
R50 Pin 1 & A
Chassis
normal?
No
20-680 PW160-7H
Hazard Switch R50
F01 (KES1-4) INDICATOR STALK
Warning
PW160-7H
1 2 3
FLASHER UNIT 45A L R
5 3 2
G3
1 2 1 2
TESTING AND ADJUSTING
G101 G102
G02 4 5 6
FB1 (DT-12)
19
20A 1 2 5 6 8
J05 (J-20) G05
(Pink) (DT-12)
16 17 18 19 20
15A
D04 (KES1)
1
Circuit Diagram for Indicators & Hazard
D03 (KES1-2)
1
A07
2 (SWP-16) 11 10
G12 G8
(DT-6) (DT-4)
6 2
A01 A02
(X-4) (X-4) 5 1
3 4
FRONT REAR
G13 G7
INDICATOR INDICATOR
(DT-6) (DT-4)
LIGHTS LIGHTS
5 1
6 2
A64
A65
J08 (J-20) 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20
(Black)
20-681
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Yes
Is voltage
between R50 Yes Replace damaged
Pin 5 & Chassis relay R50
normal?
No
Defective
Is voltage connector or
between J08 Yes disconnection in
Pin 19 & Chassis wiring between
normal? J08 Pin 19 &
R50 Pin 5
C No
Is voltage
between J08 Yes Replace damaged
Pin 20 & Chassis splice head J08
normal?
No
Defective
Voltage between
connector or
hazard switch Pin No
disconnection in
G110 & Chassis
wiring between
normal
Pin G110 &
Yes J08 Pin 20
Is voltage between
hazard switch Pin Yes Replace
G111 & Chassis damaged hazard
normal switch
No
Defective
connector or
disconnection in
wiring between
Pin G111 &
FB1 Pin 19
20-682 PW160-7H
Hazard Switch R50
F01 (KES1-4) INDICATOR STALK
Warning
PW160-7H
1 2 3
FLASHER UNIT 45A L R
5 3 2
G3
1 2 1 2
TESTING AND ADJUSTING
G101 G102
G02 4 5 6
FB1 (DT-12)
19
20A 1 2 5 6 8
J05 (J-20) G05
(Pink) (DT-12)
16 17 18 19 20
15A
D04 (KES1)
D03 (KES1-2)
1
A07
2 (SWP-16) 11 10
G12 G8
(DT-6) (DT-4)
6 2
A01 A02
(X-4) (X-4) 5 1
3 4
FRONT REAR
G13 G7
INDICATOR INDICATOR
(DT-6) (DT-4)
LIGHTS LIGHTS
5 1
6 2
A64
A65
J08 (J-20) 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20
(Black)
20-683
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Is voltage
Yes Replace
between J08
damaged splice
Pin 5 & Chassis
head J08
normal?
No
Defective
Is voltage connector or
between F01 Yes disconnection in
Pin 4 & Chassis wiring between
normal? F01 Pin 4 &
J08 Pin 5
No
Is voltage
Yes Replace
between F01
damaged flasher
Pin 3 & Chassis
unit F01
normal?
No
Defective
Is voltage connector or
between J08 Yes disconnection in
Pin 17 & Chassis wiring between
normal? J08 Pin 17 &
F01 Pin 3
No
Is voltage
between J08 Yes Replace damaged
Pin 16 & Chassis splice head J08
normal?
No
Defective
Is voltage connector or
between D03 Yes disconnection in
Pin 1 & Chassis wiring between
normal? D03 Pin 1 &
J08 Pin 16
No
Is voltage
Yes Replace
between D03
damaged diode
Pin 2 & Chassis
block D03
normal?
No
Defective
Is voltage connector or
between J08 Yes disconnection in
Pin 18 & Chassis wiring between
normal? J08 Pin 18 &
D03 Pin 2
No
20-684 PW160-7H
Hazard Switch R50
F01 (KES1-4) INDICATOR STALK
Warning
PW160-7H
1 2 3
FLASHER UNIT 45A L R
5 3 2
G3
1 2 1 2
TESTING AND ADJUSTING
G101 G102
G02 4 5 6
FB1 (DT-12)
19
20A 1 2 5 6 8
J05 (J-20) G05
(Pink) (DT-12)
16 17 18 19 20
15A
D04 (KES1)
1
Circuit Diagram for Indicators & Hazard
D03 (KES1-2)
1
A07
2 (SWP-16) 11 10
G12 G8
(DT-6) (DT-4)
6 2
A01 A02
(X-4) (X-4) 5 1
3 4
FRONT REAR
G13 G7
INDICATOR INDICATOR
(DT-6) (DT-4)
LIGHTS LIGHTS
5 1
6 2
A64
A65
J08 (J-20) 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20
(Black)
20-685
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Start
Yes
Defective connector or
Yes
disconnection in wiring
between C01 Pin 16 &
A91 Pin A
Defective connector or
Yes
disconnection in wiring
between C02 Pin 3 &
A91 Pin B
20-686 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Main Controller
C01 (DRC-24)
10 GND (Sig)
C02 (DRC-40)
3 Brake Lock Proximity
28 Swing Proximity
A06 A99
(SWP-16) (SWP-8)
3 13 8
A90 A91
(DT-3) 2 3 (DT-3)
1 C B A
PW160-7H 20-687
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Start
Yes
Defective connector or
Yes
disconnection in wiring
between C01 Pin 16 &
A90 Pin 1
Defective connector or
Yes
disconnection in wiring
between C02 Pin 28 &
A90 Pin 2
20-688 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Main Controller
C01 (DRC-24)
10 GND (Sig)
C02 (DRC-40)
3 Brake Lock Proximity
28 Swing Proximity
A06 A99
(SWP-16) (SWP-8)
3 13 8
A90 A91
(DT-3) 2 3 (DT-3)
1 C B A
PW160-7H 20-689
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-690 PW160-7H
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)
PW160-7H 20-701
TESTING AND ADJUSTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
Pressure
relief valve
Travel PPC valve
27
Travel
2nd 2P
HCU Boom Travel creep SOL.
PPC PPC
8
5 8
21 22 18 17
25
24
23
33
Pump pressure
Pump
Gear 1
Pump
7
6
Travel Forward / Reverse SOL.
5
11
10
Stabilizer / Boom up SOL.
9
14
13
Stabilizer / Boom down SOL.
12
30
20-702 PW160-7H
TESTING AND ADJUSTING 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.
Control Valve
Service
21 2 valve 22
See next pages detail A, B
Service
19 1 valve 20
17 2P Boom 18
Bucket
15 valve 16
Dig Dump
Adjust cylinder
14 Stabilizer 11 Sa
Down Up
Sa
O/Load caution
34
13 10
Down Up
1
3 4
Left Right
2
Travel
reverse / forward 6 See next pages detail C
Reverse Forward
Dig Dump
Main
Unload 23
relief
valve
valve
PW160-7H 20-703
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Detail A Detail B
Up
Down
Down
Up
Detail C
29
27 33
B
A
Travel
motor
Powershift
Transmission
20-704 PW160-7H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Detail D
Accumulators
31
To Service
32 brakes
30
Detail E
33
LH Steer
LH Steer
RH Steer
RH Steer
31
Priority
valve 25
Orbitrol valve
PW160-7H 20-705
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
20-706 PW160-7H
TESTING AND ADJUSTING H-1
H-1 All work equipment lacks power, or travel and swing speeds are slow
Failure information All the work equipment lacks power, or their travel and swing speeds are slow.
Relative information Set the working mode at A mode for troubleshooting.
PW160-7H 20-707
TESTING AND ADJUSTING H-2
Failure information The engine speed sharply drops or the engine stalls.
Relative information Relative Information
malfunctioning of the main relief valve or its internal failure is suspected. In that
case, check the valve itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
2
functioning of PC valve PC valve output pressure Arm digging relief Approx. 3/5
If the oil pressure does not return to normal condition even after the adjustment,
malfunctioning of the PC valve or its internal failure is suspected. In that case,
check the valve itself.
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure ratio
Oil pressure to be mea- Travel without load
sured Travel
(travel pedal held at half
NEUTRAL
Improper adjustment or mal- stroke)
3
functioning of LS valve Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approx. 3/5
If the oil pressure does not return to normal condition even after the adjustment,
malfunctioning 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.
20-708 PW160-7H
TESTING AND ADJUSTING H-3, H-4
Failure information No work equipment or travel and swing functions can be set in motion.
Relative information Set the working mode at A mode for the troubleshooting.
It is presumed that the pump shaft does not rotate due to some internal failure of
4 Damper defective
the damper. Check the damper itself.
Failure information An abnormal noise is heard from around the hydraulic pump.
Relative information
2 Quality of hydraulic oil bad Air may have 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.
PW160-7H 20-709
TESTING AND ADJUSTING H-5, H-6
Failure information The fine control mode poorly functions or its response is slow.
Relative information Set the working mode at A mode for the troubleshooting.
Hi F/R 0{0}
Presumed cause and stan-
Orifice in LS circuit
2 The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
clogged
Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure ratio
20-710 PW160-7H
TESTING AND ADJUSTING H-7
PW160-7H 20-711
TESTING AND ADJUSTING H-8
20-712 PW160-7H
TESTING AND ADJUSTING H-9, H-10
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.
PW160-7H 20-713
TESTING AND ADJUSTING H-11
Failure information (1) Hydraulic drift of the boom is a bit too fast.
Relative information Set the working mode at A mode for the troubleshooting.
1 Boom cylinder defective Boom control lever Amount oil leakage from cylinder
condition
Failure information (2) Hydraulic drift of the arm is a bit too fast.
Relative information Set the working mode at A mode for the troubleshooting.
Failure information (3) Hydraulic drift of the bucket is a bit too fast.
Relative information Set the working mode at A mode for the troubleshooting.
20-714 PW160-7H
TESTING AND ADJUSTING H-12, H-13, H-14
Lo NEUTRAL
Presumed cause and stan-
{35.7 38.8kg/cm2}
Hi Operation 0{0}
Malfunctioning of control valve
The regeneration valve in the control valve is presumed to malfunction.
2 (regeneration valve) - with
Check the valve itself.
boom and arm only
The safety and suction valves of the control valve are presumed to
malfunction. Check those valves themselves directly.
Malfunctioning of control For the arm and boom, whether they are defective or not may well be de-
3
valves (safety & suction valve) termined by changing them for other safety and suction valves. (Do not at-
tempt to change them for the safety and suction valves for the boom
LOWER and the lock valve, because each set pressure differs)
Malfunctioning of control valve
The pressure compensation valve of the control valve is presumed to mal-
4 (pressure compensation
function. Check the valve itself directly.
valve)
Failure information Other work equipment moves when relieving the single circuit of specific work equipment.
Relative information Set the working mode at A mode for the troubleshooting.
Control valve (pressure com- The seal for pressure compression valve in the control valve is suspected to
1
pensation valve) seal defective be defective. Check the seal itself.
Failure information The one-touch power max. switch does not operate.
Relative information Set the working mode at A mode for the troubleshooting.
PW160-7H 20-715
TESTING AND ADJUSTING H-15, H-16, H-17
H-15 In compound operation, work equipment with larger load moves slowly
Failure information In a compound operation, work equipment with larger load tends to move slowly.
Relative information
The pressure compensation valve for the work equipment with larger load is
presumed to malfunction. Check the valve itself.
Combination of compound operation Work equipment with larger load
Malfunctioning of pressure Boom RAISE + arm DIGGING Boom RAISE
1 compensation valve for work
Boom RAISE + arm DUMPING Arm DUMPING
equipment with larger load
Boom RAISE + bucket DIGGING Boom RAISE
Arm DUMPING + bucket DIGGING Arm DUMPING
Boom LOWER + arm DUMPING Arm DUMPING
Failure information In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.
Failure information In a compound operation of swing + travel, the travel speed drops sharply.
Relative information If the travel speed is slow in the single operation of travel, carry out the H-19 check first.
Malfunctioning of travel and The travel and swing control valves are presumed to malfunction. Check
1
swing control valves. both of them directly.
20-716 PW160-7H
TESTING AND ADJUSTING H-18
PW160-7H 20-717
TESTING AND ADJUSTING H-19
Failure information Travel speed does not shift, or it is either too fast or slow.
Relative information Set the working mode at A mode for the troubleshooting.
20-718 PW160-7H
TESTING AND ADJUSTING H-20
Failure information (1) The machine swings neither to the right nor to the left.
Relative information Set the working mode at A mode for the troubleshooting.
Failure information (2) The machine does not swing in one direction.
Relative information Set the working mode at A mode for the troubleshooting.
PW160-7H 20-719
TESTING AND ADJUSTING H-21
Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction. Check
1 (parking brake) it directly.
Failure information (2) Swing acceleration is poor only on one side, or swing speed is slow.
Relative information Set the working mode at A mode for the troubleshooting.
20-720 PW160-7H
TESTING AND ADJUSTING H-22
Failure information (1) The work equipment overruns excessively when stopping swing.
Relative information Set the working mode at A mode for the troubleshooting.
Failure information (2) Swing acceleration is poor only on one side, or swing speed is slow.
Relative information Set the working mode at A mode for the troubleshooting.
The PPC slow return valve is suspected of clogging. Check the valve itself.
Swing PPC slow return valve
2
clogged Whether the valve is clogged or not may well be determined by swapping
the right and left valves and watching the result.
Malfunctioning of swing control The spool in the swing control valve is resumed to malfunction. Check the
3
valve (spool) valve itself.
The seal in the suction valve of the swing motor is suspected of defect.
Check the seal itself.
Swing motor (suction valve)
4
seal defective
Whether the seal is defective or not may well be determined by swapping
the right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect.
Check the seal itself.
Swing motor (check valve)
5
seal defective
Whether the seal is defective or not may well be determined by swapping
the right and left check valves and watching the result.
PW160-7H 20-721
TESTING AND ADJUSTING H-23, H-24,
Failure information There is a big shock caused when stopping a swing motion.
Relative information Set the working mode at A mode for the troubleshooting.
Failure information There is a loud abnormal noise caused when stopping a swing motion.
Relative information Set the working mode at A mode for the troubleshooting.
Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction. Check the
2
(safety valve) valve itself.
The seal in suction valve of the swing motor is suspected of defect. Check
the seal itself.
Malfunction of swing motor
3
(suction valve)
Whether the seal is defective or not may well be determined by swapping
the right and left valves and watching the result.
The swing machinery is suspected of an internal failure. Check the inside of
the machinery itself.
4 Swing machinery defective
A failure inside the swing machinery may well be determined by monitoring
abnormal noise, abnormal heat generated or metal dust or chips contained
in the drained oil.
20-722 PW160-7H
TESTING AND ADJUSTING H-25
Failure information (1) Natural drift of the swing is too big (when the parking brake is activated).
When the emergency swing release switch is in the OFF position (this is a normal condition), the
Relative information
swing and parking brake is activated and the swing is fixed with a disc brake.
Swing motor (parking brake The parking portion of the swing motor is suspected of malfunctioning and
2
portion) malfunctioned interior failure. Check that portion directly.
Failure information (2) Natural drift of the swing is too big (when the parking brake is released).
When the emergency swing release switch is in the ON condition (this is an emergent condition),
Relative information
the swing and parking brake is released and the swing is retained only hydraulically.
Swing control valve (spool) The seal in the spool of the swing control valve is suspected of defect.
1
Presumed cause and stan-
PW160-7H 20-723
TESTING AND ADJUSTING H-26
20-724 PW160-7H
30 DISASSEMBLY AND ASSEMBLY
PW160-7H 30-1
DISASSEMBLY AND ASSEMBLY
30-2 PW160-7H
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL
Special tools that are deemed necessary for Except where otherwise instructed, install parts
List of the special tools contains the following Instructions and precautions for installing parts
removal or installation of parts are listed. is the reverse order of removal.
that they are locally made parts and as such not Various special tools are illustrated for the conve-
interchangeable with those made by Komatsu in nience of local manufacture.
Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
PW160-7H 30-3
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS ASSEMBLY
Special tools which are deemed necessary for Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
List of the special tools contains the following Various symbols used in the ASSEMBLY Section
tion. well as the amount of oil or water to be added.
30-4 PW160-7H
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS
12
SPECIAL TOOLS
SKETCHES
Note: Komatsu cannot accept any responsibility for
special
tools manufactured according to these sketches.
F2 Push Tool
PW160-7H 30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS
12
LIST OF TOOLS
30-6 PW160-7H
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
pull on the wires. In-order to prevent exces- Fit the following blind plugs into the piping after
sive force to the wiring, hold onto the con- disconnecting it during disassembly operations.
nectors when disconnecting them.
A. Hoses and tubes using sleeve nuts
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
PW160-7H 30-7
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
12
Tighten all bolts and nuts (sleeve nuts) to the If the engine coolant water has been
2. Precautions when carrying out installation work 3. Precautions when completing the operations
30-8 PW160-7H
DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR ASSEMBLY
12
E11 E10 4
INSTALLATION OF GOVERNOR MOTOR ASSEM-
BLY
PW160-7H 30-9
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF Assembly
12
REMOVAL AND INSTALLATION OF STARTING MOTOR
ASSEMBLY ASSEMBLY
REMOVAL INSTALLATION
Disconnect the cable from the negative (-) Install in reverse order of removal.
terminal of the battery.
3 1
4 5
30-10 PW160-7H
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF Assembly
12
A 795-799-1390 Puller n 1
*Distinction between new and existing part.
Disconnect the fuel drain manifold. (A)
Remove the injection pump supply. (B)
Remove the high-pressure lines. (C)
Disconnect the electrical wire to the fuel
shutoff valve. (D)
A
4
3
B C
2
PW160-7H 30-11
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
6. Pull the fuel injection pump drive gear loose from 2. Install a new gasket (1).
the pump driveshaft.
30-12 PW160-7H
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
4. Use your hands to tighten the 3 mounting nuts. 6. If installing the original pump, rotate the pump to
Note:Fuel pumps on engines designed to meet align the scribe marks.
Tier 2 industrial emissions levels have
straight holes (not kidney slots) and do not
use a timing key. Torque value: 24Nm
4 3
PW160-7H 30-13
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
9. The special washer is wired to the pump and 12. Tighten the bracket capscrews to the cylinder
must be installed under the lockscrew. block (5).
Tighten the tail support bracket capscrew to the
fuel pump (6).
Torque value: 13Nm
30-14 PW160-7H
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
16. Bleed air from the fuel system and reinstall fan
guard as initial machine condition.
PW160-7H 30-15
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
4. Remove air conditioner compressor belt.[*1] 10. Remove 4 mounting bolts (10) and crank pulley
(11). [*2]
5. Disconnect connector E06 (16) and remove air
Remove the crank pulley with its timing mark
conditioner compressor (5) and bracket and
(a) matched to pointer (12) or make match
Do not separate the air conditioner pip-
move them toward the counterweight.
marks on the crank pulley and front cover so
that you can position the crank pulley cor-
ing. rectly when installing it.
2 4
1 6 3 16 5
30-16 PW160-7H
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
12
12. Remove engine front seal (15) from front cover Installation
(14). [*4]
[*1]
Install the air conditioner compressor belt.
For details, see TESTING AND ADJUSTING,
Inspection and adjustment of air compressor
belt tension.
[*2]
Install the belt to the position from which it
was removed.
Install the crank pulley temporarily and fan
belt, and then tighten the mounting bolts to
the specified torque.
Mounting bolt:
125 5 Nm {12.75 0.51 kgm}
[*3]
Apply ThreeBond 1207D or equivalent in the
form of a continuous string 1 2 mm thick to
the fitting face of the front cover.
Install the gasket to the front cover, and then
install them to the engine.
Tighten the mounting bolts in the following
order.
Mounting bolt:
24 4 Nm {2.45 0.41 kgm}
[*4]
PW160-7H 30-17
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
Dimension b: 21 0.38 mm
b will be as follows.
30-18 PW160-7H
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
12
Removal
4. Remove engine rear seal (3). [*2]
1. Remove the hydraulic pump assembly. For Break the seal carrier with a screwdriver, etc.
details, see Removal and installation of hydraulic to remove the seal.
pump assembly. Take care not to damage the other parts.
The engine rear seal may be removed
2. Remove damper assembly (1). according to the following procedure.
1) Make a hole about 3 mm in diameter on the
seal with a drill.
PW160-7H 30-19
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
Installation 2. Install pilot [2] fitted with engine rear seal (3) in
the crankshaft.
[*1]
Tighten the mounting bolts in the following
numerical order.
Mounting bolt:
137 7 Nm {13.97 0.71 kgm}
Dimension a: 25.8 mm
that dimension "a" will be the following value.
[*2]
Install the engine rear seal according to the
following procedure.
30-20 PW160-7H
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
New/Remodel
Necessity
9. Remove the bracket mounting bolts of engine oil
Symbol
Sketch
Q'ty
Part No. Part name level gauge guide (5) and move the level gauge
guide.
REMOVAL 12. Remove bracket (9) and fuel filter as a unit. [*3]
Disconnect the cable from the negative () 13. Remove air intake connector (10) and ribbon
terminal of the battery. heater (11). [*4]
Cover the openings with adhesive tapes, etc.
1. Drain the coolant. to prevent foreign matter from entering the
engine.
1
14
2
13
3
12
35
PW160-7H 30-21
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
30-22 PW160-7H
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
Cover the nozzle holder assembly mounting 30. Remove push rods (31). [*13]
parts to prevent foreign matter from entering
the engine.
PW160-7H 30-23
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
Tube (17):
[*1]
Turbocharger side:
10.3 1.2 Nm {1.1 0.1 kgm}
Hose clamp: Cylinder block side:
1st time: 10.8 1 Nm {1.1 0.1 kgm} 35 5 Nm {3.6 0.5 kgm}
2nd time: 10.8 1 Nm {1.1 0.1 kgm}
[*2]
Tube (18):10 2 Nm {1.0 0.2 kgm}
Install the air conditioner compressor belt.
For details, see TESTING AND ADJUSTING,
Inspection and adjustment of air compressor
belt tension. Mounting nut: 24 4 Nm {2.4 0.4 kgm}
[*3] [*8]
Apply gasket sealant to the threads of the
Mounting nut: 24 4 Nm {2.4 0.4 kgm}
bolt (only 1 piece) on the head cover side
among the 3 fuel filter bracket mounting [*9]
bolts.
Tighten the mounting bolts in the following
numerical order.
[*4]
Apply gasket sealant to the threads of only
the 2 of the air intake connector mounting Mounting bolt:
bolts indicated by the arrows in the following 1st time : Tighten all the bolts to:
figure 43 6 Nm {4.38 0.61 kgm}.
2nd time: Tighten only bolts 1 4 to:
43 6 Nm {4.38 0.61 kgm}
[*5]
When connecting the exhaust pipe to under
the muffler, apply thermosetting sealant [*10]
(Firegum manufactured by Nihon Holts Co.,
Ltd. or equivalent) all round the pipe end. Clamp of hose (22):
8.8 0.5 Nm {0.9 0.05 kgm}
30-24 PW160-7H
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
12
[*12] [*13] [*14]
Install the rocker arm assembly and cylinder
Cylinder head bolt:
head assembly according to the following
1st time: Tighten all the bolts to:
procedure.
90 5 Nm {9.18 0.51 kgm} in the
Check that there is not foreign matter on the numerical order shown in the figure.
cylinder head mounting face and in the cylin- 2nd time: Tighten bolts 3, 6, 11, and 14
der. to:
1) Set cylinder head gasket (33) to the cylinder 120 5 Nm {12.24 0.51 kgm} in order.
2) Sling cylinder head assembly (32) and set it When not using tool A3, make marks on
to the cylinder block. the bolts and cylinder head, and then
tighten each bolt by the above angle.
Mounting bolt:
24 4 Nm {2.45 0.41 kgm}
PW160-7H 30-25
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
Bleeding air
30-26 PW160-7H
DISASSEMBLY AND ASSEMBLY COMBINATION COOLER
6
7
2
PW160-7H 30-27
DISASSEMBLY AND ASSEMBLY COMBINATION COOLER
8. Remove guards (9). 11. Remove two mounting bolts (11) and lift radiator
. assembly out.
9 9
11
10 10
30-28 PW160-7H
DISASSEMBLY AND ASSEMBLY COMBINATION COOLER
INSTALLATION
Centre of
fan
D
C
B
A
PW160-7H 30-29
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES
12
REMOVAL
1
Lower the work equipment to the ground for
safety and stop the engine. Disconnect the
cable from the negative terminal (- ) of the bat-
tery.
Attach an identification tag to each pipe. This will 4. Remove pin (2) and mounting bolt (3). Lift off the
avoid a possible mistake when reinstalling. hood and set it aside.
30-30 PW160-7H
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES
5. Remove radiator fan guards (5) and (6) by 10. Disconnect fuel inlet hose (13) and fuel outlet
removing bolts (4).
hose (14).
4
15
14
13
7. Disconnect E06 air conditioner wiring connector 12. Disconnect engine wiring connectors at the fol-
8. Displace air compressor assembly (11). (17): E05 (Engine cooling water temperature
16
10 11 9 8 19
20
18
17
12 7
PW160-7H 30-31
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES
13. Remove the combination cooler (21) (See 17. Remove cover (27) and bracket (28).
COMBINATION COOLER on page 20-27.).
18. Remove muffler guard (29) by removing bolts
14. Disconnect two radiator hoses (22) on the upper (30).
and lower sides.
29 30
27
28
21
22
(31): Pump delivery port hose
15. Disconnect engine starting motor wiring (23) and (32): Pump pressure input port hose
(33): Case drain port hose
(23): Engine starting motor terminal B (red)
connectors (24), (25) and (26).
(34): PPC basic pressure input port hose
(24): T13 (Engine starting motor terminal C)
(35): Load pressure input port hose
(25): E03 (Engine oil level sensor) (36): Pump suction port hose - Note orienta-
tion of hose clamp.
34 32 33 31
23
24
25
35
36
16. Disconnect engine ground (26).
26
30-32 PW160-7H
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES
20. Disconnect the pump wiring connectors at the Check that there is no wiring or piping still
(38): V21 (PC-EPC solenoid valve) 24. Lift out engine and hydraulic pump assembly
(39): V22 (LS-EPC solenoid valve) (43).
40
43
38
39
37
PW160-7H 30-33
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES
Air bleeding
Refer to the Air Bleeding of Various Part section
in the TESTING AND ADJUSTING chapter of
this manual.
30-34 PW160-7H
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR ASSEMBLY
12
Blanking Kit
Description Part Number Qty Where Used
Cap Plug 07376-70422 1
O-ring 02896-11012 1 Top Drain Hose
7
Cap Plug 07376-70210 1 Top Pilot Pressure
O-ring 02896-11008 1 Hose
Flange 07379-01260 2
O-ring 07000-13038 2 Front Main Travel
Bolt 01010-51245 8 Hoses
Washer 01643-51032 8
9
2 2
4
3
5
6
PW160-7H 30-35
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR ASSEMBLY
INSTALLATION
Air bleeding
again.
30-36 PW160-7H
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR ASSEMBLY
12
PW160-7H 30-37
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR ASSEMBLY
12
Counterbalance
Qmax adjustment
valve assembly
screw
30-38 PW160-7H
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR ASSEMBLY
1. Put the unit in a bench with a hole or place it on a 3. Before removing the port plate measure and
fixture for assembly. record dimension X of the Qmin adjustment
screw and dimension Y of the Qmax adjustment
screw.
X
Y
Qmin
screw
Qmax
screw
Fixing
bolt
PW160-7H 30-39
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR ASSEMBLY
Insert
Qmin
screw
New
o-ring
Port plate
Fixing screw
Control Sliding
lens surface
30-40 PW160-7H
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR ASSEMBLY
3. Assemble the port plate by locating the lens plate 5. Assemble the counterbalance valve assembly
onto the rotary group. using the six fixing bolts.
Secure the port plate by tightening the eight fix- Tightening torque - 205 Nm.
ing bolts.
Tightening torque - 310 Nm
Counterbalance
Port plate valve Fixing
bolt
Fixing
bolt
PW160-7H 30-41
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF
(3) :
2. Disconnect 5 hoses (3) (7).
Between swing motor and control valve
(4) :
(Port MA)
Between swing motor and control valve 8
(5) :
(Port MB)
(6) :
Suction hose (Port S)
Drain hose between swing motor and
(7) :
swivel joint (Port DB)
Drain hose between swing motor and
hydraulic tank (Port DB)
Installation
Bleeding air
3 again.
30-42 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEM-
ASSEMBLY BLY
SPECIAL TOOLS
3. No. 1 carrier assembly
New/Remodel
1) Remove No. 1 sun gear (5).
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 KBATZ080080 Wrench t 1 N
G 2 KBATZ030190 Adapter t 1 N
3 KBATZ060400 Stopper t 1 N
Disassembly
1. Draining oil
Loosen the drain plug and drain the oil from the
swing machinery case.
Swing machinery case: 4.5 l planetary gear (7) to float and remove
the planetary gear.
2 3
16
PW160-7H 30-43
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
7. Ring nut
5. No. 2 carrier assembly 1) Using punch [1], etc., straighten the bent
1) Remove No. 2 sun gear (17). parts (3 places) of ring nut (27) around the
pinion shaft spline.
6. Ring gear
30-44 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
4) Fix tool G2. Using power wrench (25-time 2) Using puller [3], separate housing (28) and
power) [2], turn tool G1 to loosen the ring pinion shaft assembly (29).
PW160-7H 30-45
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
30-46 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
4) Set front cover (31) to pinion shaft (29). 7) Using push tool [6], press fit pinion shaft
Bearing: Grease
(SHELL RETINAX HD-2 or equivalent) Mounting screw:
LOCTITE 243 or equivalent
Housing: Grease
(SHELL RETINAX HD-2 or equivalent)
PW160-7H 30-47
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
Ring nut:
reaches the shoulder of pinion shaft (29).
1100 1200 Nm {112.2 122.3 kgm}
30-48 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
4. Ring gear
1) Fit the O-ring to the housing. 2) Install No. 1 sun gear (5).
PW160-7H 30-49
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
Mounting bolt:
85 4.3 Nm {8.7 0.44 kgm}
2 3
16
30-50 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
Disassembly
3. Cover assembly
PW160-7H 30-51
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
4. Springs
5. Brake piston
Using tool D1, supply compressed air to port PB
6. Collar
30-52 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
9. Thrust plate
Remove thrust plate (19).
PW160-7H 30-53
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
6) Remove oil seal (24) from case (21). Lip surface of oil seal: Grease (G2-LI)
30-54 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
3) Press the end of shaft (23) with a press, etc. 3. Cylinder block assembly
5) Install inner race (20). they will not fall when the cylinder block
assembly is installed.
2. Thrust plate
Install thrust plate (19). 4) Install retainer holder (16).
Install the thrust plate with small hole side b
up.
PW160-7H 30-55
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
30-56 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
7. Springs
PW160-7H 30-57
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
Relief valve assembly: match the dowel pin on the cover side to
373 20 Nm {38.0 2.0 kgm} the dowel pin hole on the brake piston
Mounting bolt:
294 20 Nm {29.9 2.0 kgm}
30-58 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING MOTOR ASSEMBLY
Mounting bolt:
32.4 2.0 Nm {3.3 0.2 kgm}
PW160-7H 30-59
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
4
Support suspension cylinder rod as this
will drop freely when the axle is removed
1
1
1 1
5
30-60 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
Installation
PW160-7H 30-61
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
30-62 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
7. Remove the head of the cylinder (8). Strike by 10. Remove the rod complete with cylinder (16) and
means of a plastic hammer. cylinder liner (17).
8. Remove the gaskets (11), (12) and the scraper 11. Remove the head of the cylinder (14).
ring.
PW160-7H 30-63
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
13. Lock the rod of the cylinder (16) on a vice after 16. Remove the gaskets (21), (22) and the scraper
having screwed the head (6). ring (23).
30-64 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
1. Fit the gaskets (21) and (22) and the scraper ring
(23).
3. Thicknesses to be fitted.
PW160-7H 30-65
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
8. Assemble the thicknesses X (24) and the O-ring 11. Assemble the O-ring (15).
(20).
30-66 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
14. Lock the rod of the cylinder (16) on a vice after 17. Lubricate with grease the gaskets of the left cyl-
having screwed the head (6) and assemble the inder rod.
cylinder liner (17).
PW160-7H 30-67
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
20. Lubricate the threads of the steering cylinder with 23. Assemble steering bars (3).
grease.
30-68 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
Disassembly of epicyclic reduction gear and 4. Remove the planetary gear carrier cover (3) and
brake O-ring (30).
PW160-7H 30-69
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
7. Remove brake discs (6). 10. Remove seal rings (9) and (10) from piston (8).
8. Remove fastening screws of piston (7) and 11. Remove snap ring (24).
springs (15).
30-70 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
13. Remove screws (11) and washers (21) from 16. Remove seal rings (13) and (14) from brake car-
brake carrier (12). rier (12).
14. Assemble carrier (28) and split ring (4). Remove 17. Remove shims (26).
brake carrier (12).
PW160-7H 30-71
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
19. Remove the drain valve (17). 22. Remove outer cup of bearing (20).
20. Remove seal ring (19). 23. Remove outer cup of bearing (18).
21. Remove inner cup of bearing (18). 24. Remove snap ring (31). Remove planetary gears
(23) from planetary gear carrier cover (3).
30-72 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
Assembly of Epicylic Reduction Gear and Brake 4. Apply Loctite 510 on seal ring (19).
PW160-7H 30-73
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
7. Assemble the whole wheel hub (16). Alternately 10. Assemble the tool 2897013, 3 draw plates M10 x
strike bearings (18). 285 and 3 nuts M10.
Warning: The roller bearing should be rested on
the beam trumpet.
30-74 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
13. Calculate shims X1 of adjustment shims by using 16. Assemble O-rings (13) and (14) on brake carrier
the following procedure: X1 (G-F) + 0.05. (12).
14. Assemble previously calculated shims (26) X1. 17. Fit piston (8) on brake carrier (12) with springs
(15) and screws (7). Apply Loctite 638 on the
screws (7).
PW160-7H 30-75
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
19. Assemble brake discs (6). 22. Test the brake by temporarily fitting two screws
Warning: During assembly operations all the (11).
inner disc slots should coincide. Warning: Do not assemble bushes (22).
20. Assemble brake discs (6). 23. Fit snap ring (4).
Warning: During assembly operations all the
outer disc slots should coincide.
21. Fit ring bevel gear (5) with carrier (28) and split
ring (29).
30-76 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
25. Fit an adapter instead of the plug. 28. Apply Loctite 242 inside slots.
26. Test the brakes by considering that pressure 29. Fit screws (11) and shims (21).
should be 100-50 bar for about one minute. Tightening torque: 68Nm
27. Fit bushes (22). 30. Line up brake discs. Use tool 2897014.
Warning: Pay attention to the assembly direction Warning: A tooth should coincide with a brake
of bushes. fastening screw (7).
PW160-7H 30-77
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
31. Put brakes under pressure to avoid outer disc 34. Assemble snap ring.
misalignment.
30-78 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
37. Apply Loctite 242 on screw. 40. Apply pressure of 45-50 bar and check the dis-
tance between brake locking and unlocking (Min:
1.7mm; Max: 3.8 mm)
39. Remove oil drain plug and turn the final drive up
to meeting item (28) hole.
PW160-7H 30-79
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
Disassembly of joint box 4. Remove the planetary gear carrier cover (3) and
O-ring (6).
1. Before draining the oil, position the wheel hub (1)
with the plug on the upper part and loosen it off
some turns in order to eliminate any possible
inner pressure, then remove it completely. Turn
the wheel hub upside down till the hole is in the
lowest point.
Drain the oil completely.
30-80 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
7. Remove the screw (7). 10. Screw two screws M12 x 100 and remove the
pivot.
PW160-7H 30-81
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
13. Remove the complete joint (11). 16. Remove gasket (30).
14. Remove the gasket (12). 17. Use an extractor to remove bush (18).
15. Remove the gasket (13). 18. Remove the O-ring (19).
30-82 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
19. Remove the disk (20). 22. Remove the gasket (24).
20. Remove the bush (21). 23. Remove the bush (25).
21. Remove the O-ring (22) and the disk (23). 24. Remove pins (26).
PW160-7H 30-83
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
30-84 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
4. Assemble the O-ring (22) and the disk (23). Pay 7. Apply Loctite 510 on the gasket (24).
attention to assembling direction.
PW160-7H 30-85
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
10. Apply Loctite 510 on the gasket (28). 13. Grease and assemble the spacer (27).
30-86 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
16. Assemble the gasket (13). Pay attention to 19. Lubricate and assemble the pivot.
assembling direction.
PW160-7H 30-87
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
22. Apply Loctite 242 and assemble the screw (8). 25. Line up brake discs. Use tool 2897014.
Torque - 285 (29kgf-m) WARNING! A tooth should coincide with a brake
fastening screw (7)
30-88 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
28. Lubricate with grease the contact surface of 31. Fit screws (2).
planetary gear cover (3). Torque - 55 Nm (6 kgf-m)
Apply Loctite 510 in the holes.
PW160-7H 30-89
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
30-90 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
7. Remove shims (6). 10. Use an extractor to remove bearing (7) from dif-
ferential unit.
PW160-7H 30-91
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
13. Remove ring bevel gear (2) by means of a mal- 16. Remove differential pins (13 and (14), planetary
let. gears (15), (16), (17) and (18) and spheric wash-
ers (19), (20), (21), and (22).
15. Remove planetary gear (23) and shim (25). 18. Remove discs (28) and (29).
30-92 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
19. Remove planetary gear (30). 22. Remove discs (42) and (43).
PW160-7H 30-93
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
Assembly of beam trumpet and differential unit. 4. Fit the differential unit pin (13) and planetary
gears (15) and (16) and washers (19) and (20).
Note:Without differential torque limiter.
30-94 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
PW160-7H 30-95
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
13. Assemble planetary gears (30). 16. Fit ring bevel gear (2) by using a hammer.
14. Assemble discs (28) and (29). 17. Apply Loctite 242 on thread of screws (10).
15. Fit the two half boxes of differential unit (11) and 18. Tighten screws (10)
(12). Torque - 205 Nm (21 kgf-m)
WARNING! Carefully check that the marks of both Note:Fix differential housing in the vice.
differential half boxes coincide.
30-96 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
19. Press bearing (7) or assemble after preheating. 22. Use tool 2897004 to fit bearing washer (5) on
beam trumpet (4).
PW160-7H 30-97
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
25. Use tool 2897004 to fit the bearing outer washer 28. While Screwing the tool nut until the value of
(7) on beam trumpet (3). 10Nm has been reached turn the ring bevel gear
and strike it with a hammer to fix whole unit.
30-98 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
31. Drawing used to determine backlashes between 33. Apply Loctite 510 on contact surface of beam
the bevel gear pair teeth. trumpet (4).
X1 = 1.8
Check adjusting shims X2 through the suggested
procedure for axles
X2 = F1
PW160-7H 30-99
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
30-100 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
7. Remove the nut (6) and the flange (10). 10. Once the bevel pinion (2) has been removed,
collect shims (9) and spacer (8).
PW160-7H 30-101
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
13. Remove the outer cup of the taper roller bearing Assembly of pinion group
(13) and shims (9) from the central body. Use a
chisel and a hammer. 1. Bevel pinion adjustment.
30-102 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
PW160-7H 30-103
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
5. To determine shim S2. 8. Position half bearing (11) on beam trumpet (4).
S2 = B1 - (L1 - S - G - L2)
S = previously detected shims
G = beam value
6. L1 = Bearing Height
L2 = Bearing Height.
30-104 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
11. Press inner bearing (13) on pinion (2). 14. Fit bearing (11) in relevant housing on beam
Use tool 2897009. trumpet (4).
WARNING! Use a special glove to protect from-
scorching.
13. Preheat bearing (11) on proper plate up to 16. Fit oil seal (7) inside tool 2897015.
100C. Apply Loctite 510 on the oil seal outer edge.
PW160-7H 30-105
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
17. Assemble the oil seal by slightly striking with a 20. Assemble the flange (10) and the nut (6).
plastic hammer.
Note:Clean the box with a rolling brush.
30-106 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
23. Carry out the preloading measurement (P) of the 26. Apply Loctite 510 on contact surface of beam
pinion taper roller using a dynamometer whose trumpet (4).
cord is wound on the flange diameter. The
adjustment is performed by gradually increasing
shims (12) mounted under bearing (11).
WARNING! All preloadings should be measured
without the seal ring.
P = 2/3 Nm
PW160-7H 30-107
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
30-108 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
PW160-7H 30-109
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
30-110 PW160-7H
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
PW160-7H 30-111
DISASSEMBLY AND ASSEMBLY REAR AXLE AND TRANSMISSION ASSEMBLY
12
REMOVAL AND INSTALLATION OF REAR AXLE AND TRANS-
TRANSMISSION MISSION ASSEMBLY
REMOVAL 4. Attach an identification tag to hoses to avoid
incorrect connection during re-assembly
2 2
30-112 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE AND TRANSMISSION ASSEMBLY
8. Disconnect electrical connection (9). 10. Disconnect propshaft (12) by removing bolts (13)
and retracting propshaft in direction shown.
9 13
12
t
rac
Ret
14
10
12. Roll axle and wheels clear of machine.
11
15
Disengage from
16 transmission
PW160-7H 30-113
DISASSEMBLY AND ASSEMBLY REAR AXLE AND TRANSMISSION ASSEMBLY
Installation
30-114 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
PW160-7H 30-115
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
5. Remove split ring (4). 8. Remove fastening screws of piston (7) and
springs (15).
7. Remove brake discs (6). 10. Remove seal rings (9) and (10) from piston (8).
30-116 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
11. Remove screws (11) and washers (21) from 14. Remove seal rings (13) and (14) from brake car-
brake carrier (12). rier (12).
12. Assemble carrier (28) and split ring (4). Remove 15. Remove shims (26).
brake carrier (12) using tool 289701.
PW160-7H 30-117
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
17. Remove the drain valve (17). 20. Remove outer cup of bearing (20).
18. Remove seal ring (19). 21. Remove outer cup of bearing (18).
19. Remove inner cup of bearing (18). 22. Remove sleeve (25).
30-118 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
23. Remove shaft and pinion (24). Installation of Epicylic Reduction Gear and Brake
PW160-7H 30-119
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
4. fit the remaining part of bearing 18) on wheel hub 7. Lubricate axle shaft to assemble the wheel hub.
(16). Warning: Polish hub and oil holes.
5. Apply Loctite 510 on seal ring (19). 8. Assemble the whole wheel hub (16). Alternately
strike bearings (18).
Warning: The roller bearing should be rested on
the beam trumpet.
30-120 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
10. Fit bearing (20) inside beam trumpet. 13. Use a depth gauge to measure dimension (F) of
Warning: Wear gloves to avoid getting burnt. brake carrier (12).
11. Assemble the tool 2897013, 3 draw plates M10 x 14. Calculate shims X1 of adjustment shims by using
285 and 3 nuts M10. the following procedure: X1=(G-F) + 0.05.
12. Use a depth gauge to measure dimension (G) of 4 15. Assemble previously calculated shims (26) (X1).
wheel hub.
PW160-7H 30-121
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
16. Assemble O-rings (9) and (10) on piston (8). 19. Fit the whole unit of the brake carrier on wheel
hub.
Warning: The brake carrier and beam trumpet
holes should coincide.
30-122 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
22. Fit ring bevel gear (5) with carrier (28) and split 25. Remove plug (27).
ring (29).
PW160-7H 30-123
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
28. Fit bushes (22). 31. Line up brake discs. Use tool 2897014.
Warning: Pay attention to the assembly direction Warning: A tooth should coincide with a brake
of bushes. fastening screw (7).
29. Apply Loctite 242 inside slots. 32. Put brakes under pressure to avoid outer disc
misalignment.
30-124 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
34. Heat planetary gear bearing at 110C. Assemble 37. Fit sleeve (25).
planetary gear (23).
WARNING! Wear suitable gloves to avoid being
burnt
PW160-7H 30-125
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
40. Apply Loctite 242 on screw (2). 43. Apply a pressure of 45-50 bar and check the dis-
tance between brake locking and unlocking
(MIN: 1.7mm, MAX: 3.8mm).
42. Remove oil drain plug and turn the final drive up
to meeting the item (28) hole.
Note:Brakes wear check.
30-126 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
12
Disassembly of Beam Trumpet and Differential 4. Remove O-ring (9).
Unit
PW160-7H 30-127
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
7. Remove shims (6). 10. Use and extractor to remove bearing (7) from dif-
ferential unit.
30-128 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
13. Remove ring bevel gear (2) by means of a mal- 16. Remove differential pins (13) and (14), planetary
let. gears (15), (16), (17) and (18) and spheric wash-
ers (19), (20), (21) and (22).
15. Remove planetary gear (23) and shim (25). 18. Remove discs (28) and (29).
PW160-7H 30-129
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
19. Remove planetary gear (30). 22. Remove discs (42) and (43).
30-130 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
Installation of Beam Trumpet and Differential Unit 4. Fit differential unit pin (13) and planetary gears
(15), (16) and washers (19) and (20).
1. Apply a thin layer of molicote G-n plus paste on
half boxes of differential (11) and (12).
WARNING! Remove remains of old sealing com-
pound.
PW160-7H 30-131
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
7. Apply a thin layer of molicote G-n plus paste on 10. Assemble planetary gears (41).
half boxes of differential (44) and (45)
WARNING! Remove remains of old sealing com-
pound.
30-132 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
13. Assemble planetary gears (30). 16. Fit ring bevel gear (2) by using a hammer.
14. Assembly discs (28) and (29). 17. Apply loctite242 on thread of screws (10).
15. Fit the two half boxes of differential unit (11) and 18. Tighten screws (10).
(12).
WARNING! Carefully check that the marks of both
differential half boxes coincide Screws (10) torque: 205Nm
PW160-7H 30-133
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
21. Fit adjustment shims (6) (X1)=1.8. 24. Assemble adjusting shims (8) (X2).
30-134 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
25. Assemble cup of bearing (3). 28. While screwing the tool nut until the value of
10Nm has been reached, turn the ring bevel gear
and strike it with a hammer to fix the whole unit.
PW160-7H 30-135
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
31. Drawing used to determine backlashes between 33. Apply loctite 510 on contact surface of beam
the bevel gear pair teeth. trumpet (4).
X1 = 1.8
Check adjusting shims X2 through the suggested
procedure: X2 = F1.
30-136 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
PW160-7H 30-137
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
9. Remove O-ring (18), ring (19) and seal (20). 12. Remove the disc (17).
30-138 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
13. Take the bevel pinion out of its housing, by beat- 16. Take the cup of the taper roller bearing (11) out of
ing with a hammer made of soft material on the the central body using a chisel and hammer.
splined end.
15. Take the bearing cone (13) out of the bevel pin-
ion end, using a suitable extractor.
PW160-7H 30-139
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
Installation of Pinion Group 3. To determine shim (S) between pinion and bear-
ing it is enough to add value (V) printed on pinion
head (V = prescribed conical distance) to value B
1. Bevel pinion adjustment. - bearing width - and subtract X from the value
printed on beam.
X 155.50 155.50 155.70 S=X - (V+B)
B 29.25 29.45 29.45 Example: shim S = 163.7 - (132.80 + 29.25) =
1.55mm.
V 125.00 125.20 124.80
A 154.25 154.65 154.05
S 1.25 0.85 1.65
4. Bearings adjustment.
30-140 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
6. L1 = bearing height
L2 = bearing height
PW160-7H 30-141
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
11. Fit the whole pinion of bearing on beam trumpet 14. Grease bevel pinion.
(4), spacer (14) and shims (12).
30-142 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
18. Assemble O-ring (18), ring (19) and seal (20). 21. Assemble sleeve (7) and grease surface.
19. Grease gear wheel (9) and assemble. 22. Assemble flange (10) and nut (6). (Tightening
torque - 400Nm).
PW160-7H 30-143
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
23. Carry out the preloading measurement (P) of pin- 26. Apply Loctite 510 on contact surface of beam
ion taper roller using a dynamometer whose cord trumpet (4).
is wound on the flange diameter. The adjustment
is performed by gradually increasing shims
mounted under bearing.
Warning: All preloadings should be measured
without the seal ring.
P = 2 / 3 Nm
30-144 PW160-7H
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
PW160-7H 30-145
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
DISASSEMBLY
30-146 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
7. Loosen nut (6). 10. Use an extractor to remove the inner ring of the
bearing (8).
PW160-7H 30-147
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
13. Remove hydraulic motor flange (11) and O-ring Installation of Travel Motor
(12).
1. Assemble flange (11) and O-ring (12).
30-148 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
4. Assemble flange protection (9) on flange (7). 7. Apply Loctite 242 on nut (6).
PW160-7H 30-149
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
10. Assemble O-ring (5). 13. Assemble the travel motor (2).
11. Assemble spring (4). 14. Apply Loctite 242 on screws (1).
12. Assemble disc (3). 15. Assemble screws (1). (Tightening torque -
285Nm)
30-150 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
12510.
Removal of Transmission Box 4. Remove the O-ring (3).
PW160-7H 30-151
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
30-152 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
13. Remove thrust plate (13) from bush (11). 16. Remove complete planetary gears carrier.
PW160-7H 30-153
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
19. Use an extractor to remove the bearing (17). 22. Use an extractor to remove bering inner cup
(20).
30-154 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
PW160-7H 30-155
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
31. Remove bearing outer cup (31). 34. Remove piston (35) and springs (36), (37).
33. Remove gasket (33) and O-ring (34). 36. Remove gasket (39).
30-156 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
PW160-7H 30-157
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
43. Remove snap ring (45). 46. Remove discs (49), (50), (51) and (52).
44. Remove external geared wheel (46) from hollow 47. Remove piston assembly.
wheel (47).
30-158 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
49. Remove piston gasket (54) and O-ring (55). 52. Loosen screw (60).
50. Remove outer ring (56) from piston (57). 53. Remove screw (60), washer (61), spring (62),
and ball (63).
PW160-7H 30-159
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
56. Remove the cover (67). 59. Remove snap ring (70).
30-160 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
PW160-7H 30-161
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
7. Apply Loctite 242 on screws (66). Note:to unlock the transmission in case of need,
turn the eccentric pin 180 (notch upward).
30-162 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
12. Assemble gasket (58) and O-ring (59) in the ring 15. Assemble O-ring (53).
(56).
PW160-7H 30-163
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
18. Assemble disc (48). 21. Assemble bearing (44) on hollow wheel assem-
bly.
30-164 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
PW160-7H 30-165
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
29. Install O-ring (38) and gasket (39). 31. Assemble piston assembly
Use tool 2912484.
30-166 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
35. Assemble bearing (31). 38. Assemble bearing outer cup (20).
PW160-7H 30-167
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
40. Assemble O-ring (27). 43. Assemble gear wheel (21) on planetary gears
carrier (22).
42. Assemble pins (24). 45. Apply Loctite 638 on inner race of bearing(20)
30-168 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
46. Assemble the ring (19). 49. Measure the distance (B) between the case sup-
porting plate and the upper detent of the bear-
ing(17).
PW160-7H 30-169
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
52. Assemble gear (16). 55. Assemble bush (11) and thrust plate (13).
Note:pay attention to assembly direction.
30-170 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
59. Apply Loctite 242 on screws (14). 62. Assemble disc (9).
PW160-7H 30-171
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
64. Unlock the clutch by pressing 50 - 100 bar. 67. Assemble springs (4), (5) and (6).
65. Measure the lowering of the discs using a digital 68. Assemble O-ring (3).
gauge. the stroke should be between 1.7 and 1.9 Apply Loctite 510.
mm. Otherwise replace the ring (8) with one of
different thickness.
30-172 PW160-7H
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
70. Apply Loctite 242 on screws (2). 73. Assemble screws (2).
(Tightening torque - 285Nm)
PW160-7H 30-173
DISASSEMBLY AND ASSEMBLY PROPSHAFT ASSEMBLY
12
2 2
5
4
Retract
6 6
3
30-174 PW160-7H
DISASSEMBLY AND ASSEMBLY PROPSHAFT ASSEMBLY
Installation
PW160-7H 30-175
DISASSEMBLY AND ASSEMBLY WHEEL ASSEMBLY
12
INSTALLATION
1 Install in reverse order of removal.
When inflating tyres, inflate to:
2
30-176 PW160-7H
DISASSEMBLY AND ASSEMBLY SUSPENSION LOCK CYLINDER ASSEMBLY
12
REMOVAL
2 2
INSTALATION
PW160-7H 30-177
DISASSEMBLY AND ASSEMBLY SUSPENSION LOCK ASSEMBLY
30-178 PW160-7H
DISASSEMBLY AND ASSEMBLY OUTRIGGER ASSEMBLY
12
4
2
8. Remove all bolts (5) and remove outriggers.
INSTALLATION
PW160-7H 30-179
DISASSEMBLY AND ASSEMBLY OUTRIGGER ASSEMBLY
30-180 PW160-7H
DISASSEMBLY AND ASSEMBLY DOZER BLADE ASSEMBLY
12)
1 1
INSTALLATION
2. Lower dozer blade until it just touches the Install in reverse order to removal.
Grease all pins and cylinders.
ground, but dont take any of the weight of the
machine.
2
2
PW160-7H 30-181
DISASSEMBLY AND ASSEMBLY DOZER BLADE ASSEMBLY
30-182 PW160-7H
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
12
REMOVAL
1. Remove revolving frame assembly. For details, Swing circle mounting bolt:
see REMOVAL OF REVOLVING FRAME 1st pass:
ASSEMBLY. Tighten to 191.2 19.6 Nm
{19.5 2 kgm}
2. Remove 36 mounting bolts (1) to remove the 2nd pass:
swing circle assembly.
1) Using the angle of the bolt head as the
base, make start marks on the swing cir-
3. Lift off swing circle assembly (2). cle and socket.
2) Make an end mark at a point (on swing cir-
cle) 48 5 from the start mark.
Swing circle assembly: 207.3 kg 3) Tighten so that the start mark on the
socket is aligned with the end mark on the
swing circle at the 48 5 position.
Outer race
soft zone
INSTALLATION
Front of machine
PW160-7H 30-183
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY
30-184 PW160-7H
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY
9 8 5
15 16 17
18
10 11 7 6
12
19
13 14
PW160-7H 30-185
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY
Air bleeding
check the level again.
20
30-186 PW160-7H
DISASSEMBLY AND ASSEMBLY CENTRE SWIVEL JOINT ASSEMBLY
12
(1): Travel B
tags to prevent mistakes when installing.
(2): Brake 1
(3): Attachment bottom
(4): 1st clutch 3. Disconnect connector (14)
(5): Drain
(6): 2nd clutch
(7): Travel A
(8): Suspension lock
(9): Steer left
(10): Steer right
14
(11): Brake 2
(12): Attachment head
(13): Motor volume pilot
2
3
4
PW160-7H 30-187
DISASSEMBLY AND ASSEMBLY CENTRE SWIVEL JOINT ASSEMBLY
(16): Brake 2
(21): Brake 1
(22): Travel B
(23): Travel A
(25): Drain
28
20 21 17 16
23 24
30-188 PW160-7H
DISASSEMBLY AND ASSEMBLY CENTRE SWIVEL JOINT ASSEMBLY
30
INSTALLATION
Bleeding air
again.
PW160-7H 30-189
DISASSEMBLY AND ASSEMBLY CENTRE SWIVEL JOINT ASSEMBLY
12
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
*Distinction between new and existing part.
DISASSEMBLY 3
2. Remove all 4 screws (2) TE M10 x 30 on enclo- 5. Prevent any possibility of damage on chromium
sure flange. plated surface of spool.
30-190 PW160-7H
DISASSEMBLY AND ASSEMBLY CENTRE SWIVEL JOINT ASSEMBLY
7. Remove the seals (6) from the end and top grove
of housing.
6 6
ASSEMBLY
PW160-7H 30-191
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
12
30-192 PW160-7H
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
8. To remove cover (8) remove bolts (9). 11. Remove cover (17).
9 17
9. Disconnect the all hoses and connectors at 12. Disconnect hose (18).
points (10, 11, 12).
10
12 18
11
13. Remove 4 of 6 mounting bolts (19)
10. Remove jubilee clips (13), then remove hoses
(14), (15), (16).
14
19
19
16 13
13
15
16
16
16 16
16
16
16 16 16
PW160-7H 30-193
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
20
Hydraulic tank drain plug:
58.8 - 78.5 Nm
{6.0 - 8.0 kgm}
20
21 21
30-194 PW160-7H
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
Bleeding air
Bleed the air.
For details, see TESTING AND ADJUSTING.
Air Bleeding of Various Parts.
PW160-7H 30-195
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
12
30-196 PW160-7H
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
INSTALLATION
10
12
11
13 13
PW160-7H 30-197
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY
12
12 10
1. Drain oil from the hydraulic tank and then drain 15 14
17
13 11 9
oil out of the system. 16 7
16
17
19
21
23 20
22
24
18
17 17
18
30-198 PW160-7H
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY
8. Also disconnect hoses 17 and 18 from swing 11. Step removal. Remove top step (38), by remov-
machinery to aid removal of control valve and ing 2 bolts (39) and lifting step out.
improve accessibility.
38 39
17
18
17
18
35
34 33 30 29 28 27
32 31 25
26
36 37
PW160-7H 30-199
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY
Middle step removal (40), by removing 6 bolts 14. Disconnect hoses (63 through 66).
(41) and lifting out (optional).
38
64
66
63
65
39
44
47
43 67
48
44 68
45
42 46
39
72
71
48
49
53
51 54 55 61 62 58 59 60
50 52 56 57
70
73
69
30-200 PW160-7H
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY
74
75
73
INSTALLATION
Bleeding air
the system. Then check the oil level again.
PW160-7H 30-201
DISASSEMBLY AND ASSEMBLY LS SEPARATION VALVE ASSEMBLY
12
4
3
1
INSTALLATION
30-202 PW160-7H
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE ASSEMBLY
12
2
1
INSTALLATION
PW160-7H 30-203
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE ASSEMBLY
12
INSTALLATION
30-204 PW160-7H
DISASSEMBLY AND ASSEMBLY LS CONTROL EPC VALVE ASSEMBLY
12
1
2
INSTALLATION
PW160-7H 30-205
DISASSEMBLY AND ASSEMBLY EPC SOLENOID VALVE ASSEMBLY
12
2 1
INSTALLATION
30-206 PW160-7H
DISASSEMBLY AND ASSEMBLY PPC SOLENOID VALVE BLOCK ASSEMBLY
12
8 7
6 5
2 1 2
Remove middle step (3), by removing 6 bolts (4) 4. Remove all hoses and electrical connections.
and lifting step out.
5. Remove 4 securing bolts (9).
PW160-7H 30-207
DISASSEMBLY AND ASSEMBLY PPC SOLENOID VALVE BLOCK ASSEMBLY
10
11
INSTALLATION
30-208 PW160-7H
DISASSEMBLY AND ASSEMBLY MANIFOLD BLOCK ASSEMBLY
12
REMOVAL AND INSTALLATION OF MANIFOLD BLOCK ASSEM-
ASSEMBLY BLY
REMOVAL 4. Remove 2 bolts (5), disconnect earth strap (6)
and remove manifold block (7).
1. Remove middle step (1), by removing 6 bolts (2)
and lifting step out.
2 INSTALLATION
Remove bottom step (3), by removing 4 bolts (4) Install in reverse order of removal.
lifting step out.
PW160-7H 30-209
DISASSEMBLY AND ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
12
Mark Part No. Part Name Necessity Qty Distinction* Sketch Install in reverse order of removal.
790-201-2000 Push tool 1
N
790-201-2740 Spacer 1
*Distinction between new and existing part. Oil seal lip portion: Grease (G2-LI)
30-210 PW160-7H
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY
12
ASSEMBLY
P1, P2 44.4 mm
P3, P4 42.4 mm
The location of each port is stamped in the
lower part of the valve body.
PW160-7H 30-211
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
12
3 790-720-1000 Expander 1
Rubber Band
796-720-1670
(for boom and arm)
1
07281-01279 Clamp 1
4
Rubber band
796-720-1660
(for bucket)
1
07281-01159 Clamp 1
01010-50816 Bolt 1
Push tool kit
790-201-1500
(for bucket)
1
790-101-5021 Grip 1
01010-50816 bolt 1
6
790-201-1980 Plate (for boom) 1
790-101-5021 Grip 1
DISASSEMBLY OF ARM AND BUCKET CYLIN- and bucket cylinder: M12 x Pitch 1.75.
DERS
30-212 PW160-7H
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
12
PW160-7H 30-213
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
12
3. Disassembly of cylinder head assembly 4) Using tool Q6, install dust seal (17), and
1) Remove O-ring and backup ring (15). secure with snap ring (16).
2) Remove snap ring (16), then remove dust 5) Install backup ring and O-ring (15).
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove busing (20).
30-214 PW160-7H
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
12
3) Install backup ring and O-ring (14). 2) Assemble head assembly (7).
4) Assemble wear ring (12). 3) Fit O-ring and backup ring to collar (6), then
PW160-7H 30-215
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
Drill Bottom
Tap used Tap depth
diameter hole depth
10.3 27 12 x 1.75 20
30-216 PW160-7H
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
12
iii) After machining, wash thoroughly to remove 7) Assemble piston rod assembly (2).
all metal particles and dust. Set the end gap of the ring horizontally (at
the side position), align axial center of cylin-
der tube, then insert.
After inserting, check that the ring is not bro-
ken and has not come out, then push in fully.
Mounting bolt:
9) Install piping.
PW160-7H 30-217
DISASSEMBLY AND ASSEMBLY MONOBOOM WORK EQUIPMENT ASSEMBLY
12
790-101-4000
Puller
1 5. Disconnect stabilizer hoses (6), arm cylinder
R (490 kN 50-T-long)
hoses (7), boom cylinder hoses (8) two for each.
790-101-1102
Pump
(294 kN 30 T)
1 Plug the hoses to prevent oil flow-out, and
*Distinction between new and existing part. fasten them on the valve side.
1
4 10
3
2
30-218 PW160-7H
DISASSEMBLY AND ASSEMBLY MONOBOOM WORK EQUIPMENT ASSEMBLY
12 INSTALLATION
12
2.0 mm.
14
PW160-7H 30-219
DISASSEMBLY AND ASSEMBLY MONOBOOM WORK EQUIPMENT ASSEMBLY
12
Inside surface of bushing when assem-
bling pin:
Anti-friction compound (LM-P)
Grease after assembling pin:
Grease (LM-G)
Bleeding air
Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Air Bleed-
30-220 PW160-7H
DISASSEMBLY AND ASSEMBLY 2 PIECE BOOM WORK EQUIPMENT ASSEMBLY
790-101-4000
Puller
1 5. Disconnect arm cylinder (6), boom cylinder
R (490 kN 50-T-long)
hoses (7), adjust cylinder hoses (8), stabilizer
Pump
790-101-1102
(294 kN 30 T)
1 hose (9) two for each.
*Distinction between new and existing part. Plug the hoses to prevent oil flow-out, and
fasten them on the valve side.
REMOVAL
6. Disconnect intermediate connector CN-A86 (10)
for a working lamp.
Extend the arm and bucket fully. Lower the work
equipment to the ground and set the safety
lock lever to the lock position.
Release the residual pressure in the hydraulic
circuit. Refer to the Release of Remaining 7
Pressure in Hydraulic Circuit section in the
TESTING AND ADJUSTING chapter of this 7 8
manual.
6 8
1. Disconnect grease hose (1).
6 9
2. Sling boom cylinder assembly (2), and remove
9
lock bolt (3) on both sides of boom. 10
1
4
11
5
3
2
PW160-7H 30-221
DISASSEMBLY AND ASSEMBLY 2 PIECE BOOM WORK EQUIPMENT ASSEMBLY
12 INSTALLATION
12
2.0 mm.
14
30-222 PW160-7H
DISASSEMBLY AND ASSEMBLY 2 PIECE BOOM WORK EQUIPMENT ASSEMBLY
12
Inside surface of bushing when assem-
bling pin:
Anti-friction compound (LM-P)
Grease after assembling pin:
Grease (LM-G)
Bleeding air
Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Air Bleed-
PW160-7H 30-223
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
12
REMOVAL
3
2. Bleed gas from the air conditioner, using tool S.
30-224 PW160-7H
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
12
7. Remove duct (6) on the right side. 10. Remove plate (11).
11
6
12
15
13
7
14
10
PW160-7H 30-225
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
13. Disconnect cab intermediate connectors at the 18. Remove the 8 mounting bolts (20) and remove
following two points. (Refer to TROUBLE- air conditioner unit assembly (21) carefully.
SHOOTING section on CONNECTOR LOCA- When removing the air conditioner unit
TION CHART AND ELECTRICAL CIRCUIT assembly, do not forget to disconnect the two
DIAGRAM BY SYSTEM<$paranumonly>-20 - air conditioner hoses connected to the bot-
17
21
16 20
D02
(Assembled-type diode connector)
19
18
30-226 PW160-7H
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
INSTALLATION
PW160-7H 30-227
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT ASSEMBLY
12
1
3
Counterweight assembly
3. Insert lifting eyes into holes. The lifting eyes you PW160: 3,101 kg
require are:
Thread - 48x3
Must have safe working load of - 3,500 Kg
30-228 PW160-7H
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT ASSEMBLY
12
INSTALLATION
PW160-7H 30-229
DISASSEMBLY AND ASSEMBLY OPERATOR CAB ASSEMBLY
12
REMOVAL AND INSTALLATION OF OPERATOR CAB ASSEM-
ASSEMBLY BLY
REMOVAL 4. Disconnect all hoses at (4).
6
5 5
2. Remove covers (2) and (3) under the monitor
panel. 6
When removing cover (2), first disconnect
the M19 wiring for cigarette lighter.
7
7
2
30-230 PW160-7H
DISASSEMBLY AND ASSEMBLY OPERATOR CAB ASSEMBLY
7. Disconnect hoses (8) from brake valve. 9. Remove 3 hoses (10) from engine and 1 hose
from the dryer (11).
8
10
8
8
10 11
11. Ensure all hoses are loose and all clips have
been removed.
12
9 12
13
9
9
13
PW160-7H 30-231
DISASSEMBLY AND ASSEMBLY OPERATOR CAB ASSEMBLY
INSTALLATION
30-232 PW160-7H
DISASSEMBLY AND ASSEMBLY MONITOR ASSEMBLY
5
2
1 4
PW160-7H 30-233
DISASSEMBLY AND ASSEMBLY MONITOR ASSEMBLY
INSTALLATION
30-234 PW160-7H
DISASSEMBLY AND ASSEMBLY GOVERNOR / PUMP CONTROLLER ASSEMBLY
2 6
2
1 4 5
PW160-7H 30-235
DISASSEMBLY AND ASSEMBLY GOVERNOR / PUMP CONTROLLER ASSEMBLY
Installation
30-236 PW160-7H
90 OTHERS
PW160-7H 90-1
HYDRAULIC CIRCUIT DIAGRAM 1/3
PW160-7H 90-3
HYDRAULIC CIRCUIT DIAGRAM 2/3
PW160-7H 90-5
HYDRAULIC CIRCUIT DIAGRAM 3/3
PW160-7H 90-7
ELECTRICAL CIRCUIT DIAGRAM 1/5
PW160-7H 90-9
ELECTRICAL CIRCUIT DIAGRAM 2/5
PW160-7H 90-11
ELECTRICAL CIRCUIT DIAGRAM 3/5
PW160-7H 90-13
ELECTRICAL CIRCUIT DIAGRAM 4/5
PW160-7H 90-15
ELECTRICAL CIRCUIT DIAGRAM 5/5
PW160-7H 90-17