Komatsu PC170LC-10 Install guide
HYDRAULIC
EXCAVATOR
SEN06367-03
PC170LC-10
SERIAL NUMBERS
30001
and up
00 Index and foreword
Index
Index
(ALL-0310-001-A-00-A)
00 Index and foreword .......................................................................................................................00-1
Index .........................................................................................................................................00-2
Foreword, safety and general information ................................................................................... 00-13
Important safety notice .......................................................................................................00-13
How to read the shop manual.............................................................................................. 00-20
Explanation of terms for maintenance standard .................................................................... 00-22
Handling equipment of fuel system devices .......................................................................... 00-24
Handling of intake system parts........................................................................................... 00-25
Handling of hydraulic equipment.......................................................................................... 00-26
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-28
Handling of electrical equipment.......................................................................................... 00-31
How to read electric wire code............................................................................................. 00-39
Precautions when performing operation ............................................................................... 00-42
Practical use of KOMTRAX................................................................................................. 00-47
Standard tightening torque table.......................................................................................... 00-48
List of abbreviation ............................................................................................................. 00-54
Conversion table................................................................................................................ 00-59
01 Specification.................................................................................................................................01-1
Table of contents ........................................................................................................................01-2
Specifications.............................................................................................................................01-3
Specification drawing ...........................................................................................................01-3
Working range drawings .......................................................................................................01-4
Specifications ......................................................................................................................01-5
Weight table ........................................................................................................................01-8
Table of fuel, coolant, and lubricants ...................................................................................... 01-9
10 Structure and function ...................................................................................................................10-1
Table of contents ........................................................................................................................10-2
Engine and cooling system..........................................................................................................10-3
Engine related parts .............................................................................................................10-3
Variable flow turbocharger ....................................................................................................10-5
EGR system piping drawing..................................................................................................10-9
EGR system circuit diagram................................................................................................ 10-11
EGR valve......................................................................................................................... 10-12
EGR cooler........................................................................................................................ 10-14
KCCV layout drawing ......................................................................................................... 10-16
KCCV ventilator ................................................................................................................. 10-19
KDOC muffler .................................................................................................................... 10-21
Cooling system .................................................................................................................. 10-23
Power train............................................................................................................................... 10-25
Power train system............................................................................................................. 10-25
Swing circle ....................................................................................................................... 10-27
Swing machinery ............................................................................................................... 10-28
Final drive ......................................................................................................................... 10-30
Undercarriage and frame........................................................................................................... 10-32
Track frame and idler cushion ............................................................................................. 10-32
Hydraulic system ...................................................................................................................... 10-34
Hydraulic component layout................................................................................................ 10-34
Valve control...................................................................................................................... 10-37
Hydraulic tank.................................................................................................................... 10-39
CLSS................................................................................................................................ 10-41
Main pump ........................................................................................................................ 10-45
Control valve ..................................................................................................................... 10-71
Swing motor .................................................................................................................... 10-119
Travel motor .................................................................................................................... 10-121
PPC valve ....................................................................................................................... 10-136
Solenoid valve ................................................................................................................. 10-158
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-162
00-2 PC170LC-10
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00 Index and foreword
Index
Attachment circuit selector valve (for low pressure circuit).................................................... 10-164
Center swivel joint............................................................................................................ 10-167
Accumulator .................................................................................................................... 10-169
Work equipment ..................................................................................................................... 10-170
Work equipment............................................................................................................... 10-170
Work equipment shim....................................................................................................... 10-171
Bucket play adjustment shim............................................................................................. 10-172
Cab and its attachments.......................................................................................................... 10-173
Cab mount and cab tipping stopper ................................................................................... 10-173
ROPS cab....................................................................................................................... 10-174
Electrical system .................................................................................................................... 10-175
Electrical control system ................................................................................................... 10-175
Machine monitor system................................................................................................... 10-220
KOMTRAX system........................................................................................................... 10-242
Sensor ............................................................................................................................ 10-245
20 Standard value tables....................................................................................................................20-1
Table of contents ........................................................................................................................20-2
Standard service value table........................................................................................................20-3
Standard value table for engine.............................................................................................20-3
Standard value table for machine ..........................................................................................20-5
Standard value table for electrical system............................................................................. 20-19
30 Testing and adjusting ....................................................................................................................30-1
Table of contents ........................................................................................................................30-2
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ...............................................................................................30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Engine and cooling system..........................................................................................................30-7
Testing engine speed ...........................................................................................................30-7
Testing boost pressure .........................................................................................................30-8
Testing exhaust gas color ................................................................................................... 30-10
Testing and adjusting valve clearance.................................................................................. 30-11
Testing compression pressure............................................................................................. 30-14
Testing blowby pressure ..................................................................................................... 30-18
Testing engine oil pressure ................................................................................................. 30-19
Testing fuel pressure .......................................................................................................... 30-20
Testing fuel discharge, return and leakage............................................................................ 30-25
Bleeding air from fuel system ..............................................................................................30-30
Testing fuel circuit for leakage ............................................................................................. 30-32
Handling cylinder cutout mode operation.............................................................................. 30-33
Handling no-injection cranking operation.............................................................................. 30-34
Testing and adjusting air conditioner compressor belt tension ................................................ 30-35
Replacing fan belt .............................................................................................................. 30-36
Power train............................................................................................................................... 30-37
Testing swing circle bearing clearance ................................................................................. 30-37
Undercarriage and frame........................................................................................................... 30-38
Testing and adjusting track tension ...................................................................................... 30-38
Hydraulic system ...................................................................................................................... 30-39
Releasing remaining pressure from hydraulic circuit.............................................................. 30-39
Testing oil pressure of control circuit .................................................................................... 30-40
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-41
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-45
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-48
Testing outlet pressure of solenoid valve .............................................................................. 30-52
Testing PPC valve outlet pressure ....................................................................................... 30-55
Adjusting play of work equipment and swing PPC valves....................................................... 30-57
Testing pump swash plate sensor ........................................................................................ 30-58
Isolating the parts causing hydraulic drift in work equipment................................................... 30-59
Testing and adjusting travel deviation................................................................................... 30-61
Testing oil leakage ............................................................................................................. 30-63
PC170LC-10 00-3
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00 Index and foreword
Index
Bleeding air from hydraulic circuit ........................................................................................ 30-66
Cab and its attachments............................................................................................................ 30-68
Testing cab tipping stopper ................................................................................................. 30-68
Adjusting mirrors ................................................................................................................ 30-69
Electrical system ...................................................................................................................... 30-71
Special functions of machine monitor ................................................................................... 30-71
KOMTRAX terminal start-up procedure .............................................................................. 30-130
Adjusting rearview camera angle....................................................................................... 30-133
Handling voltage circuit of engine controller........................................................................ 30-135
Handling battery disconnect switch .................................................................................... 30-136
Testing diodes ................................................................................................................. 30-137
Pm clinic ................................................................................................................................ 30-138
Pm Clinic service ............................................................................................................. 30-138
40 Troubleshooting............................................................................................................................40-1
Table of contents ........................................................................................................................40-2
Related information on troubleshooting ......................................................................................... 40-8
Troubleshooting points .........................................................................................................40-8
Sequence of events in troubleshooting................................................................................. 40-10
Checks before troubleshooting............................................................................................ 40-12
Inspection procedure before troubleshooting ........................................................................ 40-14
Preparation work for troubleshooting of electrical system....................................................... 40-32
Classification and procedure for troubleshooting................................................................... 40-37
Symptom and troubleshooting numbers ............................................................................... 40-40
Information in troubleshooting table ..................................................................................... 40-43
Procedure for troubleshooting wiring harness of pressure sensor system for open
circuit................................................................................................................... 40-45
Connector list and layout .................................................................................................... 40-48
Connector contact identification........................................................................................... 40-58
T-branch box and T-branch adapter table ............................................................................. 40-97
Fuse location table........................................................................................................... 40-102
Failure codes table........................................................................................................... 40-104
Troubleshooting by failure code (Display of code) .......................................................................40-111
Failure code [879AKA] A/C Inner Sensor Open Circuit .........................................................40-111
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-112
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-113
Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................ 40-114
Failure code [879CKA] Ventilating Sensor Open Circuit....................................................... 40-115
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-116
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-117
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-118
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-119
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-120
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-121
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-122
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-123
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-124
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-126
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-128
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-129
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-130
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-131
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-133
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-134
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-135
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-137
Failure code [CA131] Throttle Sensor High Error................................................................. 40-139
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-141
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-143
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-145
00-4 PC170LC-10
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00 Index and foreword
Index
Failure code [CA153] Chg Air Temp Sensor High Error........................................................ 40-147
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-149
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-151
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-153
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-155
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-157
Failure code [CA234] Eng Overspeed ................................................................................ 40-158
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-159
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-160
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-161
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-163
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-165
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-166
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-168
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-170
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-172
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-174
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-175
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-176
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-178
Failure code [CA357] Mass Air Flow Sensor Low Error........................................................ 40-180
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-182
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-183
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-185
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-187
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-188
Failure code [CA442] Battery Voltage High Error................................................................. 40-190
Failure code [CA449] Rail Press Very High Error................................................................. 40-191
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-192
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-194
Failure code [CA466] KVGT Motor Driver Position Error ...................................................... 40-196
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-198
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-199
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-201
Failure code [CA553] Rail Press High Error ........................................................................ 40-203
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-204
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-205
Failure code [CA559] Rail Press Low Error......................................................................... 40-206
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-210
Failure code [CA691] Intake Air Temp Sens High Error........................................................ 40-212
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-214
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-216
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-217
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-218
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-219
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-222
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-223
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-224
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-225
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-227
Failure code [CA1896] EGR Valve Stuck Error.................................................................... 40-229
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-230
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error............................................. 40-231
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-232
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-234
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-236
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-237
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-239
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-240
PC170LC-10 00-5
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00 Index and foreword
Index
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-242
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-244
Failure code [CA2373] Exhaust Manifold Press Sens High Error .......................................... 40-245
Failure code [CA2374] Exhaust Manifold Press Sens Low Error........................................... 40-247
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-249
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-251
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-253
Failure code [CA2555] Grid Htr Relay Volt Low Error........................................................... 40-254
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-256
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-258
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-259
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-260
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-262
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error........................................ 40-264
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-266
Failure code [CA3918] KVGT Stuck Error........................................................................... 40-267
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................ 40-268
Failure code [CA3921] KVGT Servo Error 2........................................................................ 40-269
Failure code [CA3922] KVGT Motor Driver Open Error ........................................................ 40-270
Failure code [CA3923] KVGT Motor Driver Short Error ........................................................ 40-272
Failure code [D110KB] Battery Relay Drive Short Circuit...................................................... 40-274
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-276
Failure code [D811MC] KOMTRAX Error............................................................................ 40-279
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-280
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)........................ 40-281
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .......................... 40-283
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-284
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-286
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-287
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-289
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-291
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ........................ 40-293
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ........................... 40-295
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-296
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-298
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-299
Failure code [DAF0MC] Monitor Error ................................................................................ 40-300
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-301
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-303
Failure code [DAFGMC] GPS Module Error........................................................................ 40-304
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-305
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor)................................ 40-307
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-308
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-309
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-310
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-314
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-318
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-323
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit....................................... 40-325
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-327
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-329
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality........................................ 40-331
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-333
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-335
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality .................................. 40-337
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ..................................... 40-339
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ...................................... 40-341
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-343
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-345
00-6 PC170LC-10
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00 Index and foreword
Index
Failure code [DKR0MA] Pump Swash Plate Sensor Abnormality.......................................... 40-347
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-349
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ........................................ 40-351
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-352
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-354
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-356
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-358
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-361
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-363
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-365
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-367
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-369
Failure code [DWJ0KA] Merge-divider Sol Open Circuit....................................................... 40-370
Failure code [DWJ0KB] Merge-divider Sol Short Circuit....................................................... 40-371
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-372
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit...................................................... 40-374
Failure code [DXA8KA] PC-EPC Sol Open Circuit............................................................... 40-375
Failure code [DXA8KB] PC-EPC Sol Short Circuit............................................................... 40-377
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-379
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-381
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-382
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-384
Failure code [DY2CKB] Washer Drive Short Circuit............................................................. 40-386
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-388
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-390
Troubleshooting of electrical system (E-mode) .......................................................................... 40-392
E-1 Engine does not start (Engine does not crank) .............................................................. 40-392
E-2 Manual preheating system does not work..................................................................... 40-398
E-3 Automatic preheating system does not work................................................................. 40-401
E-4 While preheating is working, preheating monitor does not light up .................................. 40-403
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-405
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level
monitor lights up in yellow.................................................................................... 40-408
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level
monitor lights up in yellow.................................................................................... 40-409
E-8 Engine coolant temperature monitor lights up in red while engine is running .................... 40-410
E-9 Hydraulic oil temperature monitor lights up in red while engine is running ........................ 40-411
E-10 Charge level monitor lights up in red while engine is running ........................................ 40-412
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-413
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-414
E-13 Water separator monitor lights up in red while engine is running ................................... 40-415
E-14 Engine coolant temperature monitor lights up in red while engine is running .................. 40-416
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-417
E-16 Engine oil pressure monitor lights up in red while engine is running .............................. 40-418
E-17 Fuel gauge display does not move from minimum or maximum .................................... 40-419
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-420
E-19 Engine coolant temperature gauge display does not move from minimum or
maximum........................................................................................................... 40-421
E-20 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full
nor empty).......................................................................................................... 40-422
E-21 Hydraulic oil temperature gauge does not move from minimum or maximum ................. 40-423
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-425
E-23 Contents of display on machine monitor is different from actual machine
condition ............................................................................................................ 40-426
E-24 Some areas of machine monitor screen are not displayed............................................ 40-427
E-25 Function switch does not work................................................................................... 40-428
E-26 Automatic warm-up system does not operate (in cold season)...................................... 40-429
PC170LC-10 00-7
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00 Index and foreword
Index
E-27 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration
switch is operated ............................................................................................... 40-430
E-28 Auto-deceleration function does not operate or is not canceled while lever is
operated ............................................................................................................ 40-431
E-29 Working mode selection screen is not displayed while working mode selector switch is
operated ............................................................................................................ 40-432
E-30 Setting of engine and hydraulic pump is not changed while working mode is
changed............................................................................................................. 40-433
E-31 Travel speed monitor does not change when travel speed switch is operated ................ 40-434
E-32 Travel speed does not change while travel speed selection is changed......................... 40-435
E-33 Alarm buzzer does not stop sounding......................................................................... 40-436
E-34 Service meter is not displayed, while starting switch is in OFF position.......................... 40-437
E-35 Service mode cannot be selected .............................................................................. 40-438
E-36 Any of work equipment, swing and travel does not work............................................... 40-439
E-37 Any of work equipment, swing and travel cannot be locked .......................................... 40-441
E-38 Upper structure does not swing while swing parking brake cancel switch is set to
CANCEL position................................................................................................ 40-443
E-39 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position.............................................................................................................. 40-445
E-40 One-touch power maximizing function does not operate, or indicator is not displayed on
monitor .............................................................................................................. 40-447
E-41 One-touch power maximizing function cannot be canceled .......................................... 40-449
E-42 Alarm does not sound during travel............................................................................ 40-450
E-43 Alarm does not stop sounding while machine is stopped.............................................. 40-451
E-44 Horn does not sound ................................................................................................ 40-452
E-45 Horn does not stop sounding..................................................................................... 40-454
E-46 Wiper monitor does not light up, or does not go out, while wiper switch is
operated ............................................................................................................ 40-455
E-47 Wiper does not operate while wiper switch is operated ................................................ 40-456
E-48 Window washer does not operate while window washer switch is operated ................... 40-458
E-49 Boom LOWER is not displayed correctly with monitoring function................................. 40-459
E-50 Arm OUT is not displayed correctly with monitoring function ......................................... 40-460
E-51 Arm IN is not displayed correctly with monitoring function ............................................ 40-461
E-52 Boom RAISE is not displayed correctly with monitoring function ................................... 40-462
E-53 Bucket CURL is not displayed correctly with monitoring function................................... 40-463
E-54 Bucket DUMP is not displayed correctly with monitoring function.................................. 40-464
E-55 Swing is not displayed correctly with monitoring function.............................................. 40-465
E-56 Travel is not displayed correctly with monitoring function ............................................. 40-466
E-57 Service is not displayed correctly with monitoring function ........................................... 40-468
E-58 Attachment hydraulic circuit cannot be changed.......................................................... 40-470
E-59 KOMTRAX system does not operate normally ............................................................ 40-471
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-472
Information described in troubleshooting table (H-mode) ..................................................... 40-472
System chart of hydraulic and mechanical systems............................................................. 40-473
Failure mode and cause table ........................................................................................... 40-475
H-1 All of work equipments, swing and travel operations lack speed or power ....................... 40-483
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-485
H-3 All work equipment, swing and travel does not work ...................................................... 40-486
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-487
H-5 Fine control performance or response is poor ............................................................... 40-488
H-6 Boom speed or power is low ....................................................................................... 40-489
H-7 Arm speed or power is low.......................................................................................... 40-492
H-8 Bucket speed or power is low...................................................................................... 40-495
H-9 Work equipment does not move in single operation....................................................... 40-497
H-10 Hydraulic drift of boom is large .................................................................................. 40-498
H-11 Hydraulic drift of arm is large ..................................................................................... 40-499
H-12 Hydraulic drift of bucket is large ................................................................................. 40-500
H-13 Time lag of work equipment is large ........................................................................... 40-501
00-8 PC170LC-10
Find manuals at https://best-manuals.com
00 Index and foreword
Index
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-503
H-15 One-touch power maximizing function does not operate .............................................. 40-504
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-505
H-17 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-506
H-18 In combined operation of swing and travel, travel speed drops largely .......................... 40-507
H-19 Machine does not travel straight ................................................................................ 40-508
H-20 Travel speed is slow................................................................................................. 40-510
H-21 Machine is hard to steer or travel power is low ............................................................ 40-512
H-22 Travel speed does not change, or travel speed is too slow or fast ................................. 40-515
H-23 One of tracks does not run ........................................................................................ 40-516
H-24 Upper structure does not swing to the right or left ........................................................ 40-518
H-25 Upper structure swing only to the right or left .............................................................. 40-519
H-26 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-520
H-27 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-521
H-28 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-522
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-523
H-30 Shock is large when upper structure stops swinging.................................................... 40-524
H-31 Large unusual noise is heard when upper structure stops swinging .............................. 40-525
H-32 Swing drift on a slope is large while swing parking brake is applied............................... 40-526
H-33 Swing drift on a slope is large while swing parking brake is released............................. 40-527
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed................ 40-528
H-35 Oil flow in attachment circuit cannot be controlled ....................................................... 40-529
Troubleshooting of engine (S-mode)......................................................................................... 40-530
Information mentioned in troubleshooting table (S mode)..................................................... 40-530
S-1 Engine does not crank when starting switch is turned to START position......................... 40-531
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-532
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-533
S-4 Engine startability is poor............................................................................................ 40-534
S-5 Engine does not pick up smoothly ............................................................................... 40-536
S-6 Engine stops during operation ..................................................................................... 40-538
S-7 Engine runs rough or is unstable ................................................................................. 40-540
S-8 Engine lacks power .................................................................................................... 40-541
S-9 Exhaust smoke is black .............................................................................................. 40-543
S-10 Engine oil consumption is excessive .......................................................................... 40-545
S-11 Oil becomes contaminated quickly ............................................................................. 40-546
S-12 Fuel consumption is excessive .................................................................................. 40-547
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-548
S-14 Oil pressure drops .................................................................................................... 40-549
S-15 Fuel mixes into engine oil.......................................................................................... 40-550
S-16 Water mixes into engine oil (milky) ............................................................................. 40-551
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-552
S-18 Unusual noise is heard ............................................................................................. 40-553
S-19 Vibration is excessive ............................................................................................... 40-554
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-555
50 Disassembly and assembly ...........................................................................................................50-1
Table of contents ........................................................................................................................50-2
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual .......................................................................................................50-4
Coating materials list ............................................................................................................50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system........................................................................................................ 50-19
Removal and installation of supply pump assembly............................................................... 50-19
Removal and installation of injector assembly....................................................................... 50-23
PC170LC-10 00-9
00 Index and foreword
Index
Removal and installation of cylinder head assembly.............................................................. 50-29
Removal and installation of radiator assembly ...................................................................... 50-46
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-48
Removal and installation of aftercooler assembly.................................................................. 50-51
Removal and installation of engine and main pump assembly ................................................ 50-53
Removal and installation of engine front oil seal .................................................................... 50-60
Removal and installation of engine rear oil seal..................................................................... 50-64
Removal and installation of fuel cooler assembly .................................................................. 50-67
Removal and installation of fuel tank assembly ..................................................................... 50-69
Removal and installation of engine hood assembly ............................................................... 50-71
Removal and installation of KDOC assembly........................................................................ 50-73
Removal and installation of KCCV assembly ........................................................................ 50-75
Removal and installation of air cleaner assembly .................................................................. 50-80
Power train............................................................................................................................... 50-82
Removal and installation of travel motor and final drive assembly........................................... 50-82
Disassembly and assembly of final drive assembly ............................................................... 50-83
Removal and installation of swing motor and swing machinery assembly................................ 50-92
Disassembly and assembly of swing machinery assembly..................................................... 50-94
Removal and installation of swing circle assembly .............................................................. 50-101
Undercarriage and frame......................................................................................................... 50-102
Separation and connection of track shoe assembly............................................................. 50-102
Removal and installation of sprocket.................................................................................. 50-104
Removal and installation of idler and idler cushion assembly ............................................... 50-105
Disassembly and assembly of idler assembly ..................................................................... 50-106
Disassembly and assembly of idler cushion assembly......................................................... 50-109
Disassembly and assembly of track roller assembly .............................................................50-111
Disassembly and assembly of carrier roller assembly .......................................................... 50-113
Removal and installation of revolving frame assembly ......................................................... 50-116
Removal and installation of counterweight assembly ........................................................... 50-118
Hydraulic system .................................................................................................................... 50-120
Removal and installation of center swivel joint assembly ..................................................... 50-120
Disassembly and assembly of center swivel joint assembly ................................................. 50-123
Removal and installation of hydraulic tank assembly ........................................................... 50-124
Removal and installation of main pump assembly ............................................................... 50-128
Removal and installation of main pump input shaft oil seal ................................................... 50-131
Removal and installation of control valve assembly ............................................................. 50-132
Disassembly and assembly of control valve assembly......................................................... 50-136
Disassembly and assembly of work equipment PPC valve assembly.................................... 50-138
Disassembly and assembly of travel PPC valve assembly ................................................... 50-140
Work equipment ..................................................................................................................... 50-142
Removal and installation of work equipment assembly ........................................................ 50-142
Disassembly and assembly of work equipment cylinder assembly........................................ 50-145
Cab and its attachments.......................................................................................................... 50-151
Removal and installation of operator's cab assembly........................................................... 50-151
Removal and installation of operator cab glass (adhered glass) ........................................... 50-156
Removal and installation of front window assembly ............................................................. 50-166
Removal and installation of floor frame assembly................................................................ 50-172
Removal and installation of air conditioner unit assembly..................................................... 50-177
Removal and installation of operator's seat......................................................................... 50-181
Removal and installation of seat belt .................................................................................. 50-183
Removal and installation of front wiper assembly ................................................................ 50-185
Electrical system .................................................................................................................... 50-192
Removal and installation of air conditioner compressor assembly......................................... 50-192
Removal and installation of air conditioner condenser assembly .......................................... 50-194
Removal and installation of engine controller assembly ....................................................... 50-196
Removal and installation of pump controller assembly......................................................... 50-198
Removal and installation of machine monitor assembly ....................................................... 50-201
Removal and installation of pump swash plate sensor ......................................................... 50-203
Removal and installation of mass air flow and temperature sensor ....................................... 50-204
00-10 PC170LC-10
00 Index and foreword
Index
Removal and installation of KOMTRAX terminal assembly .................................................. 50-205
60 Maintenance standard...................................................................................................................60-1
Table of contents ........................................................................................................................60-2
Engine and cooling system..........................................................................................................60-3
Engine mount ......................................................................................................................60-3
Cooling system ....................................................................................................................60-4
Power train.................................................................................................................................60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery .................................................................................................................60-6
Final drive ...........................................................................................................................60-7
Sprocket..............................................................................................................................60-9
Undercarriage and frame........................................................................................................... 60-11
Track frame and idler cushion ............................................................................................. 60-11
Idler .................................................................................................................................. 60-13
Track roller ........................................................................................................................ 60-15
Carrier roller ...................................................................................................................... 60-16
Track shoe ........................................................................................................................ 60-17
Hydraulic system ...................................................................................................................... 60-21
Hydraulic tank.................................................................................................................... 60-21
Main pump ........................................................................................................................ 60-22
Control valve ..................................................................................................................... 60-25
Travel motor ...................................................................................................................... 60-36
Work equipment and swing PPC valve................................................................................. 60-39
Travel PPC valve ............................................................................................................... 60-42
1st-line attachment PPC valve (with EPC valve) ................................................................... 60-45
2nd-line attachment PPC valve ........................................................................................... 60-48
Solenoid valve ................................................................................................................... 60-50
Attachment circuit selector valve (for high-pressure circuit) .................................................... 60-51
Attachment circuit selector valve (for low-pressure circuit) ..................................................... 60-52
Center swivel joint.............................................................................................................. 60-53
Work equipment ....................................................................................................................... 60-54
Work equipment................................................................................................................. 60-54
Boom cylinder.................................................................................................................... 60-63
Arm cylinder ...................................................................................................................... 60-64
Bucket cylinder .................................................................................................................. 60-65
80 Appendix......................................................................................................................................80-1
Table of contents ........................................................................................................................80-2
Air conditioner components .........................................................................................................80-3
Precautions for refrigerant.....................................................................................................80-3
Air conditioner component ....................................................................................................80-4
Configuration and function of refrigeration cycle......................................................................80-7
Outline of refrigeration cycle..................................................................................................80-8
Air conditioner unit .............................................................................................................80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller .....................................................................................................80-18
Compressor....................................................................................................................... 80-19
Air conditioner condenser ...................................................................................................80-20
Sunlight sensor.................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Input and output signals of the air conditioner controller......................................................... 80-29
Parts and connectors layout................................................................................................80-31
Testing air leakage (duct).................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-41
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
PC170LC-10 00-11
00 Index and foreword
Index
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-46
Troubleshooting chart 1 ...................................................................................................... 80-47
Troubleshooting chart 2 ...................................................................................................... 80-48
Information in troubleshooting table ..................................................................................... 80-51
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-54
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-55
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-57
Failure code [879CKA] Ventilating Sensor Open Circuit......................................................... 80-59
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-60
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-61
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-63
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-64
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-65
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-66
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-68
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-71
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-73
Troubleshooting with gauge pressure................................................................................... 80-75
Connection of service tool................................................................................................... 80-78
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-80
Handling of compressor oil.................................................................................................. 80-82
Desiccant replacement ....................................................................................................... 80-84
90 Diagrams and drawings.................................................................................................................90-1
Table of contents ........................................................................................................................90-2
Hydraulic circuit diagram .............................................................................................................90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram.......................................................................................................90-7
Electric circuit diagram ................................................................................................................90-9
Symbols in electric circuit diagram.........................................................................................90-9
Electrical circuit diagram..................................................................................................... 90-13
Electric circuit diagram of air conditioner unit ........................................................................ 90-25
Index.................................................................................................................................................................... 1
00-12 PC170LC-10
00 Index and foreword
Foreword, safety and general information
Foreword, safety and general information
(ALL-0370-001-A-00-A)
Important safety notice
(ALL-1120-012-A-01-A)
(Rev. 2014/08)
•Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
•The symbol mark kis used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
Safety points
•Good arrangement
•Correct work clothes
•Observance of work standard
•Practice of making and checking signals
•Prohibition of operation and handling by
unlicensed workers
•Safety check before starting work
•Wearing protective goggles (for cleaning or
grinding work)
•Wearing shielding goggles and protectors (for
welding work)
•Good physical condition and preparation
•Precautions against work which you are not
used to or you are used to too much
General precautions
kk Inappropriate handling causes an extreme
danger. Read and understand what is
described in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.
•Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For
the locations of the safety labels and detailed
explanation of precautions, see the operation
and maintenance manual.
•Locate a place in the repair workshop to keep
the 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, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
•When performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when
hitting parts with a hammer.
2. Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
•When performing any work with 2 or more
workers, always agree on the working procedure
before starting. While working, always keep
conversations of the work between your fellow
workers and your self on any step of the work.
During the work, hang the warning tag of
"UNDER WORKING" in the operator's
compartment.
•Only qualified workers must perform the work
and operation which require license or
qualification.
•Keep the tools in good condition. And learn the
correct way to use the tools, and use the proper
ones among them. Before starting the work,
thoroughly check the tools, lift truck, service
vehicle, etc.
•If welding repairs is required, always have a
trained and experienced welder with good
knowledge of welding perform the work. When
performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
•Before starting work, warm up your body
thoroughly to start work under good condition.
•Avoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Preparation
•Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
•Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to
prevent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
•When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
•Remove all of mud and oil from the steps or
other places used to get on and off the machine
completely. Always use the handrails, ladders of
steps when getting on or off the machine. Never
PC170LC-10 00-13
00 Index and foreword
Foreword, safety and general information
jump on or off the machine. When the scaffold is
not provided, use steps or stepladder to secure
your footing.
Precautions during work
•For the machine equipped with the battery
disconnect switch, check that the system
operating lamp is turned off before starting the
work. Then, turn the battery disconnect switch to
OFF (Q) position and remove the switch key. For
the machine not equipped with the battery
disconnect switch, remove the cable from the
battery before starting the work. Be sure to
remove the negative end (-) of the battery cable
first.
•Release the remaining pressure in the circuits
completely before the work when the parts in the
circuits of oil, fuel, coolant and air are
disconnected or removed. When the cap of the
oil filter, drain plug or oil pressure pickup plug is
removed, loose them slowly to prevent the oil
from spurting out.
•When removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start
the work after the remaining pressure is
released from the fuel circuit.
•Immediately after the engine is shut down, the
coolant and oil in the circuits are hot. Be careful
not to get scalded by the hot coolant and oil.
Start the work after checking that the coolant
and oil are cooled down sufficiently.
•Start the work after the engine is shut down. Be
sure to shut down the engine when working on
or around the rotating parts in particular. When
checking the machine without shutting down the
engine (measuring oil pressure, rotational speed,
oil or coolant temperature), take extreme care
not to get caught in the rotating parts or the
working equipment.
•The hoist or crane must be used to sling the
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the
slings with ample capacity and install them to
the proper places. Operate the hoist or crane
slowly to prevent the component from hitting any
other part. Do not work with any part still raised
by the hoist or crane.
•When removing the part which is under internal
pressure or reaction force of the spring, always
leave 2 bolts in diagonal positions. Loosen those
2 bolts gradually and alternately and release the
pressure, then, remove the part.
•When removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
•When removing piping, prevent the fuel or oil
from spilling out. If any fuel or oil drips onto the
floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
fires.
•As a general rule, do not use gasoline to wash
parts. Do not use gasoline to clean the electrical
parts, in particular.
•Reinstall the parts removed to their original
places. Replace the damaged parts and the
parts which must not be used with new ones.
When installing the hoses and wiring harnesses,
be careful that they are not damaged by
contacting with other parts when the machine is
operated.
•When connecting the high pressure hoses and
tubes, make sure that they are not twisted. The
damaged high pressure hoses and tubes are
very dangerous when they are installed. So, be
extremely careful when connecting the high
pressure pipings. In addition, check that their
connections are correct.
•When assembling or installing the parts, be sure
to tighten the bolts to the specified torque. When
installing the protective parts such as guards, or
the parts which vibrate violently or rotate at high
speeds, be sure to check that they are installed
correctly.
•When aligning 2 holes, never insert your fingers
or hand into the holes. Align the holes with care
so that your fingers are not caught in the hole.
•When measuring hydraulic pressure, check that
the measuring tools are correctly installed.
•Pay attention to safety when removing and
installing the tracks of the track type machines.
When removing the track, it separates suddenly.
The workers should not stand at either end of
the track.
•If the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
Precautions for slinging work and making
signals
•Only one appointed worker must make signals
and co-worker must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at the place
where the signaler is well seen from the
operator's seat and where the signaler can see
the working condition easily. The signaler must
always stand in front of the load and guide the
operator safely.
1. Do not stand under the load.
2. Do not step on the load.
•Check the slings before starting sling work.
•Keep putting on the gloves during sling work.
(Put on the leather gloves, if available.)
00-14 PC170LC-10
00 Index and foreword
Foreword, safety and general information
•Measure the weight of the load by the eye and
check its center of gravity.
•Use the proper sling according to the weight of
the load and method of slinging. If too thick wire
ropes are used to sling a light load, the load may
slip and fall.
•Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
kSlinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
•Hanging angle must be 60 deg. or smaller as a
rule.
•When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower
than that of the hook.
aWhen slinging a load with 2 ropes or more,
the larger the hanging angle is, the larger the
tension of each rope. The figure bellow
shows the variation of allowable load in kg
when hoisting is made with 2 ropes, each of
which is allowed to sling up to 9.8 kN
{1,000kg} a load vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 2,000 kg of total weight
can be suspended. This weight is reduced to
1,000 kg when the 2 ropes make a hanging
angle of 120 deg.. If the 2 ropes sling a 2,000
kg load at a hanging angle of 150 deg., each
rope is subjected to a force as large as 4,000
kg.
•When installing wire ropes to an angular load,
apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.
•Use the specified eye bolts and fix wire ropes,
chains, etc. to them with shackles, etc.
•Apply wire ropes to the middle part of the hook.
aSlinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
The strength of the hook is maximum at its
central part.
•Do not use twisted or kinked wire ropes.
•When slinging up a load, observe the following.
1. Wind up the rope slowly until the wire rope
tensions. When putting your hands on the
wire ropes, do not grasp them but press them
down from above. If you grasp them, your
fingers may be caught.
2. After the wire ropes are stretched, stop the
crane and check the condition of the slung
load, wire ropes, and pads.
3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it
up again.
4. Do not lift up the load at an angle.
•When lowering a load, pay attention to the
following.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane
aRead the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane
kk The hoist or crane must be used to sling the
components weighing 25 kg or heavier. A
part weighing 25 kg or heavier in
"disassembly and assembly" section is
indicated with the symbol of 44.
•Before starting work, check the wire ropes,
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter
PC170LC-10 00-15
00 Index and foreword
Foreword, safety and general information
for electric shock prevention, crane collision
prevention device, and energizing warning lamp,
and check the following safety items.
•Observe the signals for sling work.
•Operate the hoist at a safe place.
•Be sure to check the directions of the direction
indication plate (north, south, east and west) and
the operating button.
•Do not sling a load at an angle. Do not move the
crane while the slung load is swinging.
•Do not raise or lower a load while the crane is
moving longitudinally or laterally.
•Do not drag a sling.
•When lifting up a load, stop it just after it leaves
the ground and check safety, and then lift it up.
•Consider the travel route in advance and lift up a
load to a safe height.
•Place the control switch in a position where it will
not be an obstacle to work and passage.
•After operating the hoist, do not swing the
control switch.
•Remember the position of the main switch so
that you can turn off the power immediately in an
emergency.
•Shut down the main switch when the hoist stops
because of a blackout. When turning on a switch
which is turned OFF by the ground fault circuit
interrupter for electric shock prevention, check
that the devices related to that switch are not in
operating condition.
•If you find an obstacle around the hoist, stop the
operation.
•After finishing the work, stop the hoist at the
specified position and raise the hook to at least 2
meters above the floor. Do not leave the sling
attached to the hook.
Selecting wire ropes
•Select adequate ropes depending on the weight
of the parts to be hoisted, referring to the table
below
Wire rope (JIS G3525, 6 x 37 - Type A)
(Standard Z twist wire ropes without galvanizing)
Nominal
diameter of rope Allowable load
mm kN ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
aThe allowable load is calculated as one sixth of
the breaking load of the rope to be used (safety
coefficient: 6).
Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit
Disconnection
kk When replacing the air conditioner unit, air
conditioner compressor, condenser or
receiver drier, etc., collect the refrigerant (air
conditioner gas: R134a) from the air
conditioner circuit before disconnecting the
air conditioner hoses.
aAsk a qualified person for collecting, adding and
filling operations of the refrigerant (air
conditioner gas: R134a). (Only registered
persons can work.)
aNever release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
kk If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.
•When loosening the nuts fixing air conditioner
hoses and tubes, be sure to use 2 wrenches;
use one wrench to fix and use the other one to
loosen the nut.
Connection
•When installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
•Check that the O-rings are fitted to the joints
when connecting the air conditioner piping.
•Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
•When removing the O-rings, use a soft tool so
that the piping is not damaged.
•Check that the O-ring is not damaged or
deteriorated.
•Apply compressor oil for refrigerant (R134a) to
the O-ring.
aHowever, do not apply oil to the threaded
part of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL
SYSTEMS
ZXL100PG (equivalent to
PAG46)
SANDEN SP-10
00-16 PC170LC-10
00 Index and foreword
Foreword, safety and general information
•When tightening nuts of the air conditioner
hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
aExample of fitting of O-ring
•An O-ring is fitted to every joint of the air
conditioner piping.
For tightening torques, see "Others",
"Precautions for disconnection and connection
of air conditioner piping".
PC170LC-10 00-17
00 Index and foreword
Foreword, safety and general information
Precautions to prevent fire
(ALL-0000-17B-K-03-A)
•Fire caused by fuel, oil, coolant or window
washer fluid
Do not bring any flame or fire close to flammable
substances such as fuel, oil, coolant or window
washer fluid.There is danger that they may catch
fire. Always observe the following.
•Do not smoke or use any flame near fuel or
other flammable substances.
•Shut down the engine before adding fuel.
•Do not leave the machine when adding fuel
or oil.
•Tighten all the fuel and oil caps securely.
•Be careful not to spill fuel on overheated
surfaces or on parts of the electrical system.
•After adding fuel or oil, wipe up any spilled
fuel or oil.
•Put greasy rags and other flammable
materials into a safe container to maintain
safety at the workplace.
•When washing parts with oil, use a non-
flammable oil. Do not use diesel oil or
gasoline.There is danger that they may catch
fire.
•Do not weld or use a cutting torch to cut any
pipes or tubes that contain flammable liquids.
•Determine well-ventilated areas for storing oil
and fuel. Keep the oil and fuel in the
specified place and do not allow
unauthorized persons to enter.
•When performing grinding or welding work
on the machine, move any flammable
materials to a safe place before starting.
99 JJ DD 00 11 77 22 00
99JJ DD 00 11 77 22 11
•Fire caused by accumulation or attachment
of flammable material
•Remove any dry leaves, chips, pieces of
paper, coal dust, or any other flammable
materials accumulated or attached to or
around the engine exhaust manifold, muffler,
or battery, or on the undercovers.
•To prevent fires from being caught, remove
any flammable materials such as dry leaves,
chips, pieces of paper, coal dust, or any
other flammable materials accumulated
around the cooling system (radiator, oil
cooler) or on the undercover.
•Fire coming from electric wiring
Short circuits in the electrical system can cause
fire. Always observe the following.
•Keep all the electric wiring connections clean
and securely tightened.
•Check the wiring every day for looseness or
damage. Reconnect any loose connectors or
refasten wiring clamps. Repair or replace any
damaged wiring.
•Fire caused by piping
Check that all the clamps for the hoses and
tubes, guards, and cushions are securely fixed
in position.
If they are loose, they may vibrate during
operation and rub against other parts. There is
danger that this may lead to damage to the
hoses and cause high-pressure oil to spurt out,
leading to fire and serious personal injury or
death.
•Fire around the machine due to highly heated
exhaust gas
Some machines are equipped with KDPF
(Komatsu Diesel Particulate Filter).
KDPF is a system for purifying soot in exhaust
gas. Its exhaust gas discharged during
purification process (regeneration) can be at
higher temperature than that from existing
models. Do not bring any flammable material
close to the outlet of the exhaust pipe.
•When there are thatched houses, dry leaves
or pieces of paper near the work site, set the
system to disable the regeneration before
starting work to prevent fire hazards due to
highly heated exhaust gas.
See the operation and maintenance manual
for the setting procedure.
•Explosion caused by lighting equipment
•When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
•When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
00-18 PC170LC-10
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