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KOMATSU PW160-10 SHOP MANUAL VENBM66001 – PDF DOWNLOAD
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Description
KOMATSU PW160-10 SHOP MANUAL VENBM66001 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PW160-10 SHOP MANUAL VENBM66001 – PDF DOWNLOAD
Language : English
Pages : 1292
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PW160-10 SHOP MANUAL VENBM66001 – PDF DOWNLOAD
VENBM66001 PW160-10.................................................................................................. 1 GENERAL.............................................................................................................. 5 Specification dimension drawings................................................................................. 6 Dimensions................................................................................................... 6 Working ranges................................................................................................... 8 Working range: 1-piece boom.................................................................................. 8 Working range: 2-piece boom.................................................................................. 9 Weight table..................................................................................................... 13 1-piece boom................................................................................................. 14 2-piece boom................................................................................................. 15 Fuel, coolant and lubricants..................................................................................... 16 FOREWORD............................................................................................................. 17 Safety........................................................................................................... 17 Important safety notice...................................................................................... 17 General precautions.......................................................................................... 17 Preparations for work........................................................................................ 17 Precautions during work...................................................................................... 18 General.......................................................................................................... 19 General...................................................................................................... 19 Structure and function....................................................................................... 19 Testing, adjusting and troubleshooting....................................................................... 19 Disassembly and assembly..................................................................................... 19 Troubleshooting.............................................................................................. 19 Diagrams and drawings........................................................................................ 19 How to read the shop manual...................................................................................... 20 Volumes...................................................................................................... 20 Distribution and updating................................................................................ 20 Filing method................................................................................................ 20 Revised edition mark......................................................................................... 20 Revisions.................................................................................................... 20 Symbols...................................................................................................... 20 Hoisting instructions............................................................................................ 21 Hoisting..................................................................................................... 21 Wire Ropes............................................................................................... 21 Coating materials................................................................................................ 22 Standard tightening torque....................................................................................... 24 Standard tightening torque of bolts and nuts................................................................. 24 Tightening torque of hose nuts............................................................................... 25 Tightening torque of split flange bolts...................................................................... 25 Tightening torques for hoses (taper seal type and face seal type)............................................ 25 Tightening torque for 107 engine series (bolts and nuts)..................................................... 26 Tightening torque for 107 engine series (eye joints)......................................................... 26 Tightening torque for 107 engine series (tapered screws)..................................................... 26 Electric wire code............................................................................................... 27 Classification by thickness.................................................................................. 27 Classification by color and code............................................................................. 27 Conversion tables................................................................................................ 28 Method of using the conversion table......................................................................... 28 Units............................................................................................................ 34 STRUCTURE AND FUNCTION............................................................................................... 35 Engine related parts............................................................................................. 38 Variable Flow Turbocharger................................................................................... 40 EGR system piping drawing.................................................................................... 43 EGR system circuit diagram................................................................................... 44 EGR valve.................................................................................................... 45 EGR cooler................................................................................................... 47 KCCV layout drawing.......................................................................................... 48 KCCV ventilator.............................................................................................. 50 KDOC muffler................................................................................................. 52 Cooling system............................................................................................... 54 Power train...................................................................................................... 56 Swing circle................................................................................................. 58 Specifications........................................................................................... 58 Swing machinery & motor.......................................................................................... 59 Specification................................................................................................ 60 Operation of swing lock...................................................................................... 61 Relief valve portion......................................................................................... 62 Operation................................................................................................ 62 Undercarriage.................................................................................................... 64 Transmission..................................................................................................... 66 Specifications............................................................................................... 66 Function..................................................................................................... 68 Hydraulic quick coupler.......................................................................................... 69 Schematic.................................................................................................... 69 Operation.................................................................................................... 70 Hydraulic quick coupler solenoid valve....................................................................... 70 Specification................................................................................................ 70 Quick coupler error logic.................................................................................... 71 Travel motor..................................................................................................... 72 Function..................................................................................................... 73 Operation of travel motor.................................................................................... 74 Clutch control circuit........................................................................................... 76 Function..................................................................................................... 77 Axle............................................................................................................. 78 Outline...................................................................................................... 78 Suspension lock cylinder......................................................................................... 82 Specifications............................................................................................... 82 Structure and function....................................................................................... 82 Circuit...................................................................................................... 83 Axle oscillation............................................................................................. 83 Braking system................................................................................................... 84 Structure and function....................................................................................... 85 Gear pump........................................................................................................ 86 Specifications............................................................................................... 86 Function..................................................................................................... 86 Priority valve................................................................................................... 88 Specification................................................................................................ 88 Function..................................................................................................... 88 Power brake valve................................................................................................ 90 Specifications............................................................................................... 91 Function..................................................................................................... 91 Accumulator for brake valve...................................................................................... 92 Specifications............................................................................................... 92 Structure and function....................................................................................... 92 Steering system.................................................................................................. 93 Structure and function....................................................................................... 93 Steering column.................................................................................................. 94 Orbitrol valve................................................................................................... 95 Specifications............................................................................................... 95 Structure and function....................................................................................... 95 Hydraulic equipment layout drawings.............................................................................. 96 Hydraulic circuit diagram........................................................................................ 98 Hydraulic tank................................................................................................... 99 Specifications............................................................................................... 99 Hydraulic pump................................................................................................... 100 Function..................................................................................................... 102 Structure.................................................................................................... 102 Operation.................................................................................................... 103 LS valve..................................................................................................... 105 PC valve..................................................................................................... 106 Function................................................................................................. 107 Operation................................................................................................ 108 1. LS valve.............................................................................................. 108 2. PC valve.............................................................................................. 112 LS(PC)-EPC valve............................................................................................. 119 Function................................................................................................. 120 Operation................................................................................................ 120 Pilot pressure control (PPC) system.............................................................................. 122 Function..................................................................................................... 123 Operation.................................................................................................... 123 Control valve.................................................................................................... 124 Outline...................................................................................................... 124 CLSS............................................................................................................. 139 Outline of CLSS.............................................................................................. 139 Features................................................................................................. 139 Structure................................................................................................ 139 Basic Principle.............................................................................................. 140 Operation for each function and valve........................................................................ 142 Hydraulic circuit diagram and name of valves............................................................. 142 1. Unload valve.............................................................................................. 144 Function................................................................................................. 144 Operation................................................................................................ 144 Operation................................................................................................ 145 Operation................................................................................................ 146 2. Introduction of LS pressure............................................................................... 147 Work equipment valve..................................................................................... 147 Function................................................................................................. 147 Operation................................................................................................ 147 3. LS bypass plug............................................................................................ 148 Outline.................................................................................................. 148 Operation................................................................................................ 148 4. Pressure compensation valve............................................................................... 149 Function................................................................................................. 149 Operation................................................................................................ 150 5. Area ratio of pressure compensation valve................................................................. 151 Function................................................................................................. 151 6. Boom regeneration circuit................................................................................. 152 Function................................................................................................. 152 Operation................................................................................................ 152 Function................................................................................................. 153 Operation................................................................................................ 153 7. Arm regeneration circuit.................................................................................. 154 Function................................................................................................. 154 Operation................................................................................................ 154 Function................................................................................................. 155 Operation................................................................................................ 155 8. Swing bleeding valve...................................................................................... 156 Function................................................................................................. 156 Operation (In fine control operation).................................................................... 156 9. LS select valve........................................................................................... 157 Function................................................................................................. 157 Operation................................................................................................ 157 10. Variable type pressure compensation valve (for service).................................................. 158 Function................................................................................................. 158 Simultaneous operation with work equipment under heavy load (boom RAISE, etc.)........................... 158 Centre swivel joint.............................................................................................. 159 Travel PPC pedal................................................................................................. 160 Work equipment – Swing PPC valve................................................................................. 162 Operation.................................................................................................... 164 Solenoid valve block with integrated ATT - EPC................................................................... 166 Proportional attachment control.............................................................................. 168 Proportional attachment schematic............................................................................ 169 ON / OFF Solenoid valves (3 way valve)....................................................................... 170 Operation................................................................................................ 170 ON / OFF Solenoid valves (4 way valve)................................................................... 172 Operation................................................................................................ 172 Hi/ Lo Solenoid valve (4 way valve)...................................................................... 174 Attachment PPC valve......................................................................................... 176 Function................................................................................................. 177 Operation................................................................................................ 177 Undercarriage solenoid valve block........................................................................... 179 Boom/Outrigger schematic..................................................................................... 180 Undercarriage attachment schematic........................................................................... 181 Boom safety valve................................................................................................ 182 Operation.................................................................................................... 183 Hydraulic cylinder............................................................................................... 184 Boom cylinder................................................................................................ 184 Arm cylinder................................................................................................. 184 Bucket cylinder.............................................................................................. 184 Adjust cylinder.............................................................................................. 185 Outrigger cylinder........................................................................................... 186 Dozer cylinder............................................................................................... 188 Function................................................................................................. 189 Work equipment................................................................................................... 190 Work equipment............................................................................................... 191 1. Dimension of arm.......................................................................................... 192 2. Dimension of bucket....................................................................................... 194 Air conditioner.................................................................................................. 196 Air conditioner piping....................................................................................... 196 Electrical wiring diagram........................................................................................ 197 Electrical system................................................................................................ 198 Engine control............................................................................................... 198 1. Operation of System................................................................................... 198 2. Component............................................................................................. 199 Engine controller................................................................................................ 200 Pump controller.................................................................................................. 204 Electrical control system........................................................................................ 207 Machine control system diagram................................................................................... 208 1. Engine and pump control function.......................................................................... 209 Function..................................................................................................... 210 Function..................................................................................................... 214 Function..................................................................................................... 216 Function..................................................................................................... 218 Operation.................................................................................................... 219 Function..................................................................................................... 220 Function..................................................................................................... 224 Function..................................................................................................... 226 Function..................................................................................................... 230 Specifications............................................................................................... 231 Function..................................................................................................... 231 Function..................................................................................................... 232 Operation.................................................................................................... 232 Machine monitor system........................................................................................... 236 Monitor panel................................................................................................ 238 Monitor display.............................................................................................. 242 Monitor items and display.................................................................................... 244 Caution monitor.............................................................................................. 246 Pilot monitor................................................................................................ 249 Monitor switches............................................................................................. 251 Declaration of switch function on keypad................................................................. 252 Guidance icon and function switch........................................................................ 254 Operator mode function................................................................................... 257 Service mode function.................................................................................... 258 KOMTRAX system................................................................................................... 259 KOMTRAX terminal............................................................................................. 260 Overload warning device.......................................................................................... 262 Outline...................................................................................................... 262 Function................................................................................................. 262 Structure................................................................................................ 262 Sensor........................................................................................................... 263 Ambient pressure sensor...................................................................................... 264 Charge (boost) pressure and temperature sensor............................................................... 265 Coolant temperature sensor................................................................................... 266 Ne (crankshaft) speed sensor................................................................................. 266 Bkup (camshaft) speed sensor................................................................................. 267 Common rail pressure sensor.................................................................................. 267 Exhaust manifold pressure sensor............................................................................. 268 EGR orifice temperature sensor............................................................................... 268 Variable flow turbocharger motor (with built-in position sensor)............................................. 269 EGR valve (with built-in position sensor).................................................................... 270 Mass air flow and temperature sensor......................................................................... 271 Crankcase pressure sensor.................................................................................... 271 Engine oil level sensor...................................................................................... 272 Fuel level sensor............................................................................................ 273 WIF (Water-In-Fuel detection) sensor......................................................................... 274 Coolant level sensor......................................................................................... 275 Hydraulic oil temperature sensor......................................................................... 276 Air cleaner clogging sensor.................................................................................. 276 Overload Caution sensor...................................................................................... 277 Swing proximity sensor....................................................................................... 278 Travel PPC sensor............................................................................................ 278 PPC pressure sensor.......................................................................................... 278 Park brake pressure sensor................................................................................... 279 Brake accumulator low pressure sensor.................................................................... 279 Brake stop light sensor.................................................................................. 279 PPC levers....................................................................................................... 280 LH PPC lever................................................................................................. 280 RH PPC lever................................................................................................. 281 Travel system.................................................................................................... 282 Travel circuit............................................................................................... 282 Travel Motor Performance................................................................................. 283 Auto-grease pump............................................................................................. 285 Overview................................................................................................. 286 Display and control unit................................................................................. 286 LED-display.............................................................................................. 287 Push buttons............................................................................................. 287 Three-digit LED display.................................................................................. 288 Check central lubrication system, fill up grease......................................................... 289 Lubrication diagrams............................................................................................. 290 Auto-grease pump with one-piece boom......................................................................... 290 Auto-grease pump with two-piece boom......................................................................... 291 Two point system one-piece boom.............................................................................. 292 Two point system two-piece boom.............................................................................. 293 Standard value table for engine related parts.................................................................... 296 Standard value table for chassis related parts................................................................... 297 Flow control characteristic of PC valve (STD)................................................................ 310 Items related to oil pressure................................................................................ 311 PM clinic service................................................................................................ 312 Check sheet.................................................................................................. 313 STANDARD VALUE TABLE................................................................................................. 295 TESTING AND ADJUSTING................................................................................................ 319 Measuring engine speed........................................................................................... 320 Measuring intake air pressure (boost pressure)................................................................... 321 Checking exhaust gas colour...................................................................................... 323 Measuring and adjusting valve clearance.......................................................................... 325 Testing...................................................................................................... 325 Adjusting.................................................................................................... 326 Testing compression pressure..................................................................................... 327 Testing...................................................................................................... 327 Measuring blow-by pressure....................................................................................... 331 Measuring engine oil pressure.................................................................................... 332 Handling fuel system parts....................................................................................... 333 Releasing residual pressure from fuel system..................................................................... 334 Measuring fuel pressure.......................................................................................... 335 Measuring fuel delivery, return and leakage...................................................................... 339 Bleeding air from fuel circuit................................................................................... 344 Checking fuel circuit for leakage............................................................................ 346 Checking and adjusting air conditioner compressor belt tension................................................... 347 Checking..................................................................................................... 347 Adjusting.................................................................................................... 347 Replacing the fan belt........................................................................................... 348 Measurement of clearance in swing circle bearing................................................................. 349 Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel.... 350 Measurement.................................................................................................. 350 Adjustment................................................................................................... 351 Inspection and adjustment of control circuit oil pressure........................................................ 353 Measurement.................................................................................................. 353 Procedure for pressure reducing adjustment................................................................... 354 Inspection and adjustment of pump PC (valve inlet) control oil pressure.......................................... 355 Measurement.................................................................................................. 355 Adjustment................................................................................................... 357 Inspection and adjustment of pump LS differential pressure....................................................... 358 Measurement.................................................................................................. 358 Adjustment................................................................................................... 360 Measurement of solenoid valve output pressure.................................................................... 361 Checking Proportional Control PPC Circuit.................................................................... 363 Adjustment of work equipment and swing PPC valve................................................................. 364 Measuring and adjusting quick coupler control valve output pressure.............................................. 365 Testing travel motor relief pressure............................................................................. 366 Measuring travel motor relief pressure....................................................................... 366 Testing propshaft speed.......................................................................................... 367 Measuring rotating speed of propshaft........................................................................ 367 Testing transmission clutch control circuit...................................................................... 368 Description.................................................................................................. 368 Inspection of locations of hydraulic drift of work equipment..................................................... 370 Release of remaining pressure in hydraulic circuit............................................................... 372 Measurement of oil leakage....................................................................................... 373 Air bleeding of various parts.................................................................................... 376 Inspection procedures for diode.................................................................................. 379 Special function of monitor panel................................................................................ 380 Changing the lubrication interval times.......................................................................... 447 TROUBLESHOOTING...................................................................................................... 449 Troubleshooting.................................................................................................. 449 General information on troubleshooting........................................................................... 450 Troubleshooting points....................................................................................... 450 Sequence of events in troubleshooting........................................................................ 451 1. Points to remember when handling electric equipment................................................... 454 2. Points to remember when troubleshooting electric circuits............................................. 460 3. Points to remember when handling hydraulic equipment.................................................. 461 Checks before troubleshooting................................................................................ 463 How to read electric wire code............................................................................... 464 Connector location chart and circuit diagram by system........................................................... 468 Connector table.............................................................................................. 469 Connection table for connector pin numbers....................................................................... 478 T-boxes and T-adapters table................................................................................. 514 Before carrying out troubleshooting when failure code is displayed............................................... 524 Information contained in troubleshooting table................................................................... 526 Troubleshooting by failure code (Display of code)................................................................ 528 Failure code [879AKA] – A/C inner sensor open circuit............................................................ 528 Failure code [879AKB] – A/C inner sensor short circuit........................................................... 528 Failure code [879CKA] – Ventilating sensor open circuit.......................................................... 528 Failure code [879CKB] – Ventilating sensor short circuit......................................................... 529 Failure code [879DKZ] – Sunlight sensor open or short circuit.................................................... 529 Failure code [879EMC] – Ventilation damper abnormality........................................................... 529 Failure code [879FMC] – Air mix damper abnormality............................................................... 529 Failure code [879GKX] – Refrigerant abnormality.................................................................. 529 Failure code [2G00MA] – Brake oil pressure abnormality........................................................... 530 Failure code [6B2JMA] – Travel hydraulic abnormality............................................................. 532 Failure code [989L00] – Engine controller lock caution 1......................................................... 533 Failure code [989M00] – Engine controller lock caution 2......................................................... 534 Failure code [989N00] – Engine controller lock caution 3......................................................... 535 Failure code [AA10NX] – Air cleaner clogging..................................................................... 536 Failure code [AB00KE] – Charge voltage low....................................................................... 538 Failure code [B@BAZG] – Engine oil pressure low.................................................................. 540 Failure code [B@BAZK] – Engine oil level low..................................................................... 541 Circuit diagram related to engine oil level.................................................................. 541 Failure code [B@BCNS] – Engine coolant overheat.................................................................. 542 Failure code [B@BCZK] – Engine coolant level low................................................................. 543 Circuit diagram related to radiator coolant level switch..................................................... 543 Failure code [B@HANS] – Hydraulic oil overheat................................................................... 544 Failure code [CA111] – EMC critical internal failure............................................................. 544 Failure code [CA115] – Engine neutral and backup speed sensor error.............................................. 545 Failure code [CA122] – Charge air press sensor high error........................................................ 546 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 547 Failure code [CA123] – Charge air press sensor low error......................................................... 548 Failure code [CA131] – Throttle sensor high error................................................................ 550 Circuit diagram related to fuel control dial................................................................. 551 Failure code [CA132] – Throttle sensor low error................................................................. 552 Circuit diagram related to fuel control dial................................................................. 553 Failure code [CA144] – Coolant temperature sensor high error..................................................... 554 Failure code [CA145] – Coolant temp sensor low error............................................................. 556 Circuit diagram related to coolant temperature sensor........................................................ 557 Failure code [CA153] – Charge air temperature sensor high error.................................................. 558 Failure code [CA154] – Charge air temperature sensor low error................................................... 560 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 561 Failure code [CA187] – Sensor supply 2 voltage low error......................................................... 562 Failure code [CA221] – Ambient press sensor high error........................................................... 564 Circuit diagram related to ambient pressure sensor........................................................... 565 Failure code [CA222] – Ambient press sensor low error............................................................ 566 Circuit diagram related to ambient pressure sensor........................................................... 567 Failure code [CA227] – Sensor supply 2 volt high error........................................................... 568 Failure code [CA234] – Engine overspeed.......................................................................... 569 Failure code [CA238] – NE speed sensor supply voltage error...................................................... 570 Failure code [CA239] – Ne speed sens supply volt high error...................................................... 572 Circuit diagram related to Ne speed sensor................................................................... 573 Failure code [CA271] – IMV/PCV1 short circuit error.............................................................. 574 Failure code [CA272] – IMV/PCV1 open error....................................................................... 576 Failure code [CA295] – Ambient press sens in range error......................................................... 577 Failure code [CA322] – Injector #1 (L#1) open/short circuit error................................................ 578 Circuit diagram related to no. 1 injector.................................................................... 579 Failure code [CA324] – Injector #3 (L#3) open/short circuit error................................................ 580 Circuit diagram related to no. 3 injector.................................................................... 581 Failure code [CA331] – Injector #2 (L#2) open/short circuit error................................................ 582 Circuit diagram related to no. 2 injector.................................................................... 583 Failure code [CA332] – Injector #4 (L#4) open/short circuit error................................................ 584 Circuit diagram related to no. 4 injector.................................................................... 585 Failure code [CA343] – ECM critical internal failure............................................................. 586 Failure code [CA351] – Injectors drive circuit error............................................................. 587 Failure code [CA352] – Sensor 1 supply voltage low error......................................................... 588 Failure code [CA356] – Mass air flow sensor high error........................................................... 590 Failure code [CA357] – Mass air flow sensor low error............................................................ 592 Failure code [CA386] – Sensor 1 supply voltage high error........................................................ 594 Failure code [CA428] – Water-in-fuel sensor high error........................................................... 596 Failure code [CA429] – Water-in-fuel sensor low error............................................................ 598 Failure code [CA435] – Engine oil pressure switch error.......................................................... 600 Failure code [CA441] – Battery voltage low error................................................................. 602 Failure code [CA442] – Battery voltage high error................................................................ 604 Failure code [CA449] – Common rail pressure very high error...................................................... 606 Failure code [CA451] – Rail pressure sensor high error........................................................... 608 Failure code [CA452] – Rail pressure sensor low error............................................................ 610 Failure code [CA466] – KVGT motor driver position error.......................................................... 612 Failure code [CA488] – Charge air temperature high torque derate................................................. 614 Failure code [CA515] – Rail press sens sup volt high error....................................................... 616 Failure code [CA516] – Rail press sens sup volt low error........................................................ 618 Failure code [CA553] – Common rail pressure high error........................................................... 620 Failure code [CA555] – Crankcase press high error 1.............................................................. 621 Failure code [CA556] – Crankcase press high error 2.............................................................. 622 Failure code [CA559] – Rail pressure low error................................................................... 624 Failure code [CA689] – Engine ne speed sensor error.............................................................. 626 Failure code [CA691] – Intake air temp sens high error........................................................... 628 Failure code [CA692] – Intake air temp sens low error............................................................ 630 Failure code [CA697] – ECM int temp sensor high error............................................................ 632 Failure code [CA698] – ECM int temp sensor low error............................................................. 633 Failure code [CA731] – Engine Bkup speed sensor phase error...................................................... 634 Failure code [CA778] – Engine Bkup speed sensor error............................................................ 636 Failure code [CA1117] – Persistent data lost error............................................................... 640 Failure code [CA1695] – Sensor 5 supply volt high error.......................................................... 642 Failure code [CA1696] – Sensor 5 supply volt low error........................................................... 643 Failure code [CA1843] – Crankcase press sens high error.......................................................... 644 Failure code [CA1844] – Crankcase press sens low error........................................................... 646 Failure code [CA1896] – EGR valve stuck error.................................................................... 648 Failure code [CA1942] – Crankcase press sens in range error...................................................... 650 Failure code [CA1961] – EGR motor driver IC over temp error...................................................... 651 Failure code [CA2185] – Throt sensor sup volt high error......................................................... 652 Circuit diagram related to throttle sensor................................................................... 653 Failure code [CA2186] – Throt sensor sup volt low error.......................................................... 654 Failure code [CA2249] – Rail pressure very low error............................................................. 656 Failure code [CA2272] – EGR valve pos sens low error............................................................. 658 Failure code [CA2311] – IMV solenoid error....................................................................... 660 Failure code [CA2349] – EGR valve solenoid open error............................................................ 662 Failure code [CA2353] – EGR valve solenoid short error........................................................... 664 Failure code [CA2357] – EGR valve servo error.................................................................... 666 Failure code [CA2373] – Exhaust manifold press sens high error................................................... 668 Failure code [CA2374] – Exhaust manifold press sens low error.................................................... 670 Failure code [CA2375] – EGR orifice temp sens high error......................................................... 672 Failure code [CA2376] – EGR orifice temp sens low error.......................................................... 674 Failure code [CA2554] – Exh manifold press sens in range error................................................... 676 Failure code [CA2555] – Grid heater relay volt low error......................................................... 678 Failure code [CA2556] – Grid heater relay volt high error........................................................ 680 Failure code [CA2961] – EGR orifice temperature high error 1..................................................... 682 Failure code [CA2973] – Chg air press sensor in range error...................................................... 683 Failure code [CA3419] – Mass air flow sensor sup volt high error................................................. 684 Failure code [CA3421] – Mass air flow sensor sup volt low error.................................................. 686 Failure code [CA3724] – EGR/KVGT motor driver power low error.................................................... 688 Failure code [CA3741] – Rail press valve trip error.............................................................. 690 Failure code [CA3918] – KVGT stuck error......................................................................... 691 Failure code [CA3919] – KVGT motor driver IC over temp error..................................................... 692 Failure code [CA3921] – KVGT servo error 2....................................................................... 693 Failure code [CA3922] – KVGT motor driver open error............................................................. 694 Failure code [CA3923] – KVGT motor driver short error............................................................ 696 Failure code [D110KB] – Battery relay output voltage............................................................. 698 Failure code [D161KA] – Backup alarm relay open circuit.......................................................... 700 Failure code [D161KB] – Backup alarm relay short circuit......................................................... 702 Failure code [D19JKZ] – Personal code relay abnormality.......................................................... 704 Failure code [D19QKB] – Refuel pump relay short circuit.......................................................... 706 Failure code [D1EMKA] – Parking brake relay open circuit......................................................... 708 Failure code [D1EMKB] – Parking brake relay short circuit........................................................ 710 Failure code [D811MC] – KOMTRAX error............................................................................ 712 Failure code [D862KA] – GPS antenna open circuit................................................................. 713 Failure code [D8ALKA] – System operating lamp disconnection (KOMTRAX)............................................ 714 Failure code [D8ALKB] – System operating lamp short circuit (KOMTRAX)............................................ 716 Failure code [D8AQKR] – CAN2 discon (KOMTRAX).................................................................... 718 Failure code [DA20MC] – Pump controller.......................................................................... 719 Failure code [DA22KK] – Pump solenoid power low error............................................................ 720 Failure code [DA25KP] – 5V sensor 1 power abnormality............................................................ 722 Failure code [DA26KP] – 5V sensor 2 power abnormality............................................................ 724 Failure code [DA29KQ] – Model selection abnormality.............................................................. 726 Failure code [DA2LKA] – System operating lamp disconnection (pump con)........................................... 728 Failure code [DA2LKB] – System operating lamp short circuit (pump con)........................................... 730 Failure code [DA2QKR] – CAN2 discon (pump con)................................................................... 732 Failure code [DA2RKR] – CAN1 discon (pump con)................................................................... 734 Failure code [DAB0KT] – Internal flash memory error.............................................................. 735 Failure code [DAC3KB] – Cruise control system power supply short circuit......................................... 736 Failure code [DAF0MB] – Monitor ROM abnormality.................................................................. 738 Failure code [DAF0MC] – Monitor error............................................................................ 739 Failure code [DAF8KB] – Camera power supply short circuit........................................................ 740 Failure code [DAF9KQ] – Model selection abnormality.............................................................. 742 Failure code [DAFGMC] – GPS module operation error............................................................... 743 Failure code [DAFLKA] – Operating lamp open circuit (monitor).................................................... 744 Failure code [DAFLKB] – System operating lamp short circuit (monitor)............................................ 746 Failure code [DAFQKR] – CAN2 discon (monitor).................................................................... 748 Failure code [DAZ9KQ] – A/C model selection abnormality.......................................................... 749 Failure code [DAZQKR] – CAN2 discon (AC)......................................................................... 750 Failure code [DB2QKR] – CAN2 discon (engine con)................................................................. 754 Failure code [DB2RKR] – CAN1 discon (engine con)................................................................. 758 Failure code [DDK8KA] – SUSLock forced sw open circuit........................................................... 762 Failure code [DDK8KB] – SUSLock forced sw short circuit.......................................................... 764 Failure code [DDP4KX] – Disconnection in travel PPC pressure switch.............................................. 766 Failure code [DDP6L5] – Service brake press sw abnormality....................................................... 768 Failure code [DDQ1KA] – SUSLock mode selection sw open circuit................................................... 770 Failure code [DDQ1KB] – SUSLock mode selection sw short circuit.................................................. 772 Failure code [DDWCKZ] – Direction switch abnormality............................................................. 774 Failure code [DFB1KZ] – Service lever potentio 1 abnormality..................................................... 776 Failure code [DFB2KZ] – Service lever potentio 2 abnormality..................................................... 778 Failure code [DFB3L8] – Service lever 1 potentio error........................................................... 780 Failure code [DFB4L8] – Service lever 2 potentio error........................................................... 781 Failure code [DFB5KZ] – Service lever sub potentio 1 abnormality................................................. 782 Failure code [DFB6KZ] – Service lever sub potentio 2 abnormality................................................. 784 Failure code [DGH2KB] – Hydraulic oil temperature sensor short circuit........................................... 786 Failure code [DH10KP] – 24V sensor power abnormality............................................................. 788 Failure code [DHA4KA] – Air cleaner clog sensor open circuit..................................................... 790 Failure code [DHH2MA] – Return line filter press sensor abnormally............................................... 792 Failure code [DHPAMA] – F pump press sensor abnormality.......................................................... 794 Failure code [DHS5KX] – Abnormality in travel PPC sensor......................................................... 796 Failure code [DHU1KA] – Brake accumulator press sensor open circuit.............................................. 798 Failure code [DHU1KY] – Brake accumulator press sensor hot short circuit......................................... 800 Failure code [DHUCKA] – Parking brake press sensor open circuit.................................................. 802 Failure code [DHUCKY] – Parking brake press sensor short circuit................................................. 804 Failure code [DHUGKA] – Service brake press sensor open circuit.................................................. 806 Failure code [DHUGKY] – Service brake press sensor short circuit................................................. 808 Failure code [DHX1MA] – Overload sensor abnormality (analog)..................................................... 810 Failure code [DLT4KA] – Disconnection in transmission speed sensor............................................... 812 Failure code [DR21KX] – Camera 2 picture rev. drive abnormality.................................................. 814 Failure code [DR31KX] – Camera 3 picture rev. drive abnormality.................................................. 816 Failure code [DW27KA] – Disconnection in transmission clutch solenoid............................................ 818 Failure code [DW27KB] – Short circuit in transmission clutch solenoid............................................ 820 Failure code [DW27KY] – T/M clutch sol hot short circuit......................................................... 822 Failure code [DW4AKA] – Disconnection in suspension lock solenoid................................................ 824 Failure code [DW4AKB] – Short circuit in suspension lock solenoid................................................ 826 Failure code [DW4AKY] – SUSLock sol hot short circuit............................................................ 828 Failure code [DW4CKA] – Disconnection in PPC lock solenoid....................................................... 830 Failure code [DW4CKB] – PPC lock sol. short circuit.............................................................. 832 Failure code [DW4MKA] – Disconnection in creep solenoid.......................................................... 834 Failure code [DW4MKB] – Short circuit in creep solenoid.......................................................... 835 Failure code [DW44KA] – Disconnection in travel F/R solenoid..................................................... 836 Failure code [DW44KB] – Short circuit in travel F/R solenoid..................................................... 838 Failure code [DW44KY] – Travel F/R sol hot short circuit......................................................... 840 Failure code [DW45KA] – Disconnection in swing holding brake solenoid............................................ 842 Failure code [DW45KB] – Swing holding brake solenoid short circuit............................................... 844 Failure code [DW91KA] – Disconnection in travel neutral solenoid................................................. 846 Failure code [DW91KB] – Short circuit in travel neutral solenoid................................................. 848 Failure code [DWB1KA] – Disconnection in outrigger operation solenoid............................................ 850 Failure code [DWB1KB] – Short circuit in outrigger operation solenoid............................................ 852 Failure code [DWB2KA] – Disconnection in 1st outrigger solenoid.................................................. 854 Failure code [DWB2KB] – Short circuit in 1st outrigger solenoid.................................................. 856 Failure code [DWB3KA] – Disconnection in 2nd outrigger solenoid.................................................. 858 Failure code [DWB3KB] – Short circuit in 2nd outrigger solenoid.................................................. 860 Failure code [DWB4KA] – Disconnection in 3rd outrigger solenoid.................................................. 862 Failure code [DWB4KB] – Short circuit in 3rd outrigger solenoid.................................................. 864 Failure code [DWB5KA] – Disconnection in 4th outrigger solenoid.................................................. 866 Failure code [DWB5KB] – Short circuit in 4th outrigger solenoid.................................................. 868 Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid................................................. 870 Failure code [DWK0KB] – Short circuit in 2-stage relief solenoid................................................. 871 Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid.......................................... 872 Failure code [DWK2KB] – Short circuit in 2-stage back pressure solenoid.......................................... 873 Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system.............................................. 874 Failure code [DXA8KB] – Short circuit in PC-EPC (F) solenoid..................................................... 876 Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system.................................................. 878 Failure code [DXE0KB] – Short circuit in LS-EPC solenoid......................................................... 879 Failure code [DXE7KA] – Service current EPC2 solenoid disconnection (right hand)................................. 880 Failure code [DXE7KB] – Service current EPC solenoid short (right hand).......................................... 882 Failure code [DXE8KA] – Service current EPC solenoid disconnection (left hand)................................... 884 Failure code [DXE8KB] – Service current EPC3 solenoid short (left hand).......................................... 886 Failure code [DXE9KA] – Service current EPC solenoid disconnection (right hand).................................. 888 Failure code [DXE9KB] – Service current EPC solenoid short (right hand).......................................... 890 Failure code [DXEAKA] – Service Current EPC1 open circuit (left hand)............................................ 892 Failure code [DXEAKB] – Service current EPC1 solenoid short (left hand).......................................... 894 Failure code [DXK3KA] – Travel pedal throttle EPC solenoid open circuit.......................................... 896 Failure code [DXK3KB] – Travel pedal throttle EPC solenoid short circuit......................................... 897 Failure code [DY20KA] – Wiper working abnormality................................................................ 898 Failure code [DY20MA] – Wiper parking abnormality................................................................ 900 Failure code [DY2CKA] – Window washer drive system disconnection................................................. 902 Failure code [DY2CKB] – Washer drive short circuit............................................................... 904 Failure code [DY2DKB] – Wiper drive (fwd) short circuit.......................................................... 906 Failure code [DY2EKB] – Wiper drive (rev) short circuit.......................................................... 908 Troubleshooting of central lubrication system (CLS).............................................................. 911 Trouble...................................................................................................... 911 Troubleshooting during grease pump operation................................................................. 913 Pump element................................................................................................. 914 Check power supply........................................................................................... 915 Changing the control unit.................................................................................... 915 Troubleshooting – grease system faults....................................................................... 916 Venting of the system........................................................................................ 917 TROUBLESHOOTING...................................................................................................... 519 Troubleshooting when failure code is indicated................................................................... 519 How to read this manual.......................................................................................... 922 Removal and installation of assemblies....................................................................... 922 Special tools............................................................................................ 922 Removal of parts......................................................................................... 922 Installation of parts.................................................................................... 922 Sketches of special tools................................................................................ 922 DISASSEMBLY AND ASSEMBLY............................................................................................. 919 Coating material lists........................................................................................... 923 Special tools list............................................................................................... 926 Sketches of special tools........................................................................................ 928 List of tools.................................................................................................... 929 Precautions when performing operation............................................................................ 930 Removal and installation of fuel supply pump assembly............................................................ 932 Special tools................................................................................................ 932 Removal...................................................................................................... 932 Installation................................................................................................. 934 Removal and installation of fuel injector assembly............................................................... 936 Special tools................................................................................................ 936 Removal...................................................................................................... 936 Installation................................................................................................. 938 Removal and installation of cylinder head assembly............................................................... 942 Special tools................................................................................................ 942 Removal...................................................................................................... 942 Installation................................................................................................. 949 Removal and installation of radiator assembly.................................................................... 960 Removal...................................................................................................... 960 Installation................................................................................................. 961 Removal and installation of hydraulic oil cooler assembly........................................................ 962 Special tools................................................................................................ 962 Removal...................................................................................................... 962 Installation................................................................................................. 964 Removal and installation of aftercooler assembly................................................................. 966 Removal...................................................................................................... 966 Installation................................................................................................. 967 Removal and installation of KDOC assembly........................................................................ 968 Removal...................................................................................................... 968 Installation................................................................................................. 969 Removal and installation of KCCV assembly........................................................................ 970 Removal...................................................................................................... 970 Installation................................................................................................. 970 Removal and installation of air cleaner assembly................................................................. 971 Removal...................................................................................................... 971 Installation................................................................................................. 971 Removal and installation of engine and main pump assembly........................................................ 972 Special tools................................................................................................ 972 Removal...................................................................................................... 972 Installation................................................................................................. 978 Removal and installation of front oil seal....................................................................... 980 Special tools................................................................................................ 980 Removal...................................................................................................... 980 Installation................................................................................................. 982 Removal and installation of rear oil seal........................................................................ 985 Special tools................................................................................................ 985 Removal...................................................................................................... 985 Installation................................................................................................. 985 Removal and installation of engine hood assembly................................................................. 988 Removal...................................................................................................... 988 Installation................................................................................................. 988 Removal and installation of travel motor......................................................................... 989 Removal...................................................................................................... 989 Installation................................................................................................. 989 Disassembly and assembly of travel motor assembly................................................................ 990 Disassembly.................................................................................................. 990 Assembly..................................................................................................... 992 Removal and installation of swing motor and swing machinery...................................................... 994 Removal...................................................................................................... 994 Installation................................................................................................. 995 Removal of swing motor assembly.................................................................................. 996 Removal...................................................................................................... 996 Installation................................................................................................. 997 Disassembly and assembly of swing motor and swing machinery...................................................... 998 Disassembly.................................................................................................. 998 Removal and installation of front axle assembly..................................................................1005 Removal......................................................................................................1005 Installation.................................................................................................1005 Disassembly and assembly of front axle...........................................................................1006 Disassembly of steering cylinder.............................................................................1006 Assembly of steering cylinder................................................................................1008 Disassembly of epicyclic reduction gear and brake............................................................1012 Assembly of epicylic reduction gear and brake................................................................1016 Disassembly of joint box.....................................................................................1022 Assembly of joint box........................................................................................1026 Disassembly of beam trumpet and differential unit............................................................1031 Assembly of beam trumpet and differential unit...............................................................1034 Disassembly of pinion group..................................................................................1040 Assembly of pinion group.....................................................................................1042 Toe-in adjustment............................................................................................1048 Steering angle adjustment....................................................................................1049 Removal and installation of rear axle and transmission...........................................................1050 Removal......................................................................................................1050 Installation.................................................................................................1051 Disassembly and assembly of rear axle assembly...................................................................1052 Special tools................................................................................................1052 Removal of epicyclic reduction gear and brake................................................................1052 Installation of epicylic reduction gear and brake............................................................1056 Disassembly of beam trumpet and differential unit............................................................1063 Installation of beam trumpet and differential unit...........................................................1067 Disassembly of pinion group..................................................................................1073 Installation of pinion group.................................................................................1076 Disassembly and assembly of transmission.........................................................................1082 Special tools................................................................................................1082 Removal of travel motor and flange...........................................................................1082 Installation of travel motor.................................................................................1084 Removal of transmission box..................................................................................1086 Installation of transmission box.............................................................................1094 Removal and installation of propshaft assembly...................................................................1105 Removal......................................................................................................1105 Installation.................................................................................................1105 Removal and installation of wheel................................................................................1106 Removal......................................................................................................1106 Installation.................................................................................................1106 Removal and installation of suspension lock cylinder assembly....................................................1107 Removal......................................................................................................1107 Installation.................................................................................................1107 Disassembly and assembly of suspension lock cylinders............................................................1108 Change Rod Seal..............................................................................................1108 Removal and installation of outrigger assembly...................................................................1109 Removal......................................................................................................1109 Installation.................................................................................................1109 Disassembly and assembly of outriggers...........................................................................1110 Disassembly..................................................................................................1110 Assembly.....................................................................................................1110 Removal and installation of dozer blade assembly.................................................................1111 Removal......................................................................................................1111 Installation.................................................................................................1111 Disassembly and assembly of dozer blade..........................................................................1112 Disassembly..................................................................................................1112 Assembly.....................................................................................................1112 Removal and installation of swing circle assembly................................................................1113 Removal......................................................................................................1113 Installation.................................................................................................1113 Removal and installation of revolving frame assembly.............................................................1114 Removal......................................................................................................1114 Installation.................................................................................................1116 Removal and installation of centre swivel joint..................................................................1118 Removal......................................................................................................1118 Installation.................................................................................................1119 Disassembly and assembly of centre swivel joint assembly.........................................................1120 Special tools................................................................................................1120 Disassembly..................................................................................................1120 Assembly.....................................................................................................1121 Removal and installation of fuel tank assembly...................................................................1122 Removal......................................................................................................1122 Installation.................................................................................................1123 Removal and installation of hydraulic tank assembly..............................................................1124 Removal......................................................................................................1124 Installation.................................................................................................1125 Removal and installation of control valve assembly...............................................................1126 Removal......................................................................................................1126 Installation.................................................................................................1128 Removal and installation of LS separation valve assembly.........................................................1129 Removal......................................................................................................1129 Installation.................................................................................................1129 Removal and installation of pressure compensation valve assembly.................................................1130 Removal......................................................................................................1130 Installation.................................................................................................1130 Removal and installation of main relief valve assembly...........................................................1131 Removal......................................................................................................1131 Installation.................................................................................................1131 Removal and installation of LS control EPC valve.................................................................1132 Removal......................................................................................................1132 Installation.................................................................................................1132 Removal and installation of PC EPC valve assembly................................................................1133 Removal......................................................................................................1133 Installation.................................................................................................1133 Removal and installation of PPC valve block assembly.............................................................1134 Removal......................................................................................................1134 Installation.................................................................................................1134 Removal and installation of oil seal in hydraulic pump input shaft...............................................1135 Special tools................................................................................................1135 Removal......................................................................................................1135 Installation.................................................................................................1135 Disassembly and assembly of work equipment PPC valve.............................................................1136 Assembly.....................................................................................................1136 Disassembly and assembly of hydraulic cylinder...................................................................1138 Special tools................................................................................................1138 Disassembly..............................................................................................1138 Assembly.................................................................................................1140 Removal and installation of monoboom work equipment..............................................................1144 Special tools................................................................................................1144 Removal......................................................................................................1144 Installation.................................................................................................1145 Removal and installation of 2 piece boom work equipment..........................................................1146 Special tools................................................................................................1146 Removal......................................................................................................1146 Installation.................................................................................................1147 Removal and installation of air conditioner unit.................................................................1148 Special tools................................................................................................1148 Removal......................................................................................................1148 Installation.................................................................................................1151 Removal and installation of counterweight........................................................................1152 Removal......................................................................................................1152 Installation.................................................................................................1153 Removal and installation of operator cab assembly................................................................1154 Removal......................................................................................................1154 Installation.................................................................................................1155 Removal and installation of monitor assembly.....................................................................1156 Removal......................................................................................................1156 Installation.................................................................................................1157 Removal and installation of pump controller assembly.............................................................1158 Removal......................................................................................................1158 Installation.................................................................................................1158 Removal and installation of engine controller assembly...........................................................1159 Removal......................................................................................................1159 Installation.................................................................................................1160 Removal and Installation of KOMTRAX terminal.....................................................................1161 Removal......................................................................................................1161 Installation.................................................................................................1161 Appendix.............................................................................................................1165 Table of contents................................................................................................1165 Air conditioner components.......................................................................................1166 Precautions for refrigerant..................................................................................1166 Air conditioner component....................................................................................1167 Configuration and function of refrigeration cycle............................................................1170 Outline of refrigeration cycle...............................................................................1171 Air conditioner unit.........................................................................................1173 Function.....................................................................................................1174 Functions of major components................................................................................1175 Servomotor...................................................................................................1176 Expansion valve..............................................................................................1177 Dual pressure switch.........................................................................................1179 Function.....................................................................................................1179 Air conditioner controller...................................................................................1180 Compressor...................................................................................................1181 Function.....................................................................................................1181 Air conditioner condenser....................................................................................1182 Function.....................................................................................................1182 Sunlight sensor..............................................................................................1184 Function.....................................................................................................1184 Procedure for testing and troubleshooting....................................................................1185 Circuit diagram and arrangement of connector pins............................................................1187 System diagram...............................................................................................1189 Input and output signals of the air conditioner controller...................................................1190 Function.....................................................................................................1191 Parts and connectors layout..................................................................................1192 Details......................................................................................................1193 Testing with self-diagnosis function.........................................................................1196 Testing outline..............................................................................................1196 How to open the electrical system abnormality record screen in service mode of the machine monitor...........1197 Testing vent (mode) changeover...............................................................................1199 Testing......................................................................................................1199 Testing FRESH/RECIRC air changeover..........................................................................1201 Testing......................................................................................................1201 Testing sunlight sensor......................................................................................1202 Testing......................................................................................................1202 Testing (dual) pressure switch for refrigerant...............................................................1203 Testing......................................................................................................1203 Testing relays...............................................................................................1204 Testing......................................................................................................1204 Troubleshooting chart 1......................................................................................1205 Troubleshooting chart 2......................................................................................1206 Information in troubleshooting table.........................................................................1209 Information in troubleshooting table.........................................................................1209 Failure code list related to air conditioner.................................................................1210 Failure code [879AKA] A/C Inner Sensor Open Circuit..........................................................1211 Failure code [879AKB] A/C Inner Sensor Short Circuit.........................................................1212 Failure code [879CKA] Ventilating Sensor Open Circuit........................................................1213 Failure code [879CKB] Ventilating Sensor Short Circuit.......................................................1214 Failure code [879DKZ] Sunlight sensor Open or Short Circuit..................................................1215 Circuit diagram related to sunlight sensor...................................................................1216 Failure code [879EMC] Ventilation Damper Abnormality.........................................................1217 Failure code [879FMC] Air Mix Damper Abnormality.............................................................1218 Failure code [879GKX] Refrigerant Abnormality................................................................1219 Troubleshooting for power supply system (Air conditioner does not operate)...................................1221 Circuit diagram related to blower motor system...............................................................1230 Troubleshooting with gauge pressure..........................................................................1231 Connection of service tool...................................................................................1234 Precautions for disconnecting and connecting air conditioner piping..........................................1236 Handling of compressor oil...................................................................................1238 Desiccant replacement........................................................................................1240 Tool control system..............................................................................................1243 System overview..............................................................................................1243 Operation....................................................................................................1243 System delivery condition....................................................................................1244 Adjusting and testing........................................................................................1245 Required equipment.......................................................................................1245 Software installation....................................................................................1246 Initial program start....................................................................................1248 Connect to tool control monitor/controller...............................................................1249 Analog inputs setup and calibration......................................................................1252 Tool parameters..........................................................................................1255 1st attachment pressure control..........................................................................1256 2nd attachment pressure control..........................................................................1257 1st attachment proportional switch flow control..........................................................1258 2nd attachment proportional switch flow control..........................................................1260 Additional software functionality........................................................................1262 Troubleshooting of tool control system.......................................................................1264 Software errors..........................................................................................1264 System error codes (displayed on the tool control monitor)...............................................1264 Tool control current [%] reference value table (1/2).........................................................1266 Tool control current [%] reference value table (2/2).........................................................1268 OTHER................................................................................................................1271 Hydraulic circuit diagram (1/3)..................................................................................1273 Hydraulic circuit diagram (2/3)..................................................................................1274 Hydraulic circuit diagram (3/3)..................................................................................1275 Circuit diagram (cabin 1/5)......................................................................................1276 Circuit diagram (cabin 2/5)......................................................................................1277 Circuit diagram (cabin 3/5)......................................................................................1278 Circuit diagram (cabin 4/5)......................................................................................1279 Circuit diagram (cabin 5/5)......................................................................................1280 Circuit diagram (machine 1/5)....................................................................................1281 Circuit diagram (machine 2/5)....................................................................................1282 Circuit diagram (machine 3/5)....................................................................................1283 Circuit diagram (machine 4/5)....................................................................................1284 Circuit diagram (machine 5/5)....................................................................................1285 Connector diagram 1/7............................................................................................1286 Connector table for revolving frame harness (Part 1/2).......................................................1286 Connector diagram 2/7............................................................................................1287 Connector table for revolving frame harness (Part 2/2).......................................................1287 Connector diagram 3/7............................................................................................1288 Connector table for operator‘s cab wiring harness (Part 1/2).................................................1288 Connector diagram 4/7............................................................................................1289 Connector table for operators cab wiring harness (Part 2/2)..................................................1289 Connector diagram (5/7)..........................................................................................1290 Connector table various wiring harness (Part 1/3)............................................................1290 Connector diagram (6/7)..........................................................................................1291 Connector table various wiring harness (Part 2/3)............................................................1291 Connector diagram (7/7)..........................................................................................1292 Connector table various wiring harness (Part 3/3)............................................................1292
DESCRIPTION:
KOMATSU PW160-10 SHOP MANUAL VENBM66001 – PDF DOWNLOAD
General precautions
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
S.S 28/12/24
