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SEN06597-14

WHEEL LOADER

WA320 -8 SERIAL NUMBERS

85001

and up

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00 Index and Foreword

WA320-8

00-1

Index

00 Index and Foreword

Index 00 Index and Foreword .................................................................................................................................. 00-1 Abbreviation List ................................................................................................................................... 00-23 Foreword, Safety, Basic Information...................................................................................................... 00-29 How to Read the Shop Manual ...................................................................................................... 00-29 Safety Notice for Operation ............................................................................................................ 00-31 Precautions to Prevent Fire............................................................................................................ 00-39 Procedures If Fire Occurs .............................................................................................................. 00-41 Precautions for Disposing of Waste Materials ................................................................................ 00-42 Procedures for Exhaust Gas Regulations....................................................................................... 00-43 Precautions for DEF....................................................................................................................... 00-44 Store DEF ...................................................................................................................................... 00-45 Precautions When You Handle Hydraulic Equipment ..................................................................... 00-46 Precautions When You Disconnect and Connect Pipings............................................................... 00-49 Precautions When You Handle Electrical Equipment ..................................................................... 00-56 Precautions When You Handle Fuel System Equipment ................................................................ 00-58 Precautions When You Handle Intake System Equipment ............................................................. 00-59 Practical Use of KOMTRAX ........................................................................................................... 00-60 Disconnect and Connect Push-Pull Type Coupler .......................................................................... 00-61 Precautions for Disconnection and Connection of Connectors ....................................................... 00-65 How to Disconnect and Connect Deutsch Connector ..................................................................... 00-69 How to Disconnect and Connect Slide Lock Type Connector ......................................................... 00-70 How to Disconnect and Connect Connector with Lock to Pull ........................................................ 00-72 How to Disconnect and Connect Connector with Lock to Push ...................................................... 00-73 How to Disconnect and Connect Connector with Housing to Rotate .............................................. 00-75 How to Read the Codes for Electric Cable ..................................................................................... 00-76 Explanation of Terms for Maintenance Standard ............................................................................ 00-80 Standard Tightening Torque Table.................................................................................................. 00-83 Conversion Table ........................................................................................................................... 00-90 01 Specifications............................................................................................................................................ 01-1 Table of Contents .................................................................................................................................... 01-2 Abbreviation List ..................................................................................................................................... 01-3 Specifications.......................................................................................................................................... 01-9 Specification Drawing....................................................................................................................... 01-9 Specifications..................................................................................................................................01-11 Weight Table .................................................................................................................................. 01-16 Table of Fuel, Coolant, and Lubricants ........................................................................................... 01-18 10 Structure and Function .............................................................................................................................. 10-1 Table of Contents .................................................................................................................................... 10-2 Abbreviation List ..................................................................................................................................... 10-6 Urea SCR System................................................................................................................................. 10-12 Layout Drawing of Urea SCR System ............................................................................................ 10-12 Urea SCR System Diagram ........................................................................................................... 10-14 Function of Urea SCR System ....................................................................................................... 10-15 Component Parts of Urea SCR System ......................................................................................... 10-32 Boot-up System .................................................................................................................................... 10-41 Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) ....................................... 10-41 Layout Drawing of Boot-up System (Machine with Gateway Function Controller) .......................... 10-43 System Operating Lamp System.................................................................................................... 10-45 Battery Disconnect Switch.............................................................................................................. 10-48 Preheating System......................................................................................................................... 10-49 Engine System...................................................................................................................................... 10-51 Layout Drawing of Engine System ................................................................................................. 10-51 Engine Control System .................................................................................................................. 10-54 Automatic Idle Stop System ........................................................................................................... 10-66 Component Parts of Engine System .............................................................................................. 10-67 Cooling System..................................................................................................................................... 10-87 00-2

WA320-8

00 Index and Foreword

Index

Layout Drawing of Cooling System ................................................................................................ 10-87 Cooling Fan Control System .......................................................................................................... 10-89 Component Parts of Cooling System ............................................................................................. 10-94 Control System ....................................................................................................................................10-107 Layout Drawing of Control System (Machine with KOMTRAX Terminal) .......................................10-107 Layout Drawing of Control System (Machine with Gateway Function Controller) ..........................10-109 Machine Monitor System............................................................................................................... 10-111 Rearview Monitor System .............................................................................................................10-114 KOMTRAX System .......................................................................................................................10-115 Component Parts of Control System .............................................................................................10-117 Hydraulic System .................................................................................................................................10-166 Layout Drawing of Hydraulic System.............................................................................................10-166 CLSS ............................................................................................................................................10-167 Component Parts of Hydraulic System..........................................................................................10-170 Power Train System .............................................................................................................................10-218 Layout Drawing of Power Train System ........................................................................................10-218 Operation of Power Train System .................................................................................................10-220 Directional Selector Switch Control Function.................................................................................10-221 HST Control System .....................................................................................................................10-223 HST Charge System .....................................................................................................................10-225 HST Pump Control System ...........................................................................................................10-226 HST Controller Gear Shift Control Function ..................................................................................10-228 Transfer Clutch Control Function...................................................................................................10-231 HST System Protection Function ..................................................................................................10-232 Maximum Speed Low Fuel Consumption Control..........................................................................10-237 Komatsu Traction Control System (KTCS) ....................................................................................10-240 Component Parts of Power Train System......................................................................................10-246 Work Equipment System......................................................................................................................10-294 Layout Drawing of Work Equipment System .................................................................................10-294 Work Equipment Control System ..................................................................................................10-296 Work Equipment Lock System ......................................................................................................10-297 Bucket Positioner System .............................................................................................................10-299 Fork Positioner System .................................................................................................................10-303 Remote Positioner System............................................................................................................10-307 ECSS ............................................................................................................................................10-310 Component Parts of Work Equipment System ..............................................................................10-312 Steering System...................................................................................................................................10-327 Layout Drawing of Steering System ..............................................................................................10-327 Steering Column ...........................................................................................................................10-328 Component Parts of Steering System ...........................................................................................10-329 Brake System.......................................................................................................................................10-342 Layout Drawing of Brake System ..................................................................................................10-342 Parking Brake Control System ......................................................................................................10-344 Component Parts of Brake System ...............................................................................................10-348 Auto-Greasing System .........................................................................................................................10-366 Layout Drawing of Auto-Greasing System.....................................................................................10-366 Specifications of Auto-Greasing System .......................................................................................10-367 Function of Auto-Greasing System................................................................................................10-369 Auto-Greasing System ..................................................................................................................10-370 Undercarriage and Frame ....................................................................................................................10-371 Frame, Axle Mount and Center Hinge Pin .....................................................................................10-371 Tires..............................................................................................................................................10-376 Work Equipment ..................................................................................................................................10-378 Structure of Work Equipment ........................................................................................................10-378 Structure of Bucket........................................................................................................................10-379 CAB Related Parts ...............................................................................................................................10-380 ROPS CAB ...................................................................................................................................10-380 CAB Mount ...................................................................................................................................10-382 WA320-8

00-3

Index

00 Index and Foreword

20 Standard Value Table ................................................................................................................................ 20-1 Table of Contents .................................................................................................................................... 20-2 Abbreviation List ..................................................................................................................................... 20-3 Standard Value Table for Engine ............................................................................................................. 20-9 Standard Value Table for Engine: WA320-8 ..................................................................................... 20-9 Standard Value Table for Machine......................................................................................................... 20-13 Standard Value Table for Machine: WA320-8 ................................................................................. 20-13 Machine Posture and Procedures to Measure Performance .......................................................... 20-26 30 Testing and Adjusting ................................................................................................................................ 30-1 Table of Contents .................................................................................................................................... 30-2 Precautions Before Work ........................................................................................................................ 30-6 Abbreviation List ..................................................................................................................................... 30-7 Related Information on Testing and Adjusting ....................................................................................... 30-13 Differences In Machine Monitor Symbols ....................................................................................... 30-13 Tools for Testing and Adjusting....................................................................................................... 30-14 Sketch of Tools for Testing and Adjusting ....................................................................................... 30-23 Engine and Cooling System .................................................................................................................. 30-24 Examine Engine Speed.................................................................................................................. 30-24 Examine Boost Pressure................................................................................................................ 30-27 Examine Exhaust Gas Temperature............................................................................................... 30-30 Examine Exhaust Gas Color .......................................................................................................... 30-32 Examine Mass Air Flow and Temperature Sensor.......................................................................... 30-36 Examine and Adjust Valve Clearance............................................................................................. 30-38 Examine Compression Pressure .................................................................................................... 30-40 Examine Blowby Pressure ............................................................................................................. 30-45 Examine Engine Oil Pressure ........................................................................................................ 30-48 Examine EGR Valve and VGT Oil Pressure ................................................................................... 30-50 Examine Fuel Pressure.................................................................................................................. 30-52 Examine Fuel Discharge, Return and Leakage .............................................................................. 30-58 Bleed Air from Fuel System............................................................................................................ 30-65 Examine Fuel Circuit for Leakage .................................................................................................. 30-67 Handle Cylinder Cut-out Mode Operation....................................................................................... 30-69 Handle No-Injection Cranking Operation ........................................................................................ 30-70 Examine KDPF, SCR and Muffler Stack for Looseness and Damage............................................. 30-71 Examine Installed Condition of Cylinder Heads and Manifolds....................................................... 30-72 Examine Engine Piping for Damage and Looseness...................................................................... 30-73 Examine and Adjust Air Conditioner Compressor Belt Tension ...................................................... 30-74 Examine Alternator Belt ................................................................................................................. 30-76 Examine Automatic Tensioner........................................................................................................ 30-78 Write Correction for Ash in Soot Accumulation to Engine Controller............................................... 30-81 Examine SCR Related Functions ................................................................................................... 30-82 Clean DEF Tank............................................................................................................................30-114 Clean DEF Pump ..........................................................................................................................30-118 Power Train..........................................................................................................................................30-124 Examine and Adjust HST Oil Pressure..........................................................................................30-124 Examine the Control Pressure of Transfer Clutch..........................................................................30-128 Examine Drive Shaft for Looseness, Backlash, and Damage........................................................30-130 Steering System...................................................................................................................................30-131 Examine Steering Wheel...............................................................................................................30-131 Examine and Adjust Steering Circuit Oil Pressure.........................................................................30-133 Bleed Air from Steering Cylinder Circuit ........................................................................................30-136 Brake System.......................................................................................................................................30-137 Release Remained Pressure in Brake Accumulator Circuit ...........................................................30-137 Examine Wheel Brake Oil Pressure ..............................................................................................30-138 Examine and Adjust Brake Accumulator Charge Pressure............................................................30-140 Bleed Air from Brake Circuit ..........................................................................................................30-142 Examine Brake Performance ........................................................................................................30-144 Examine Brake Pedal....................................................................................................................30-145 00-4

WA320-8

00 Index and Foreword

Index

Examine Pressure Decrease of Wheel Brake................................................................................30-146 Examine Wear of Wheel Brake Disc .............................................................................................30-149 Examine Parking Brake Oil Pressure ............................................................................................30-151 Examine Parking Brake Performance ...........................................................................................30-153 Release Parking Brake Manually ..................................................................................................30-154 Examine Wear Volume of Parking Brake Disc...............................................................................30-155 Hydraulic System .................................................................................................................................30-156 Release Remained Pressure from Work Equipment Circuit ..........................................................30-156 Examine and Adjust Work Equipment Oil Pressure.......................................................................30-158 Examine and Adjust Work Equipment PPC Oil Pressure...............................................................30-164 Bleed Air from Work Equipment Circuit .........................................................................................30-168 Examine Cooling Fan Speed.........................................................................................................30-170 Examine Cooling Fan Circuit Oil Pressure ....................................................................................30-171 Bleed Air from Cooling Fan Circuit ................................................................................................30-174 Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas.......... ..................................................................................................................................................30-176 Work Equipment ..................................................................................................................................30-182 Examine and Adjust Bucket Positioner..........................................................................................30-182 Examine and Adjust Boom Potentiometer Lever ...........................................................................30-184 CAB Related Parts ...............................................................................................................................30-185 Examine Directional Lever ............................................................................................................30-185 Examine Multifunction Mono-Lever ...............................................................................................30-186 Examine Accelerator Pedal ...........................................................................................................30-188 Adjust Play of Operator Seat.........................................................................................................30-190 Electrical System .................................................................................................................................30-191 Set and Adjust Each Equipment....................................................................................................30-191 Set and Operate Machine Monitor.................................................................................................30-195 How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) ...................................30-310 How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)..............................30-314 How to Start Up KOMTRAX System (Machine with Gateway Function Controller)........................30-316 How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller) ..................30-322 Adjust Rearview Camera Angle ....................................................................................................30-324 Set Region of Bluetooth® Compatible Radio .................................................................................30-326 Handle Voltage Circuit of Engine Controller ..................................................................................30-328 Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)........................................30-329 Handle Battery Disconnect Switch (Machine with Gateway Function Controller)...........................30-330 Examine Diodes............................................................................................................................30-331 Auto-Greasing Device ..........................................................................................................................30-332 Bleed the Air in Auto-Greasing System .........................................................................................30-332 Change Lubrication Time and Lubrication Interval.........................................................................30-335 Pm Clinic..............................................................................................................................................30-338 Pm Clinic Service ..........................................................................................................................30-338 40 Troubleshooting ........................................................................................................................................ 40-1 Table of Contents .................................................................................................................................... 40-2 Precautions Before Work ...................................................................................................................... 40-15 Abbreviation List ................................................................................................................................... 40-16 Related Information to Troubleshooting................................................................................................. 40-22 General Troubleshooting Points ..................................................................................................... 40-22 Troubleshooting Points for Urea SCR System................................................................................ 40-23 Sequence of Events in Troubleshooting ......................................................................................... 40-37 Checks Before Troubleshooting ..................................................................................................... 40-39 Inspection Procedure Before Troubleshooting................................................................................ 40-41 Test in Accordance with Testing Procedure .................................................................................... 40-43 Preparation for Troubleshooting of Electrical System ..................................................................... 40-65 Procedure for Troubleshooting ....................................................................................................... 40-74 Symptom and Troubleshooting Numbers ....................................................................................... 40-76 Information Shown in Troubleshooting Table.................................................................................. 40-80 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness .................. 40-82 WA320-8

00-5

Index

00 Index and Foreword

Connector List and Layout (Machine with KOMTRAX Terminal)..................................................... 40-85 Connector List and Layout (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) .......................................................................................................................................40-106 Connector List and Layout (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) .....................................................................................................................................40-127 Connector Contact Connection Table............................................................................................40-148 T-Branch Box and T-Branch Adapter Table ...................................................................................40-188 Fuse Location Table (Machine with KOMTRAX Terminal) .............................................................40-194 Fuse Location Table (Machine with Gateway Function Controller) ................................................40-197 Precautions When You Clean and Replace KDPF (KCSF and KDOC)..........................................40-200 Prepare Troubleshoot Machine Monitor ........................................................................................40-204 Procedure to Make Harness Checker on Machine Monitor LCD Unit ............................................40-206 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) ..............40-212 Failure Code Table ........................................................................................................................40-214 Troubleshooting by Failure Code (Display of Code) .............................................................................40-235 Failure Code [2F00MA] .................................................................................................................40-235 Failure Code [2F00MB] .................................................................................................................40-238 Failure Code [2G42ZG].................................................................................................................40-240 Failure Code [2G43ZG].................................................................................................................40-242 Failure Code [6091NX]..................................................................................................................40-244 Failure Code [7RHYKA] ................................................................................................................40-246 Failure Code [7RHYKB] ................................................................................................................40-248 Failure Code [7RHYKY] ................................................................................................................40-250 Failure Code [879AKA] .................................................................................................................40-252 Failure Code [879AKB] .................................................................................................................40-254 Failure Code [879BKA] .................................................................................................................40-256 Failure Code [879BKB] .................................................................................................................40-258 Failure Code [879CKA] .................................................................................................................40-260 Failure Code [879CKB] .................................................................................................................40-262 Failure Code [879DKZ] .................................................................................................................40-264 Failure Code [879EMC].................................................................................................................40-266 Failure Code [879FMC].................................................................................................................40-267 Failure Code [989FN1]..................................................................................................................40-268 Failure Code [989L00]...................................................................................................................40-269 Failure Code [989M00]..................................................................................................................40-270 Failure Code [989N00] ..................................................................................................................40-271 Failure Code [A1U0N3] .................................................................................................................40-272 Failure Code [A1U0N4] .................................................................................................................40-274 Failure Code [AA10NX].................................................................................................................40-276 Failure Code [AB00KE] .................................................................................................................40-278 Failure Code [AB00KY] .................................................................................................................40-280 Failure Code [AQ10N3].................................................................................................................40-282 Failure Code [AS00N3] .................................................................................................................40-284 Failure Code [AS00R2] .................................................................................................................40-286 Failure Code [AS00R3] .................................................................................................................40-287 Failure Code [AS00R4] .................................................................................................................40-288 Failure Code [AS00R5] .................................................................................................................40-289 Failure Code [AS00R6] .................................................................................................................40-290 Failure Code [AS00ZK] .................................................................................................................40-291 Failure Code [AS10KM] ................................................................................................................40-292 Failure Code [AS10NR].................................................................................................................40-293 Failure Code [AS10NT] .................................................................................................................40-294 Failure Code [B@BAZG]...............................................................................................................40-295 Failure Code [B@BAZK] ...............................................................................................................40-296 Failure Code [B@BCNS]...............................................................................................................40-298 Failure Code [B@BCZK] ...............................................................................................................40-299 Failure Code [B@C6NS] ...............................................................................................................40-301 Failure Code [B@CRNS] ..............................................................................................................40-303 00-6

WA320-8

00 Index and Foreword

Index

Failure Code [CA115]....................................................................................................................40-304 Failure Code [CA122]....................................................................................................................40-305 Failure Code [CA123]....................................................................................................................40-307 Failure Code [CA131]....................................................................................................................40-309 Failure Code [CA132]....................................................................................................................40-311 Failure Code [CA144]....................................................................................................................40-314 Failure Code [CA145]....................................................................................................................40-316 Failure Code [CA153]....................................................................................................................40-318 Failure Code [CA154]....................................................................................................................40-321 Failure Code [CA187]....................................................................................................................40-323 Failure Code [CA221]....................................................................................................................40-325 Failure Code [CA222]....................................................................................................................40-327 Failure Code [CA227]....................................................................................................................40-329 Failure Code [CA234]....................................................................................................................40-330 Failure Code [CA238]....................................................................................................................40-331 Failure Code [CA239]....................................................................................................................40-333 Failure Code [CA249]....................................................................................................................40-335 Failure Code [CA256]....................................................................................................................40-337 Failure Code [CA271]....................................................................................................................40-339 Failure Code [CA272]....................................................................................................................40-341 Failure Code [CA322]....................................................................................................................40-343 Failure Code [CA323]....................................................................................................................40-345 Failure Code [CA324]....................................................................................................................40-347 Failure Code [CA325]....................................................................................................................40-349 Failure Code [CA331]....................................................................................................................40-351 Failure Code [CA332]....................................................................................................................40-353 Failure Code [CA343]....................................................................................................................40-355 Failure Code [CA351]....................................................................................................................40-356 Failure Code [CA352]....................................................................................................................40-357 Failure Code [CA356]....................................................................................................................40-360 Failure Code [CA357]....................................................................................................................40-362 Failure Code [CA386]....................................................................................................................40-365 Failure Code [CA428]....................................................................................................................40-366 Failure Code [CA429]....................................................................................................................40-368 Failure Code [CA431]....................................................................................................................40-370 Failure Code [CA432]....................................................................................................................40-373 Failure Code [CA435]....................................................................................................................40-377 Failure Code [CA441]....................................................................................................................40-379 Failure Code [CA442]....................................................................................................................40-381 Failure Code [CA449]....................................................................................................................40-382 Failure Code [CA451]....................................................................................................................40-383 Failure Code [CA452]....................................................................................................................40-385 Failure Code [CA488]....................................................................................................................40-387 Failure Code [CA515]....................................................................................................................40-388 Failure Code [CA516]....................................................................................................................40-390 Failure Code [CA553]....................................................................................................................40-392 Failure Code [CA555]....................................................................................................................40-393 Failure Code [CA556]....................................................................................................................40-394 Failure Code [CA559]....................................................................................................................40-395 Failure Code [CA595]....................................................................................................................40-398 Failure Code [CA687]....................................................................................................................40-399 Failure Code [CA689]....................................................................................................................40-401 Failure Code [CA691]....................................................................................................................40-404 Failure Code [CA692]....................................................................................................................40-406 Failure Code [CA697]....................................................................................................................40-408 Failure Code [CA698]....................................................................................................................40-409 Failure Code [CA731]....................................................................................................................40-410 Failure Code [CA778]....................................................................................................................40-412 WA320-8

00-7

Index

00 Index and Foreword

Failure Code [CA1117] ..................................................................................................................40-417 Failure Code [CA1664]..................................................................................................................40-418 Failure Code [CA1669]..................................................................................................................40-420 Failure Code [CA1673]..................................................................................................................40-421 Failure Code [CA1677]..................................................................................................................40-422 Failure Code [CA1678]..................................................................................................................40-423 Failure Code [CA1682]..................................................................................................................40-424 Failure Code [CA1683]..................................................................................................................40-429 Failure Code [CA1684]..................................................................................................................40-431 Failure Code [CA1686]..................................................................................................................40-433 Failure Code [CA1691]..................................................................................................................40-434 Failure Code [CA1694]..................................................................................................................40-437 Failure Code [CA1695]..................................................................................................................40-440 Failure Code [CA1696]..................................................................................................................40-441 Failure Code [CA1712]..................................................................................................................40-443 Failure Code [CA1713]..................................................................................................................40-446 Failure Code [CA1714]..................................................................................................................40-448 Failure Code [CA1715]..................................................................................................................40-449 Failure Code [CA1776]..................................................................................................................40-450 Failure Code [CA1777]..................................................................................................................40-453 Failure Code [CA1843]..................................................................................................................40-456 Failure Code [CA1844]..................................................................................................................40-458 Failure Code [CA1879]..................................................................................................................40-461 Failure Code [CA1881]..................................................................................................................40-464 Failure Code [CA1883]..................................................................................................................40-466 Failure Code [CA1885]..................................................................................................................40-470 Failure Code [CA1887]..................................................................................................................40-472 Failure Code [CA1921]..................................................................................................................40-474 Failure Code [CA1922]..................................................................................................................40-477 Failure Code [CA1942]..................................................................................................................40-482 Failure Code [CA1993]..................................................................................................................40-483 Failure Code [CA2185]..................................................................................................................40-486 Failure Code [CA2186]..................................................................................................................40-488 Failure Code [CA2249]..................................................................................................................40-490 Failure Code [CA2271]..................................................................................................................40-491 Failure Code [CA2272]..................................................................................................................40-494 Failure Code [CA2288]..................................................................................................................40-497 Failure Code [CA2311] ..................................................................................................................40-498 Failure Code [CA2349]..................................................................................................................40-499 Failure Code [CA2353]..................................................................................................................40-502 Failure Code [CA2357]..................................................................................................................40-504 Failure Code [CA2381]..................................................................................................................40-505 Failure Code [CA2382]..................................................................................................................40-508 Failure Code [CA2383]..................................................................................................................40-511 Failure Code [CA2386]..................................................................................................................40-514 Failure Code [CA2387]..................................................................................................................40-516 Failure Code [CA2555]..................................................................................................................40-521 Failure Code [CA2556]..................................................................................................................40-524 Failure Code [CA2637]..................................................................................................................40-526 Failure Code [CA2639]..................................................................................................................40-528 Failure Code [CA2771]..................................................................................................................40-531 Failure Code [CA2777]..................................................................................................................40-537 Failure Code [CA2976]..................................................................................................................40-540 Failure Code [CA3133]..................................................................................................................40-542 Failure Code [CA3134]..................................................................................................................40-545 Failure Code [CA3135]..................................................................................................................40-547 Failure Code [CA3142]..................................................................................................................40-551 Failure Code [CA3143]..................................................................................................................40-552 00-8

WA320-8

00 Index and Foreword

Index

Failure Code [CA3144]..................................................................................................................40-553 Failure Code [CA3146]..................................................................................................................40-555 Failure Code [CA3147]..................................................................................................................40-556 Failure Code [CA3148]..................................................................................................................40-557 Failure Code [CA3151]..................................................................................................................40-559 Failure Code [CA3165]..................................................................................................................40-565 Failure Code [CA3229]..................................................................................................................40-567 Failure Code [CA3231]..................................................................................................................40-569 Failure Code [CA3232]..................................................................................................................40-571 Failure Code [CA3235]..................................................................................................................40-575 Failure Code [CA3239]..................................................................................................................40-577 Failure Code [CA3241]..................................................................................................................40-580 Failure Code [CA3242]..................................................................................................................40-583 Failure Code [CA3251]..................................................................................................................40-586 Failure Code [CA3253]..................................................................................................................40-588 Failure Code [CA3254]..................................................................................................................40-591 Failure Code [CA3255]..................................................................................................................40-594 Failure Code [CA3256]..................................................................................................................40-598 Failure Code [CA3311] ..................................................................................................................40-600 Failure Code [CA3312]..................................................................................................................40-602 Failure Code [CA3313]..................................................................................................................40-605 Failure Code [CA3314]..................................................................................................................40-606 Failure Code [CA3315]..................................................................................................................40-607 Failure Code [CA3316]..................................................................................................................40-610 Failure Code [CA3317]..................................................................................................................40-611 Failure Code [CA3318]..................................................................................................................40-612 Failure Code [CA3319]..................................................................................................................40-615 Failure Code [CA3321]..................................................................................................................40-616 Failure Code [CA3322]..................................................................................................................40-618 Failure Code [CA3419]..................................................................................................................40-621 Failure Code [CA3421]..................................................................................................................40-623 Failure Code [CA3497]..................................................................................................................40-625 Failure Code [CA3498]..................................................................................................................40-626 Failure Code [CA3543]..................................................................................................................40-627 Failure Code [CA3545]..................................................................................................................40-634 Failure Code [CA3547]..................................................................................................................40-636 Failure Code [CA3558]..................................................................................................................40-637 Failure Code [CA3559]..................................................................................................................40-639 Failure Code [CA3562]..................................................................................................................40-641 Failure Code [CA3563]..................................................................................................................40-643 Failure Code [CA3567]..................................................................................................................40-646 Failure Code [CA3568]..................................................................................................................40-649 Failure Code [CA3571]..................................................................................................................40-655 Failure Code [CA3572]..................................................................................................................40-657 Failure Code [CA3574]..................................................................................................................40-659 Failure Code [CA3575]..................................................................................................................40-662 Failure Code [CA3577]..................................................................................................................40-664 Failure Code [CA3578]..................................................................................................................40-666 Failure Code [CA3582]..................................................................................................................40-668 Failure Code [CA3583]..................................................................................................................40-676 Failure Code [CA3596]..................................................................................................................40-678 Failure Code [CA3649]..................................................................................................................40-681 Failure Code [CA3681]..................................................................................................................40-683 Failure Code [CA3682]..................................................................................................................40-688 Failure Code [CA3713]..................................................................................................................40-694 Failure Code [CA3717]..................................................................................................................40-697 Failure Code [CA3718]..................................................................................................................40-698 Failure Code [CA3725]..................................................................................................................40-699 WA320-8

00-9

Index

00 Index and Foreword

Failure Code [CA3741]..................................................................................................................40-702 Failure Code [CA3748]..................................................................................................................40-703 Failure Code [CA3751]..................................................................................................................40-706 Failure Code [CA3755]..................................................................................................................40-708 Failure Code [CA3866]..................................................................................................................40-710 Failure Code [CA3867]..................................................................................................................40-714 Failure Code [CA3868]..................................................................................................................40-717 Failure Code [CA3899]..................................................................................................................40-721 Failure Code [CA3911] ..................................................................................................................40-723 Failure Code [CA3912]..................................................................................................................40-727 Failure Code [CA3932]..................................................................................................................40-729 Failure Code [CA3933]..................................................................................................................40-731 Failure Code [CA3934]..................................................................................................................40-733 Failure Code [CA3935]..................................................................................................................40-736 Failure Code [CA3936]..................................................................................................................40-738 Failure Code [CA4151]..................................................................................................................40-740 Failure Code [CA4152]..................................................................................................................40-744 Failure Code [CA4155]..................................................................................................................40-748 Failure Code [CA4156]..................................................................................................................40-750 Failure Code [CA4157]..................................................................................................................40-753 Failure Code [CA4158]..................................................................................................................40-755 Failure Code [CA4159]..................................................................................................................40-756 Failure Code [CA4161]..................................................................................................................40-757 Failure Code [CA4162]..................................................................................................................40-760 Failure Code [CA4163]..................................................................................................................40-763 Failure Code [CA4164]..................................................................................................................40-765 Failure Code [CA4165]..................................................................................................................40-767 Failure Code [CA4166]..................................................................................................................40-769 Failure Code [CA4168]..................................................................................................................40-771 Failure Code [CA4169]..................................................................................................................40-774 Failure Code [CA4171]..................................................................................................................40-776 Failure Code [CA4249]..................................................................................................................40-779 Failure Code [CA4251]..................................................................................................................40-781 Failure Code [CA4259]..................................................................................................................40-783 Failure Code [CA4261]..................................................................................................................40-786 Failure Code [CA4277]..................................................................................................................40-789 Failure Code [CA4281]..................................................................................................................40-793 Failure Code [CA4459]..................................................................................................................40-796 Failure Code [CA4461]..................................................................................................................40-798 Failure Code [CA4658]..................................................................................................................40-801 Failure Code [CA4731]..................................................................................................................40-805 Failure Code [CA4732]..................................................................................................................40-806 Failure Code [CA4739]..................................................................................................................40-807 Failure Code [CA4768]..................................................................................................................40-808 Failure Code [CA4769]..................................................................................................................40-810 Failure Code [CA4842]..................................................................................................................40-812 Failure Code [CA4952] (Machine with KOMTRAX Terminal) .........................................................40-816 Failure Code [CA4952] (Machine with Gateway Function Controller) ............................................40-818 Failure Code [CA5115] ..................................................................................................................40-820 Failure Code [CA5179]..................................................................................................................40-823 Failure Code [CA5181]..................................................................................................................40-825 Failure Code [CA5383]..................................................................................................................40-827 Failure Code [D103KA] .................................................................................................................40-829 Failure Code [D103KB] .................................................................................................................40-831 Failure Code [D103KY] .................................................................................................................40-833 Failure Code [D103MC] ................................................................................................................40-835 Failure Code [D104KA] .................................................................................................................40-837 Failure Code [D104KB] .................................................................................................................40-839 00-10

WA320-8

00 Index and Foreword

Index

Failure Code [D104KY] .................................................................................................................40-841 Failure Code [D104MC] ................................................................................................................40-843 Failure Code [D110L4] ..................................................................................................................40-845 Failure Code [D160KA] .................................................................................................................40-847 Failure Code [D160KY] .................................................................................................................40-849 Failure Code [D191KA] .................................................................................................................40-850 Failure Code [D191KB] .................................................................................................................40-852 Failure Code [D191KY] .................................................................................................................40-854 Failure Code [D192KA] .................................................................................................................40-855 Failure Code [D192KB] .................................................................................................................40-856 Failure Code [D192KY] .................................................................................................................40-857 Failure Code [D19JKZ]..................................................................................................................40-858 Failure Code [D1B0KA].................................................................................................................40-860 Failure Code [D1B0KB].................................................................................................................40-862 Failure Code [D1B0KY].................................................................................................................40-864 Failure Code [D1B0MC] ................................................................................................................40-866 Failure Code [D1E6KA].................................................................................................................40-868 Failure Code [D1E6KB].................................................................................................................40-870 Failure Code [D1E6KY].................................................................................................................40-872 Failure Code [D5ZHKA] ................................................................................................................40-874 Failure Code [D5ZHKB] ................................................................................................................40-876 Failure Code [D5ZHL6] .................................................................................................................40-878 Failure Code [D811MC] (Machine with KOMTRAX Terminal) ........................................................40-879 Failure Code [D811MC] (Machine with Gateway Function Controller) ...........................................40-880 Failure Code [D862KA] (Machine with KOMTRAX Terminal).........................................................40-881 Failure Code [D862KA] (Machine with Gateway Function Controller)............................................40-882 Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) ........................................................40-883 Failure Code [D8ALKA] (Machine with Gateway Function Controller) ...........................................40-885 Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) ........................................................40-887 Failure Code [D8ALKB] (Machine with Gateway Function Controller) ...........................................40-889 Failure Code [D8AQK4] (Machine with KOMTRAX Terminal)........................................................40-891 Failure Code [D8AQK4] (Machine with Gateway Function Controller)...........................................40-895 Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) .......................................................40-899 Failure Code [D8AQKR] (Machine with Gateway Function Controller) ..........................................40-903 Failure Code [D8G1KT].................................................................................................................40-907 Failure Code [D8G6KT].................................................................................................................40-908 Failure Code [DAF0KT].................................................................................................................40-909 Failure Code [DAF0MB] ................................................................................................................40-910 Failure Code [DAF0MC] ................................................................................................................40-911 Failure Code [DAF3KK].................................................................................................................40-912 Failure Code [DAF8KB].................................................................................................................40-914 Failure Code [DAFDKB] ................................................................................................................40-915 Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) ......................................................40-917 Failure Code [DAFGMC] (Machine with Gateway Function Controller) .........................................40-918 Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) ........................................................40-919 Failure Code [DAFLKA] (Machine with Gateway Function Controller) ...........................................40-921 Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) ........................................................40-923 Failure Code [DAFLKB] (Machine with Gateway Function Controller) ...........................................40-925 Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) .......................................................40-927 Failure Code [DAFQKR] (Machine with Gateway Function Controller) ..........................................40-932 Failure Code [DAJ0KK] .................................................................................................................40-937 Failure Code [DAJ0KT] .................................................................................................................40-940 Failure Code [DAJ0MC] ................................................................................................................40-941 Failure Code [DAJ1KA] .................................................................................................................40-942 Failure Code [DAJ2KK] .................................................................................................................40-944 Failure Code [DAJ2KT] .................................................................................................................40-947 Failure Code [DAJ4KB] .................................................................................................................40-950 Failure Code [DAJ4KZ] .................................................................................................................40-952 WA320-8

00-11

Index

00 Index and Foreword

Failure Code [DAJ5KX] (Applicable Machine: 85001 to 87648).....................................................40-954 Failure Code [DAJ5KX] (Applicable Machine: 87649 and Up) .......................................................40-956 Failure Code [DAJ6KX] (Applicable Machine: 85001 to 87648).....................................................40-958 Failure Code [DAJ6KX] (Applicable Machine: 87649 and Up) .......................................................40-960 Failure Code [DAJ9KQ].................................................................................................................40-962 Failure Code [DAJLKA] (Machine with KOMTRAX Terminal) ........................................................40-963 Failure Code [DAJLKA] (Machine with Gateway Function Controller) ...........................................40-965 Failure Code [DAJLKB] (Machine with KOMTRAX Terminal) ........................................................40-967 Failure Code [DAJLKB] (Machine with Gateway Function Controller) ...........................................40-969 Failure Code [DAJQKR] (Machine with KOMTRAX Terminal) .......................................................40-971 Failure Code [DAJQKR] (Machine with Gateway Function Controller) ..........................................40-976 Failure Code [DAJRKR] ................................................................................................................40-981 Failure Code [DAJRMA] ................................................................................................................40-986 Failure Code [DAZ9KQ] ................................................................................................................40-987 Failure Code [DAZQKR] (Machine with KOMTRAX Terminal) .......................................................40-988 Failure Code [DAZQKR] (Machine with Gateway Function Controller) ..........................................40-992 Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) .......................................................40-996 Failure Code [DB2QKR] (Machine with Gateway Function Controller) ........................................40-1002 Failure Code [DB2RKR] ..............................................................................................................40-1008 Failure Code [DD1ALD] ..............................................................................................................40-1013 Failure Code [DDAAL6]...............................................................................................................40-1015 Failure Code [DDB2L4] ...............................................................................................................40-1017 Failure Code [DDB6L4] ...............................................................................................................40-1019 Failure Code [DDD7KA] ..............................................................................................................40-1021 Failure Code [DDD7KY] ..............................................................................................................40-1023 Failure Code [DDK3KA] ..............................................................................................................40-1025 Failure Code [DDK3KB] ..............................................................................................................40-1028 Failure Code [DDK6KA] ..............................................................................................................40-1031 Failure Code [DDK6KB] ..............................................................................................................40-1034 Failure Code [DDNRLD] (Applicable Machine: 85001 to 87648) .................................................40-1037 Failure Code [DDNRLD] (Applicable Machine: 87649 and Up)....................................................40-1039 Failure Code [DF10KA] ...............................................................................................................40-1041 Failure Code [DF10KB] ...............................................................................................................40-1044 Failure Code [DGH1KX] ..............................................................................................................40-1047 Failure Code [DGR2KB] ..............................................................................................................40-1049 Failure Code [DGR2KZ] ..............................................................................................................40-1051 Failure Code [DHA4KA] ..............................................................................................................40-1053 Failure Code [DHHBKA]..............................................................................................................40-1055 Failure Code [DHHBKY]..............................................................................................................40-1057 Failure Code [DHHCKA] .............................................................................................................40-1059 Failure Code [DHHCKY] .............................................................................................................40-1061 Failure Code [DHPCKA]..............................................................................................................40-1063 Failure Code [DHPCKY]..............................................................................................................40-1065 Failure Code [DHPEKA] ..............................................................................................................40-1067 Failure Code [DHPEKY] ..............................................................................................................40-1069 Failure Code [DHS8KA] ..............................................................................................................40-1071 Failure Code [DHS8KY] ..............................................................................................................40-1073 Failure Code [DHS9KA] ..............................................................................................................40-1075 Failure Code [DHS9KY] ..............................................................................................................40-1077 Failure Code [DHSDKA]..............................................................................................................40-1079 Failure Code [DHSDKY]..............................................................................................................40-1081 Failure Code [DHSNKA]..............................................................................................................40-1083 Failure Code [DHSNKY]..............................................................................................................40-1085 Failure Code [DHT8ZG] ..............................................................................................................40-1087 Failure Code [DHTCL6]...............................................................................................................40-1088 Failure Code [DJF1KA] ...............................................................................................................40-1090 Failure Code [DK55KA]...............................................................................................................40-1091 Failure Code [DK55KY]...............................................................................................................40-1093 00-12

WA320-8

00 Index and Foreword

Index

Failure Code [DK55L5]................................................................................................................40-1095 Failure Code [DK5DKA] (Applicable Machine: 85001 to 87648) ..................................................40-1096 Failure Code [DK5DKA] (Applicable Machine: 87649 and Up) ....................................................40-1099 Failure Code [DK5DKY] (Applicable Machine: 85001 to 87648) ..................................................40-1102 Failure Code [DK5DKY] (Applicable Machine: 87649 and Up) ....................................................40-1105 Failure Code [DK5DL8] (Applicable Machine: 85001 to 87648)...................................................40-1108 Failure Code [DK5DL8] (Applicable Machine: 87649 and Up) ..................................................... 40-1112 Failure Code [DK5EKA] (Applicable Machine: 85001 to 87648) .................................................. 40-1116 Failure Code [DK5EKA] (Applicable Machine: 87649 and Up) .................................................... 40-1119 Failure Code [DK5EKY] (Applicable Machine: 85001 to 87648) ..................................................40-1122 Failure Code [DK5EKY] (Applicable Machine: 87649 and Up) ....................................................40-1125 Failure Code [DK70KA]...............................................................................................................40-1128 Failure Code [DK70KY]...............................................................................................................40-1130 Failure Code [DKA0KA] ..............................................................................................................40-1132 Failure Code [DKA0KY] ..............................................................................................................40-1135 Failure Code [DKA0L0] ...............................................................................................................40-1137 Failure Code [DLM3KA] ..............................................................................................................40-1139 Failure Code [DLM3LC] ..............................................................................................................40-1140 Failure Code [DLT3KX] (Applicable Machine: 85001 to 87648) ...................................................40-1142 Failure Code [DLT3KX] (Applicable Machine: 87649 and Up) .....................................................40-1144 Failure Code [DLT4KX] (Applicable Machine: 85001 to 87648) ...................................................40-1146 Failure Code [DLT4L0] ................................................................................................................40-1148 Failure Code [DLT4LC] (Applicable Machine: 85001 to 87648) ...................................................40-1149 Failure Code [DLT4LC] (Applicable Machine: 87649 and Up) .....................................................40-1151 Failure Code [DPQ1KR] ..............................................................................................................40-1153 Failure Code [DPQ2KR] ..............................................................................................................40-1156 Failure Code [DPQ3KR] ..............................................................................................................40-1159 Failure Code [DSJ0KR] (Machine with KOMTRAX Terminal) ......................................................40-1163 Failure Code [DSJ0KR] (Machine with Gateway Function Controller) .........................................40-1168 Failure Code [DT22KB] (Applicable Machine: 85001 to 87648)...................................................40-1173 Failure Code [DT22KB] (Applicable Machine: 87649 and Up) .....................................................40-1175 Failure Code [DV00KB]...............................................................................................................40-1177 Failure Code [DW26KA] ..............................................................................................................40-1178 Failure Code [DW26KB] ..............................................................................................................40-1180 Failure Code [DW26KY] ..............................................................................................................40-1182 Failure Code [DW4BKA] (Applicable Machine: 85001 to 87648) .................................................40-1184 Failure Code [DW4BKA] (Applicable Machine: 87649 and Up) ...................................................40-1186 Failure Code [DW4BKB] (Applicable Machine: 85001 to 87648) .................................................40-1188 Failure Code [DW4BKB] (Applicable Machine: 87649 and Up) ...................................................40-1190 Failure Code [DW4BKY] (Applicable Machine: 85001 to 87648) .................................................40-1192 Failure Code [DW4BKY] (Applicable Machine: 87649 and Up) ...................................................40-1193 Failure Code [DW4RKA] .............................................................................................................40-1195 Failure Code [DW4RKB] .............................................................................................................40-1197 Failure Code [DW4RKY] .............................................................................................................40-1199 Failure Code [DWM1KA] (Applicable Machine: 85001 to 87648) ................................................40-1201 Failure Code [DWM1KA] (Applicable Machine: 87649 and Up)...................................................40-1202 Failure Code [DWM1KB] (Applicable Machine: 85001 to 87648) ................................................40-1204 Failure Code [DWM1KB] (Applicable Machine: 87649 and Up)...................................................40-1206 Failure Code [DWM1KY] (Applicable Machine: 85001 to 87648) ................................................40-1208 Failure Code [DWM1KY] (Applicable Machine: 87649 and Up)...................................................40-1209 Failure Code [DWN6KA] .............................................................................................................40-1211 Failure Code [DWN6KB] .............................................................................................................40-1213 Failure Code [DWN6KY] .............................................................................................................40-1215 Failure Code [DWN8KA] .............................................................................................................40-1216 Failure Code [DWN8KB] .............................................................................................................40-1217 Failure Code [DWN8KY] .............................................................................................................40-1218 Failure Code [DX19KA]...............................................................................................................40-1219 Failure Code [DX19KB]...............................................................................................................40-1221 WA320-8

00-13

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Index

00 Index and Foreword

Failure Code [DX19KY]...............................................................................................................40-1223 Failure Code [DX20KA]...............................................................................................................40-1225 Failure Code [DX20KB]...............................................................................................................40-1227 Failure Code [DX20KY]...............................................................................................................40-1229 Failure Code [DXAWKA] .............................................................................................................40-1230 Failure Code [DXAWKB] .............................................................................................................40-1233 Failure Code [DXAWKY] .............................................................................................................40-1236 Failure Code [DXH7KA] ..............................................................................................................40-1239 Failure Code [DXH7KB] ..............................................................................................................40-1241 Failure Code [DXH7KY] ..............................................................................................................40-1243 Failure Code [DXH8KA] ..............................................................................................................40-1245 Failure Code [DXH8KB] ..............................................................................................................40-1247 Failure Code [DXH8KY] ..............................................................................................................40-1249 Failure Code [DXHJKA] ..............................................................................................................40-1251 Failure Code [DXHJKB] ..............................................................................................................40-1253 Failure Code [DXHJKY] ..............................................................................................................40-1255 Failure Code [DXHKKA] ..............................................................................................................40-1256 Failure Code [DXHKKB] ..............................................................................................................40-1258 Failure Code [DXHKKY] ..............................................................................................................40-1260 Failure Code [F313KA]................................................................................................................40-1261 Failure Code [F313KB]................................................................................................................40-1263 Failure Code [F314KA]................................................................................................................40-1264 Failure Code [F314KB]................................................................................................................40-1266 Failure Code [F315KB]................................................................................................................40-1268 Failure Code [F315KY]................................................................................................................40-1270 Failure Code [F316KB]................................................................................................................40-1272 Failure Code [F316KY]................................................................................................................40-1274 Failure Code [F318KB]................................................................................................................40-1276 Failure Code [F318KY]................................................................................................................40-1278 Failure Code [F31AKB] ...............................................................................................................40-1279 Failure Code [F31AKY] ...............................................................................................................40-1281 Failure Code [F31BKB] ...............................................................................................................40-1283 Failure Code [F31BKY] ...............................................................................................................40-1285 Failure Code [F31CKB] ...............................................................................................................40-1287 Failure Code [F31CKY] ...............................................................................................................40-1289 Failure Code [F31DKB] ...............................................................................................................40-1291 Failure Code [F31DKY] ...............................................................................................................40-1293 Failure Code [F31EKB] ...............................................................................................................40-1295 Failure Code [F31EKY] ...............................................................................................................40-1297 Failure Code [FS10ZE] ...............................................................................................................40-1299 Failure Code [H2K0KA]...............................................................................................................40-1300 Failure Code [H2K0KY]...............................................................................................................40-1302 Failure Code [J141N1] ................................................................................................................40-1304 Failure Code [LA00L3] ................................................................................................................40-1305 Failure Code [M100N1] ...............................................................................................................40-1306 Failure Code [M400N1] ...............................................................................................................40-1307 Troubleshooting of Electrical System (E-Mode)..................................................................................40-1308 E-1 Engine Does Not Start (Engine Does Not Crank)..................................................................40-1308 E-2 Manual Preheating System Does Not Operate .....................................................................40-1316 E-3 Automatic Preheating System Does Not Operate .................................................................40-1319 E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On ...........................40-1322 E-5 The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing...................40-1324 E-6 LCD Unit on Machine Monitor Shows Nothing ......................................................................40-1327 E-7 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) ......40-1329 E-8 LCD Screen on Machine Monitor Does Not Show Correctly .................................................40-1331 E-9 Meter Unit Display on Machine Monitor is Abnormal.............................................................40-1333 E-10 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal ......................................40-1336 E-11 LED Unit Lamp on Machine Monitor is Abnormal................................................................40-1339 00-14

WA320-8

00 Index and Foreword

Index

E-12 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly ..................................................................................................................................40-1341 E-13 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate ..............40-1344 E-14 Switch Panel Buzzer of Machine Monitor is Abnormal ........................................................40-1347 E-15 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally 40-1350 E-16 DEF Level is Not Shown Correctly......................................................................................40-1351 E-17 Rearview Monitor Does Not Come On or Backlight Flickers ...............................................40-1354 E-18 Rearview Monitor Images are Not Shown Clearly...............................................................40-1357 E-19 Rearview Monitor Brightness Cannot be Adjusted ..............................................................40-1361 E-20 Night Mode Lamp of Rearview Monitor is Abnormal ...........................................................40-1365 E-21 Air Cleaner Clogging Indicator Lamp Does Not Come On ..................................................40-1367 E-22 Radiator Coolant Level Caution Lamp Does Not Come On ................................................40-1369 E-23 Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position ..........................................................................................................................................40-1370 E-24 Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low ..............................................................................................................................40-1374 E-25 Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low ..............................................................................................................................40-1375 E-26 Indication of HST Oil Temperature Gauge Does Not Increase, or HST Oil Temperature Caution Lamp Does Not Come On .......................................................................................................40-1376 E-27 When the Inching Pedal is Pushed, Inching Function Does Not Work or While the Pedal is Not Pushed, Inching Function Operates.........................................................................................40-1377 E-28 Fuel Gauge Does Not Show Normally ................................................................................40-1379 E-29 Seatbelt Caution Lamp Does Not Show Normally...............................................................40-1381 E-30 Alarm Buzzer Does Not Operate ........................................................................................40-1382 E-31 Alarm Buzzer Does Not Stop ..............................................................................................40-1383 E-32 When the Emergency HST Pump Drive Switch is Operated, It Does Not Work or When the Emergency HST Pump Drive Switch is Not Operated, It Works .......................................................40-1384 E-33 Setting Does Not Change While You Operate the Traction Control Switch .........................40-1387 E-34 The Remote Positioner Does Not Work or Cannot be Released .........................................40-1389 E-35 The Bucket Positioner Does Not Work or Cannot be Released ..........................................40-1391 E-36 Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released..................................................................................40-1394 E-37 Directional Selector (FNR) Switch Mode is Not Selected or Not Released..........................40-1398 E-38 PZ Auto Tilt-in Does Not Work ............................................................................................40-1400 E-39 Traction Level Does Not Show MAX When Max. Traction Switch is Turned on...................40-1407 E-40 ECSS Function Cannot be Selected or Cannot be Released..............................................40-1409 E-41 Horn Does Not Sound.........................................................................................................40-1414 E-42 Horn Does Not Stop ...........................................................................................................40-1417 E-43 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On ...........................................40-1419 E-44 Clearance Lamp and Tail Lamp Do Not Come On or Go Out..............................................40-1421 E-45 Clearance Lamp and Tail Lamp Do Not Come on or Go Out (For European Union) ...........40-1425 E-46 High and Low Beams of Headlamp Do Not Come On or Go Out ........................................40-1429 E-47 High and Low Beams of Headlamp Do Not Come On or Go Out (EU Specification)...........40-1433 E-48 Low Beam of Headlamp Does Not Come On or Go Out .....................................................40-1437 E-49 Low Beam of Headlamp Does Not Come On or Go Out (For European Union) ..................40-1439 E-50 High Beam of Headlamp Does Not Come On or Go Out ....................................................40-1441 E-51 High Beam of Headlamp Does Not Come On or Go Out (For European Union) .................40-1443 E-52 Front Working Lamp Does Not Come On or Go Out ...........................................................40-1445 E-53 Rear Working Lamp Does Not Come On or Go Out............................................................40-1450 E-54 Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out......................................40-1454 E-55 Turn Signal Lamp Does Not Come On or Go Out ...............................................................40-1457 E-56 Turn Signal Lamps Do Not Come On or Go Out (For European Union) ..............................40-1460 E-57 Hazard Lamp Does Not Come On or Go Out......................................................................40-1463 E-58 Hazard Lamp Does Not Come On or Go Out (For European Union)...................................40-1467 E-59 Brake Lamp Does Not Come On or Stays Lit......................................................................40-1471 E-60 Brake Lamp Does Not Light or Stays Lighted (For European Union) ..................................40-1475 E-61 Backup Lamp Does Not Come On or Stays Lit ...................................................................40-1479 WA320-8

00-15

Index

00 Index and Foreword

E-62 Backup Lamp Does Not Come On or Does Not Go Out (For European Union) ..................40-1483 E-63 Backup Buzzer Does Not Sound or Continues to Sound ....................................................40-1487 E-64 Front Wiper Does Not Operate ...........................................................................................40-1489 E-65 Rear Wiper Does Not Operate............................................................................................40-1493 E-66 Window Washer Does Not Operate ....................................................................................40-1496 E-67 KOMTRAX System Does Not Operate Correctly ................................................................40-1499 E-68 Auto-Greasing Pump Display Shows [FCS] ........................................................................40-1500 E-69 Auto-Greasing Pump Display Shows [FLL] .........................................................................40-1501 E-70 Auto-Greasing System Does Not Operate or Stop..............................................................40-1502 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).....................................................40-1503 Information Shown in Troubleshooting Table (H-Mode) ...............................................................40-1503 Failure Mode and Cause Table ...................................................................................................40-1504 H-1 Machine Can Not Move Forward or Reverse........................................................................40-1518 H-2 Machine Can Not Travel FORWARD (Machine Travels REVERSE Normally) ......................40-1521 H-3 Machine Can Not Travel REVERSE (Machine Travels FORWARD Normally) ......................40-1522 H-4 Travel Speed of FORWARD Travel and REVERSE Travel is Slow, or Power is Low ............40-1523 H-5 Forward Travel Speed is Slow or Power is Low (Machine Travels REVERSE Normally) ......40-1527 H-6 REVERSE Travel Speed is Slow or Power is Low (Machine Travels FORWARD Normally) .40-1528 H-7 Engine Speed Drops Largely or Engine Stops......................................................................40-1529 H-8 Machine Does Not Turn........................................................................................................40-1531 H-9 Steering Wheel is Heavy to Operate.....................................................................................40-1533 H-10 Machine Sways or Large Shocks are Made While Machine Turns......................................40-1535 H-11 Machine Unintentionally Turns to One Side When Machine Travels ...................................40-1536 H-12 Wheel Brakes Do Not Operate or are Weak .......................................................................40-1537 H-13 Wheel Brakes are Not Released or Drag............................................................................40-1539 H-14 Parking Brake Does Not Operate or is Weak......................................................................40-1540 H-15 Parking Brake is Not Released or Drags ............................................................................40-1541 H-16 Boom Does Not Rise ..........................................................................................................40-1543 H-17 Boom Moves Slow or Lacks Lifting Force ...........................................................................40-1546 H-18 Rising Boom Slows Down at Specified Height ....................................................................40-1549 H-19 Lift Cylinders Can Not Hold Bucket on Ground ...................................................................40-1550 H-20 Hydraulic Drift of Boom is Large .........................................................................................40-1552 H-21 Boom Moves Up and Down During Operation ....................................................................40-1553 H-22 Bucket Does Not Tilt Back ..................................................................................................40-1554 H-23 Bucket Moves Slow or Lacks Tilt-Back Force .....................................................................40-1557 H-24 Bucket Slows Down During Tilt Back Operation .................................................................40-1560 H-25 Bucket Cylinder Does Not Hold Bucket on Ground.............................................................40-1561 H-26 Hydraulic Drift of Bucket is Large........................................................................................40-1563 H-27 Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold) ......40-1564 H-28 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move ............40-1565 H-29 Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment..........40-1566 H-30 Large Shocks are Made When Work Equipment Starts to Move and Stops........................40-1567 H-31 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves...40-1569 H-32 ECSS Does Not Operate and Machine Pitches and Bounces.............................................40-1570 H-33 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .........................................40-1571 H-34 Unusual Noise is Heard from Around Fan ..........................................................................40-1574 Troubleshooting of Engine (S-Mode)..................................................................................................40-1575 Information Shown in Troubleshooting Table (S-Mode) ...............................................................40-1575 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position............................40-1576 S-2 Engine Cranks but No Exhaust Smoke Comes Out ..............................................................40-1577 S-3 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) ...40-1578 S-4 Engine Startability is Unsatisfactory......................................................................................40-1580 S-5 Engine Does Not Pick Up Smoothly......................................................................................40-1582 S-6 Engine Stops During Operation ............................................................................................40-1584 S-7 Engine Does Not Rotate Smoothly .......................................................................................40-1586 S-8 Engine Lacks Output (or Lacks Power).................................................................................40-1587 S-9 KDPF Becomes Clogged in a Short Time .............................................................................40-1589 S-10 Engine Oil Consumption is Excessive.................................................................................40-1591 00-16

WA320-8

00 Index and Foreword

Index

S-11 Engine Oil Becomes Dirty Quickly.......................................................................................40-1592 S-12 Fuel Consumption is Excessive ..........................................................................................40-1593 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down).............................40-1594 S-14 Engine Oil Pressure Drops .................................................................................................40-1595 S-15 Fuel Mixes Into Engine Oil ..................................................................................................40-1597 S-16 Water Mixes Into Engine Oil (Milky) ....................................................................................40-1598 S-17 Coolant Temperature Increases Too High (Overheat) .........................................................40-1599 S-18 Unusual Noise is Heard ......................................................................................................40-1600 S-19 Vibration is Excessive.........................................................................................................40-1601 S-20 Air Cannot be Bled from Fuel Circuit...................................................................................40-1602 S-21 Active Regeneration is Done Frequently.............................................................................40-1603 S-22 Active Regeneration Continues Long..................................................................................40-1605 S-23 White Smoke is Exhausted During Active Regeneration.....................................................40-1606 S-24 DEF Consumption is Excessive ..........................................................................................40-1607 S-25 Foreign Materials Enter DEF (DEF Increases)....................................................................40-1609 Troubleshooting for Auto-Greasing System........................................................................................40-1610 Outline of Failure Display ............................................................................................................40-1610 Troubleshooting for FCS .............................................................................................................40-1611 Troubleshooting for Auto-Greasing Pump ...................................................................................40-1612 Replacement of Pump Element...................................................................................................40-1615 Troubleshooting for Grease Supply System ................................................................................40-1616 Replace Auto-Greasing Controller...............................................................................................40-1618 Assembly procedure when disassembled in troubleshooting.......................................................40-1619 50 Disassembly and Assembly ...................................................................................................................... 50-1 Table of Contents .................................................................................................................................... 50-2 Precautions Before Work ........................................................................................................................ 50-7 Abbreviation List ..................................................................................................................................... 50-8 Related Information on Disassembly and Assembly.............................................................................. 50-14 How to Read This Manual .............................................................................................................. 50-14 Coating Materials List..................................................................................................................... 50-15 Special Tool List ............................................................................................................................. 50-20 Sketches of Special Tools .............................................................................................................. 50-43 Engine and Cooling System .................................................................................................................. 50-57 Remove and Install Supply Pump Assembly .................................................................................. 50-57 Remove and Install Injector Assembly ........................................................................................... 50-69 Remove and Install Cylinder Head Assembly................................................................................. 50-87 Remove and Install EGR Valve Assembly .....................................................................................50-114 Remove and Install EGR Cooler Assembly ...................................................................................50-122 Remove and Install Starter Assembly ...........................................................................................50-130 Remove and Install Air Conditioner Compressor Belt....................................................................50-136 Remove and Install Alternator Belt ................................................................................................50-139 Remove and Install Alternator Assembly.......................................................................................50-145 Remove and Install Automatic Tensioner ......................................................................................50-152 Remove and Install Radiator Assembly.........................................................................................50-153 Remove and Install Cooling Fan and Fan Motor Assembly ...........................................................50-160 Remove and Install Hydraulic Oil Cooler Assembly.......................................................................50-167 Remove and Install Aftercooler Assembly .....................................................................................50-170 Remove and Install Engine Assembly ...........................................................................................50-173 Remove and Install Engine Front Oil Seal.....................................................................................50-213 Remove and Install Engine Rear Oil Seal .....................................................................................50-218 Remove and Install Engine Hood Assembly..................................................................................50-224 Remove and Install KDPF Assembly.............................................................................................50-238 Disassemble and Assemble KDPF Assembly ...............................................................................50-262 Remove and Install KDPF and SCR Assembly .............................................................................50-272 Remove and Install Bellows Pipe Assembly ..................................................................................50-298 Remove and Install Fuel Tank Assembly.......................................................................................50-306 Remove and Install DEF Tank Assembly.......................................................................................50-314 Remove and Install DEF Tank Sensor Flange Assembly...............................................................50-326 WA320-8

00-17

Index

00 Index and Foreword

Remove and Install DEF Tank Sensor...........................................................................................50-331 Remove and Install DEF Tank Strainer..........................................................................................50-339 Remove and Install SCR Assembly...............................................................................................50-341 Remove and Install KCCV Assembly ............................................................................................50-366 Remove and Install VGT Assembly...............................................................................................50-371 Remove and Install DEF Mixing Tube ...........................................................................................50-387 Remove and Install DEF Injector...................................................................................................50-401 Remove and Install DEF Pump .....................................................................................................50-409 Remove and Install DEF Hose ......................................................................................................50-414 Remove and Install Air Cleaner Assembly ....................................................................................50-430 Remove and Install Air Conditioner Compressor Assembly...........................................................50-436 Remove and Install Air Conditioner Condenser Assembly ............................................................50-441 Power Train..........................................................................................................................................50-446 Remove and Install HST Pump Assembly.....................................................................................50-446 Remove and Install HST Motor 1 Assembly ..................................................................................50-462 Remove and Install HST Motor 2 Assembly ..................................................................................50-468 Remove and Install Transfer Assembly .........................................................................................50-487 Disassemble and Assemble Transfer Assembly............................................................................50-499 Remove and Install Front Axle Assembly ......................................................................................50-546 Remove and Install Rear Axle Assembly.......................................................................................50-551 Disassemble and Assemble Axle Housing Assembly ....................................................................50-559 Disassemble and Assemble Differential Assembly ........................................................................50-578 Undercarriage and Frame ....................................................................................................................50-612 Remove and Install Center Hinge Pin ...........................................................................................50-612 Remove and Install Counterweight Assembly ...............................................................................50-633 Hydraulic System .................................................................................................................................50-644 Remove and Install Hydraulic Tank Assembly ...............................................................................50-644 Remove and Install Control Valve Assembly .................................................................................50-665 Remove and Install Quick Coupler LS Pressure Rise Valve Assembly..........................................50-676 Disassemble and Assemble Work Equipment Cylinder Assembly.................................................50-682 Work Equipment ..................................................................................................................................50-695 Remove and Install Work Equipment Assembly ............................................................................50-695 CAB Related Parts ...............................................................................................................................50-711 Remove and Install Operator Cab and Floor Frame Assembly......................................................50-711 Remove and Install Operator Cab Glass (Adhered Glass) ............................................................50-728 Remove and Install Air Conditioner Unit Assembly .......................................................................50-738 Remove and Install Operator Seat Assembly ................................................................................50-751 How to Remove and Install Seat Belt ............................................................................................50-753 Electrical System .................................................................................................................................50-755 Remove and Install Engine Controller Assembly...........................................................................50-755 Remove and Install HST Controller Assembly...............................................................................50-766 Remove and Install Air Conditioner Controller Assembly ..............................................................50-770 Remove and Install Monitor Controller Assembly ..........................................................................50-773 Remove and Install Machine Monitor Assembly ............................................................................50-778 Remove and Install Mass Air Flow and Temperature Sensor ........................................................50-784 Remove and Install KCCV Crankcase Pressure Sensor ...............................................................50-786 Remove and Install KDPF Temperature Sensor ............................................................................50-789 Remove and Install KDPF Differential Pressure Sensor ................................................................50-794 Remove and Install SCR Temperature Sensor ..............................................................................50-799 Remove and Install Ammonia Sensor ...........................................................................................50-802 Remove and Install SCR Outlet NOx Sensor ................................................................................50-807 Remove and Install KOMTRAX Terminal Assembly ......................................................................50-813 Remove and Install Gateway Function Controller Assembly .........................................................50-815 Remove and Install Communication Terminal................................................................................50-817 60 Maintenance Standard .............................................................................................................................. 60-1 Table of Contents .................................................................................................................................... 60-2 Abbreviation List ..................................................................................................................................... 60-3 Engine and Cooling System .................................................................................................................... 60-9 00-18

WA320-8

00 Index and Foreword

Index

Maintenance Standard for Engine Mount ......................................................................................... 60-9 Maintenance Standard for Damper ................................................................................................ 60-10 Maintenance Standard for Cooling Fan Motor ................................................................................ 60-12 Power Train........................................................................................................................................... 60-14 Maintenance Standard for Drive Shaft ........................................................................................... 60-14 Maintenance Standard for Transfer ................................................................................................ 60-15 Maintenance Standard for Transfer Mount ..................................................................................... 60-23 Maintenance Standard for Front Axle............................................................................................. 60-24 Maintenance Standard for Rear Axle ............................................................................................. 60-25 Maintenance Standard for Front Torque Proportioning Differential ................................................. 60-26 Maintenance Standard for Rear Torque Proportioning Differential.................................................. 60-28 Maintenance Standard for Limited Slip Differential ......................................................................... 60-30 Maintenance Standard for Final Drive ............................................................................................ 60-32 Steering System.................................................................................................................................... 60-34 Maintenance Standard for Steering Column................................................................................... 60-34 Maintenance Standard for Priority Valve ........................................................................................ 60-35 Maintenance Standard for Steering Cylinder .................................................................................. 60-36 Maintenance Standard for Secondary Steering Valve .................................................................... 60-39 Brake System........................................................................................................................................ 60-40 Maintenance Standard for Brake Circuit Accumulator Charge Valve .............................................. 60-40 Maintenance Standard for Slack Adjuster ...................................................................................... 60-41 Maintenance Standard for Front Brake .......................................................................................... 60-42 Maintenance Standard for Rear Brake ........................................................................................... 60-43 Maintenance Standard for Parking Brake....................................................................................... 60-44 Maintenance Standard for Parking Brake Solenoid Valve............................................................... 60-46 Undercarriage and Frame ..................................................................................................................... 60-47 Maintenance Standard for Frame, Axle Mount and Center Hinge Pin ............................................ 60-47 Hydraulic System .................................................................................................................................. 60-56 Maintenance Standard for Hydraulic Tank...................................................................................... 60-56 Maintenance Standard for Brake and Cooling Fan Pump and Transfer Lubrication Pump ............. 60-57 Maintenance Standard for Steering and Work Equipment Pump.................................................... 60-58 Maintenance Standard for Control Valve ........................................................................................ 60-62 Maintenance Standard for Self-Pressure Reducing Valve .............................................................. 60-74 Maintenance Standard for Multifunction Mono-Lever PPC Valve.................................................... 60-76 Maintenance Standard for Work Equipment Lock Solenoid Valve .................................................. 60-78 Work Equipment ................................................................................................................................... 60-79 Maintenance Standard for Work Equipment Linkage...................................................................... 60-79 Maintenance Standard for Bucket .................................................................................................. 60-83 Maintenance Standard for Lift Cylinder .......................................................................................... 60-85 Maintenance Standard for Bucket Cylinder .................................................................................... 60-86 CAB Related Parts ................................................................................................................................ 60-87 Maintenance Standard for CAB Mount ........................................................................................... 60-87 80 Appendix ................................................................................................................................................... 80-1 Table of Contents .................................................................................................................................... 80-2 Precautions Before Work ........................................................................................................................ 80-4 Abbreviation List ..................................................................................................................................... 80-5 Air Conditioner System ..........................................................................................................................80-11 Precautions for Refrigerant .............................................................................................................80-11 Air Conditioner Component ............................................................................................................ 80-12 Specifications of Air Conditioner .................................................................................................... 80-14 Structure and Function of Refrigeration Cycle ................................................................................ 80-15 Outline of Refrigeration Cycle ........................................................................................................ 80-16 Component Parts of Air Conditioner System ......................................................................................... 80-18 Air Conditioner Unit ........................................................................................................................ 80-18 Component Parts of Air Conditioner Unit........................................................................................ 80-20 Air Conditioner Controller ............................................................................................................... 80-23 Compressor ................................................................................................................................... 80-24 Condenser ..................................................................................................................................... 80-25 WA320-8

00-19

Index

00 Index and Foreword

Receiver Drier ................................................................................................................................ 80-26 Air Conditioner Related Sensors .................................................................................................... 80-27 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner ........................................ 80-28 Circuit Diagram and Configuration of Connector Pins of Air Conditioner ............................................... 80-30 System Diagram of Air Conditioner ....................................................................................................... 80-33 Input and Output Signals of Air Conditioner Controller ................................................................... 80-34 Locations of Air Conditioner Parts and Layout of Connectors................................................................ 80-36 Examine Air Conditioner with Self-Diagnosis Function .......................................................................... 80-42 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor.............. 80-43 Examine Temperature Control Function ................................................................................................ 80-44 How to Examine Temperature Control Function ............................................................................. 80-44 Examine Vent (Mode) Changeover ....................................................................................................... 80-46 How to Examine Vent (Mode) Changeover .................................................................................... 80-46 Examine Fresh/Recirc Air Changeover ................................................................................................. 80-48 How to Examine Fresh/Recirc Air Changeover .............................................................................. 80-48 Examine Evaporator Temperature Sensor............................................................................................. 80-50 Examine Relay...................................................................................................................................... 80-52 How to Examine Relay................................................................................................................... 80-52 Air Conditioner Troubleshooting Chart 1 ............................................................................................... 80-54 Air Conditioner Troubleshooting Chart 2 ............................................................................................... 80-55 Failure Code [879AKA] ......................................................................................................................... 80-58 Failure Code [879AKB] ......................................................................................................................... 80-60 Failure Code [879BKA] ......................................................................................................................... 80-62 Failure Code [879BKB] ......................................................................................................................... 80-64 Failure Code [879CKA] ......................................................................................................................... 80-66 Failure Code [879CKB] ......................................................................................................................... 80-68 Failure Code [879DKZ] ......................................................................................................................... 80-70 Failure Code [879EMC]......................................................................................................................... 80-72 Failure Code [879FMC]......................................................................................................................... 80-73 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) ............................. 80-74 A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)................................. 80-77 A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) ................. 80-80 A-4 Troubleshooting for Fresh/Recirc Air Changeover .......................................................................... 80-84 Troubleshooting by Gauge Pressure ..................................................................................................... 80-86 Connect Service Tool ............................................................................................................................ 80-89 How to Connect Service Tool ......................................................................................................... 80-90 Precautions for Disconnection and Connection of Air Conditioner Piping .............................................. 80-91 Handle Compressor Oil......................................................................................................................... 80-93 90 Circuit Diagrams........................................................................................................................................ 90-1 Table of Contents .................................................................................................................................... 90-2 Abbreviation List ..................................................................................................................................... 90-5 Hydraulic Circuit Diagram.......................................................................................................................90-11 Symbols Used in Hydraulic Circuit Diagram ....................................................................................90-11 Hydraulic Circuit Diagram (1/2) ...................................................................................................... 90-15 Hydraulic Circuit Diagram (2/2) ...................................................................................................... 90-17 Hydraulic Auto-Greasing Diagram.................................................................................................. 90-19 Electrical Circuit Diagram ...................................................................................................................... 90-21 Symbols Used in Electric Circuit Diagram ...................................................................................... 90-21 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (1/7)............................ 90-25 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (2/7)............................ 90-27 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (3/7)............................ 90-29 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (4/7)............................ 90-31 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (5/7)............................ 90-33 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (6/7)............................ 90-35 Electrical Circuit Diagram of Machine (Machine with KOMTRAX Terminal) (7/7)............................ 90-37 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (1/8)....................................................................................................... 90-39

00-20

WA320-8

00 Index and Foreword

Index

Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (2/8)....................................................................................................... 90-41 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (3/8)....................................................................................................... 90-43 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (4/8)....................................................................................................... 90-45 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (5/8)....................................................................................................... 90-47 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (6/8)....................................................................................................... 90-49 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (7/8)....................................................................................................... 90-51 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (8/8)....................................................................................................... 90-53 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (1/8) ......................................................................................................... 90-55 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (2/8) ......................................................................................................... 90-57 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (3/8) ......................................................................................................... 90-59 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (4/8) ......................................................................................................... 90-61 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (5/8) ......................................................................................................... 90-63 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (6/8) ......................................................................................................... 90-65 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (7/8) ......................................................................................................... 90-67 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (8/8) ......................................................................................................... 90-69 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller and Collision Detection System) (Applicable Machine: 87649 and Up) (1/8) ............................................................. 90-71 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller and Collision Detection System) (Applicable Machine: 87649 and Up) (2/8) ............................................................. 90-73 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller and Collision Detection System) (Applicable Machine: 87649 and Up) (3/8) ............................................................. 90-75 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller and Collision Detection System) (Applicable Machine: 87649 and Up) (4/8) ............................................................. 90-77 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller and Collision Detection System) (Applicable Machine: 87649 and Up) (5/8) ............................................................. 90-79 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller and Collision Detection System) (Applicable Machine: 87649 and Up) (6/8) ............................................................. 90-81 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller and Collision Detection System) (Applicable Machine: 87649 and Up) (7/8) ............................................................. 90-83 Electrical Circuit Diagram of Machine (Machine with Gateway Function Controller and Collision Detection System) (Applicable Machine: 87649 and Up) (8/8) ............................................................. 90-85 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (1/9) ................................. 90-87 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (2/9) ................................. 90-89 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (3/9) ................................. 90-91 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (4/9) ................................. 90-93 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (5/9) ................................. 90-95 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (6/9) ................................. 90-97 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (7/9) ................................. 90-99 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (8/9) ................................90-101 Electrical Circuit Diagram of Floor (Machine with KOMTRAX Terminal) (9/9) ................................90-103 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (1/10) ..............................................................................................................90-105

WA320-8

00-21

Index

00 Index and Foreword

Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (2/10) ..............................................................................................................90-107 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (3/10) ..............................................................................................................90-109 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (4/10) .............................................................................................................. 90-111 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (5/10) ..............................................................................................................90-113 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (6/10) ..............................................................................................................90-115 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (7/10) ..............................................................................................................90-117 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (8/10) ..............................................................................................................90-119 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (9/10) ..............................................................................................................90-121 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 85001 to 87648) (10/10) ............................................................................................................90-123 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (1/11).................................................................................................................90-125 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (2/11).................................................................................................................90-127 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (3/11).................................................................................................................90-129 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (4/11).................................................................................................................90-131 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (5/11).................................................................................................................90-133 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (6/11).................................................................................................................90-135 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (7/11).................................................................................................................90-137 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (8/11).................................................................................................................90-139 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (9/11).................................................................................................................90-141 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (10/11)...............................................................................................................90-143 Electrical Circuit Diagram of Floor (Machine with Gateway Function Controller) (Applicable Machine: 87649 and Up) (11/11) ...............................................................................................................90-145 Index ....................................................................................................................................................................1

00-22

WA320-8

00 Index and Foreword

Abbreviation List

Abbreviation List •

This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.

•

Abbreviations that are used in general society may not be included.

•

Special abbreviations which appear infrequently are noted in the text.

•

This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of Abbreviations Used in the Text Purpose of use (major applicable machine (*1), or component/system)

Abbreviation

Actual word spelled out

ABS

Antilock Brake System

AISS

Automatic Idling Setting Engine System

This is a function that automatically sets the idle speed.

Steering AJSS

Advanced Joystick Steering System

This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.

ARAC

Automatic Retarder Accelerator Control

Travel and brake (HD, HM)

(WA) Travel and brake (HD, HM) Travel and brake

Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.

This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill.

This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.

ARSC

Automatic Retarder Speed Control

ASR

Travel and brake Automatic Spin Regulator (HD, HM)

This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.

ATT

Attachment

A function or component that can be added to the standard specification.

BCV

BRAKE Brake cooling oil control valve (HD)

CAN

Controller Area Network

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

CDR

Crankcase Depression Regulator

Engine

This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.

CLSS

Closed-center Load Sensing System

Hydraulic system

This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).

WA320-8

(HD, HM)

Work equipment

This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.

00-23

Abbreviation List

Abbreviation

Actual word spelled out

00 Index and Foreword

Purpose of use (major applicable machine (*1), or component/system)

Explanation

Engine

This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.

Electronic control system

This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)

CRI

Common Rail Injection

ECM

Electronic Control Module

ECMV

Electronic Control Modulation Valve

ECSS

Travel Electronically Controlled Suspension System (WA)

This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.

ECU

Electronic Control Unit

This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)

EGR

Exhaust Gas RecirculaEngine tion

This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.

EMMS

Equipment ManageMachine monitor ment Monitoring System

This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).

EPC

Electromagnetic ProporHydraulic system tional Control

Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.

FOPS

Falling Object Protective Cab and canopy Structure

Transmission (D, HD, WA, etc)

Electronic control system

This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.

This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.

F-N-R

Forward-Neutral-Reverse

GPS

Global Positioning System

GNSS

Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)

HSS

Hydrostatic Steering System

HST

Hydro Static Transmission

Operation Communication (KOMTRAX, KOMTRAX Plus)

Steering

00-24

(D Series) Transmission (D, WA)

Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.

This is a general term for system uses satellites such as GPS, GALILEO, etc.

This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft.

Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.

WA320-8

00 Index and Foreword

Abbreviation List

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*1), or component/system)

Explanation

ICT

Information and Communication Technology

Communication and electronic control

A general term for the engineering and its socially applied technology of information processing and communication.

IMA

Inlet Metering Actuator

Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)

IMU

Inertial Measurement Unit

Engine

This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.

IMV

Inlet Metering Valve

Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)

KCCV

Komatsu Closed CrankEngine case Ventilation

This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.

KCSF

Komatsu Catalyzed Soot Filter

KDOC

Komatsu Diesel Oxidation Catalyst

KDPF

Engine

Engine

Komatsu Diesel ParticuEngine late Filter

This is a filter that captures soot in exhaust gas.

It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas.

It is built in to KDPF or assembled with the muffler.

This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it.

It is installed instead of the conventional muffler.

Travel and brake

This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.

KTCS

Komatsu Traction Control System

(HM)

LCD

Liquid Crystal Display

Machine monitor

This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.

LED

Light Emitting Diode

Electronic parts

This is a semiconductor element that emits light when the voltage is applied in forward direction.

LIN

Local Interconnect Network

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

LS

Load Sensing

Hydraulic system

This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.

LVDS

Low Voltage Differential Signaling

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

Engine

This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.

MAF

WA320-8

Mass Air Flow

00-25

Abbreviation List

00 Index and Foreword

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*1), or component/system)

MMS

Multimedia Messaging Service

Communication

NC

Normally Closed

This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.

NO

Normally Open

This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.

OLSS

Open-center Load Sensing System

Hydraulic system

PC

Pressure Compensation Hydraulic system

PCCS

Palm command control system

PCV

Pre-stroke Control Valve Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.

PPC

Proportional Pressure Control

This is a system that operates actuators in proportion to the oil pressure.

PPM

Piston Pump and Motor

PTO

Power Take Off

PTP

Power Tilt and power Pitch dozer

Steering

ROPS

Roll-Over Protective Structure

(D Series)

Hydraulic system Hydraulic system (D, PC, etc)

Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.

This is a hydraulic system that can operate multiple actuators at the same time regardless of the load.

This is a function that corrects the oil pressure.

This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.

Piston type hydraulic pump and motor.

Power train system

Power take-off mechanism

Work equipment

This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.

(D Series)

Cab and canopy

ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2.

This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.

SCR

Selective Catalytic Reduction

SI

Le Systeme International d' Unites (Internation- Unit al unit system)

Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.

SOL

Solenoid

This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.

00-26

Urea SCR system

Electrical system

WA320-8

00 Index and Foreword

Abbreviation

TOPS

Abbreviation List

Purpose of use (major applicable machine (*1), or component/system)

Actual word spelled out

Tip-Over Protective Structure

Cab and canopy

Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.

TWV

2-Way Valve

Hydraulic system

This is a solenoid valve that switches over direction of flow.

VGT

Variable Geometry Turbocharger

Engine

This is a turbocharger on which the cross-section area of the exhaust passage is variable.

VHPC

Variable Horse Power Control

Engine control

This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.

*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader

List of Abbreviations Used in the Circuit Diagrams Abbreviation

Actual word spelled out

A/C

Air Conditioner

A/D

Analogue-to-Digital

A/M

Air Mix Damper

ACC

Accessory

ADD

Additional

AUX

Auxiliary

BR

Battery Relay

CW

Clockwise

CCW

Counter Clockwise

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actuator

NC

No Connection

WA320-8

00-27

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Abbreviation List

00 Index and Foreword

Abbreviation S/T STRG

Actual word spelled out Steering

SIG

Signal

SOL

Solenoid

STD

Standard

OPT OP

Option

PRESS

Pressure

SPEC

Specification

SW

Switch

TEMP

Temperature

T/C

Torque Converter

T/M

Transmission

00-28

WA320-8

00 Index and Foreword

How to Read the Shop Manual

Foreword, Safety, Basic Information How to Read the Shop Manual •

Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.

•

The materials and specifications are subject to change without notice.

•

Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.

•

Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.

•

The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in accordance with the machine.

•

•

For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.

•

For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine Monitor”.

•

For details of the switches, see the “Operation and Maintenance Manual”.

All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.

REMARK The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the same as the terminology in the shop manual.

Composition of the Shop Manual This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.

00 Index and Foreword This section describes the index, foreword, safety, and basic information.

01 Specification This section describes the specifications of the machine.

10 Structure and Function This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.

20 Standard Value Table This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.

30 Testing and Adjusting This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.

40 Troubleshooting This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.

Descriptions of troubleshooting are sorted by failure mode.

WA320-8

00-29

How to Read the Shop Manual

00 Index and Foreword

50 Disassembly and Assembly This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.

60 Maintenance Standard This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.

80 Others This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.

90 Circuit Diagrams This section describes hydraulic circuit diagrams and electrical circuit diagrams.

Symbols Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.

Symbol

Item

Remark

Danger

This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.

Warning

This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.

Caution

This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.

Weight

This symbol shows the weight of parts and components. Refer to this symbol when you handle heavy object for selection of the required equipment such as crane and lifting tools, and for what kind of working posture to take.

Tightening torque

This signal indicates the tightening torque for portions which requires special care in assembling work.

Coat

This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.

Oil and coolant

This signal indicates a place to supply oil, coolant, etc. and the quantity.

Draining

This signal indicates a place to drain oil, coolant, etc. and the quantity.

Signal Word Signal word for notice and remark describes the following.

Symbol

Item

Remark

NOTICE

Notice

If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur.

REMARK

Remark

This signal word contains useful information to know.

Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.

00-30

WA320-8

00 Index and Foreword

Safety Notice for Operation

Safety Notice for Operation •

Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purposes.

•

The symbol mark

is indicated for such matters that require special precautions. The work indicated with

should be performed according to the instructions with special attention. Should a this warning mark hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary measures.

Safety Considerations •

Well organized work place

•

Correct work clothes

•

Observance of work standard

•

Enforcement of hand signals

•

Prohibition against unlicensed persons operating and handling the machine

•

Safety check before starting work

•

Wear of dust glasses (for cleaning or grinding work)

•

Wear of welding goggles and protectors (for welding work)

•

Being in good physical condition, and good preparation

•

Always be alert and careful.

General Precautions k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the

operation and maintenance manual before operation. Read and understand what is described in this manual before operation.

•

Read and understand the meaning of all the safety labels stuck to the machine before performing any greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation and Maintenance Manual.

•

Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on the floor. Smoke only in the designated areas. Never smoke while working.

•

Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the tools, machine, forklift truck, service car, etc. thoroughly before starting the work.

•

Always wear safety shoes and helmet when performing any operation. Do not wear loose clothes, or clothes with buttons missing.

WA320-8

00-31

Safety Notice for Operation

00 Index and Foreword

•

Always wear the protective eyeglasses when hitting parts with a hammer.

•

Always wear the protective eyeglasses when grinding parts with a grinder, etc.

•

When performing any operation with multiple workers, always agree on the operating procedure before starting. Be clear in verbal communication, and observe hand signals.

Hang “UNDER REPAIR” warning tag in the operator's compartment Before starting work.

•

Only the approved personnel can do the work in a closed environment or in a prohibited area.

•

Work and operation which require license or qualification should be performed by qualified workers.

•

Welding repairs should be performed by trained and experienced welders. When performing welding work, always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.

•

Warm up before starting the work with exercise which increases alertness and the range of motion in order to prevent injury.

•

Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe area.

•

When you work in high places, use a platform.

•

Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.

•

Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.

•

Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.

•

When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).

•

If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the machine has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.

,&

Precautions for Preparatory Work •

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 adding oil or making any repairs.

•

Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang “UNDER REPAIR” 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 mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately. ,&

00-32

WA320-8

00 Index and Foreword

Safety Notice for Operation

Precautions During Work •

For the machine with the battery disconnect switch, check before starting the work that the system operating lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.

REMARK Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.

For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.

•

For the machine with the quick release battery terminal (-), check before starting the work that the system operating lamp is not lit. Then, disconnect the quick release battery terminal (-).

REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-).

•

Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.

•

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.

•

The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.

WA320-8

00-33

Safety Notice for Operation

00 Index and Foreword

•

Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.

•

When raising a heavy component (heavier than 20kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to 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 a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.

•

When removing components, do not break or damage the electrical wiring. Damaged wiring may cause a fire.

•

When removing piping, do not spill the fuel or oil. 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.

•

Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in particular.

•

Install the disassembled parts again to the original position. Replace the damaged parts or the parts that cannot be used again with new ones. Before you connect the hoses or wiring harnesses, make sure that they do not touch and give damage to other parts when you operate the machine.

REMARK

,&

When you replace the removed or disassembled parts with new ones, refer the parts book to find out the part number.

•

When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed.

•

When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.

•

Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.

•

Check that the measuring tools are correctly installed when measuring hydraulic pressure.

•

Take care when removing or installing the tracks of track-type machines. Since the track shoe may separate suddenly when you remove it, never let anyone stand at either end of the track shoe.

•

If the engine is operated for a long time in a closed place with poor ventilation, it may cause gas poisoning. Open the windows and doors to ventilate the place well.

,&

00-34

WA320-8

00 Index and Foreword

Safety Notice for Operation

Precautions for Slinging Work and When You Make Signals •

Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely.

k Do not do the work while the lifted load is in the range where it possibly falls. It is not allowed to

go in the range where the lifted load possibly falls.

k Do not move a load over a person. k Never step on the load.

k Do not prevent the load from swinging or falling down by holding it simply with the hands.

k The sling workers and assistant workers other than the guide must move to a place where they

are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly.

•

When you lift or fix the machine, see “Operation and Maintenance Manual” or “Field Assembly Instruction”. k Do not lift or fix the machine by the positions where the name plate is not attached.

•

When you lift the machine for the disassembly and assembly, follow the instructions on the Disassembly and Assembly.

•

Check the slings before starting sling work.

•

Keep putting on gloves during sling work. (Put on leather gloves, if available.)

•

Measure the weight of the load by the eye and check its center of gravity.

•

Use proper sling corresponding 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 alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.

k Slinging 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 ° or smaller as a rule.

•

When slinging a heavy load (20kg or heavier), the hanging angle of the rope must be narrower than that of the hook.

REMARK When slinging a load with 2 or more ropes, the force subjected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kgf} vertically, at various hanging angles. When the 2 ropes sling a load vertically, they can sling up to 2000 kg of total weight. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 2000 kg load at a hanging angle of 150 °, each rope is subjected to a force as large as 39.2 kN {4000kgf} .

•

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.

WA320-8

00-35

Safety Notice for Operation

•

00 Index and Foreword

Apply wire ropes to the middle part of the hook.

k Do not use hooks if it does not have a latch sys-

tem.

k Slinging

near the tip of the hook may cause the rope to slip off the hook during hoisting.

REMARK The strength of the hook is maximum at its central part.

•

Never use a wire rope which has breaks in strands (A), reduced diameter (B), or kinks (C). There is a danger that the rope may break during the towing operation.

Precautions for slinging up •

Wind in the crane slowly until wire ropes are stretched.

When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.

•

After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

•

If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.

•

Do not lift up the load at an angle.

Precautions for slinging down •

When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.

•

Check that the load is stable, and then remove the sling.

•

Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

Precautions When You Use Mobile Crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.

Precautions When You Use Overhead Traveling Crane k When raising a heavy component (heavier than 20kg), use a hoist or crane.

Weight of component whose weight is heavier than 20kg is shown with symbol sembly”.

in “Disassembly and As-

REMARK shows the weight of the parts with weight of 20kg or more for convenience of workers. But the The symbol weight can possibly be shown even if it is less than 20kg in accordance with the work environment.

Do the work safely in response to the work environment and the physical build, preexisting condition, and physical condition of the operator. And obey the laws and regulations of each country.

•

Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing caution lamp, and check the following safety items.

•

Be sure not to touch the lifting tool and lifted load directly. Use push-pull sticks or tagline ropes.

•

Observe the signals for sling work.

•

Operate the hoist at a safe place.

00-36

WA320-8

00 Index and Foreword

Safety Notice for Operation

•

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 becomes off the ground, check the 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 is not 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.

•

If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it is turned off by the ground fault circuit interrupter, 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 m above the floor. Do not leave the sling installed to the hook.

Select Wire Ropes Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.

REMARK The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.

Wire Rope (JIS G3525 6x37-A Type) (Standard Z Twist Wire Ropes Without Galvanizing) Nominal diameter of rope (mm)

Allowable load (kN {t} )

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}

Precautions When You Disconnect Air Conditioner Piping NOTICE 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.

REMARK • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a).

• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.

WA320-8

00-37

Safety Notice for Operation

00 Index and Foreword

k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-

lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite.

•

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.

Precautions for Air Conditioner Piping •

When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.

•

Check that the O-rings are fitted to the joints when connecting the air conditioner piping.

•

Do not reuse an O-ring because it is deformed and deteriorated if it is used once.

•

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 O-ring.

REMARK Do not apply oil to the threaded portion of a bolt, nut or union.

Manufacturer

Part name

DENSO

ND-OIL8

VALEO THERMAL SYSTEMS

ZXL100PG (PAG46 or equivalent)

SANDEN

SP-10

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).

REMARK • The figure shows an example 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”.

00-38

WA320-8

00 Index and Foreword

Precautions to Prevent Fire

Precautions to Prevent Fire Fire Caused by Fuel, Oil, Coolant or Window Washer Fluid Do not bring any open flame close to fuel, oil, coolant or window washer fluid. Always observe the following.

•

Do not smoke or use any open 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.

,&

,&

Fire Caused by Accumulated or Attached Flammable Objects •

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 Caused by Electrical System 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 from Pipings 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 Caused by High Temperature Exhaust Gas Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).

KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (regeneration), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not bring any flammable materials close to exhaust pipe outlet.

WA320-8

00-39

Precautions to Prevent Fire

•

00 Index and Foreword

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 caused

by KDPF regeneration.

See the Operation and Maintenance Manual for the setting procedure.

Explosion Caused by Light •

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, follow the instructions in the Operation and Maintenance Manual.

00-40

WA320-8

00 Index and Foreword

Procedures If Fire Occurs

Procedures If Fire Occurs •

Turn the starting switch to OFF position to stop the engine.

•

Use the handrails and steps to get off the machine.

•

Do not jump off the machine. You may fall and suffer serious injury.

•

The fumes generated by a fire contain harmful materials which have a bad influence on your body when they are inhaled.

Do not breathe the fumes.

•

After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on your body.

Be sure to wear rubber gloves when handling the materials left after the fire.

The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).

When wearing cotton work gloves, wear rubber gloves under them.

WA320-8

00-41

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Precautions for Disposing of Waste Materials

00 Index and Foreword

Precautions for Disposing of Waste Materials To prevent pollution, pay full attention to the way to dispose of waste materials.

•

Always drain the oil from your machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.

•

Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and DEF.

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.

•

When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products.

00-42

WA320-8

00 Index and Foreword

Procedures for Exhaust Gas Regulations

Procedures for Exhaust Gas Regulations This machine conforms to either regulation of Tier4 Final (North America) or Stage IV (Europe).

This machine is equipped with the following two exhaust gas treatment systems: •

Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to purify exhaust gas. This process performs the combustion of soot referred to as “regeneration”.

•

Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water.

Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.

AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of Germany).

DEF is the abbreviation for Diesel Exhaust Fluid.

Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.

About DEF DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc.

If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.

•

In Europe, use AdBlue®.

•

In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).

The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification Mark when purchasing DEF. API Diesel Exhaust Fluid Certification Mark is the trade mark of API (American Petroleum Institute).

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00-43

Precautions for DEF

00 Index and Foreword

Precautions for DEF General Character and Precautions for Handling DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require immediate action: •

If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or begins to hurt, immediately consult a doctor for treatment.

•

Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor for treatment.

•

Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doctor for treatment.

•

Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear rubber gloves when you perform work handling DEF to avoid skin contact.

Precautions for Adding Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a fire. Some fluids or agents added can create and emit a toxic gas.

When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from the filler port during opening or refilling.

Precautions for Storage If the temperature of DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage. When opening the container, perform it where there is good ventilation. For storage, see “Store DEF”.

Store DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of DEF with another one. If DEF is stored in an iron or aluminum container, toxic gas may develop and a chemical reaction may corrode the container.

Precautions for Fire Hazard and Leakage DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base of “Actions if fire occurs”.

If DEF is spilled, immediately wipe and wash the area with water. If spilled DEF is left unattended and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical reactions.

Other Precautions When disposing of DEF, treat it as an industrial waste. For the waste treating method, refer to “Precautions When You Discard Waste Materials”. It should be treated in the same way.

Never use an iron or aluminum container when disposing DEF fluid, because toxic gas may develop and a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when handling the fluid waste of DEF. Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.

Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws.

00-44

WA320-8

00 Index and Foreword

Store DEF

Store DEF •

If the temperature of DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage. Only open containers in a well-ventilated area.

•

Store DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of DEF with another one. If DEF is stored in an iron or aluminum container, toxic gas may develop and a chemical reaction may corrode the container.

•

DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above.

The relation between the upper limit of storage temperature and the storage period of DEF is shown in the table.

Temperature of storage area

Storage period

Max.10 °C

Up to 36 months

Max.25 °C

Up to 18 months

Max.30 °C

Up to 12 months

Max.35 °C

Up to 6 months

*: Do not store DEF in the temperature of 35 °C or above.

Handle DEF in Cold Weather •

DEF freezes at –11 °C. DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank may be affected. Add DEF to the specified amount for cold weather (below the level of when DEF may freeze).

•

In cold weather, keep DEF or the machine installed with DEF in the indoors where the temperature is at – 11 °C or higher to prevent DEF in the tank from freezing.

If DEF or the machine installed with DEF cannot be stored in the indoors where the temperature is at – 11 °C or higher (if they are left outdoors in cold weather), DEF in the tank may freeze. Drain DEF to prevent it from freezing.

WA320-8

00-45

Precautions When You Handle Hydraulic Equipment

00 Index and Foreword

Precautions When You Handle Hydraulic Equipment Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.

Select an Applicable Workplace •

In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the machine.

Disassembly and Maintenance Work in the Field k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit

and it may result in serious personal injury or death when removing and disassembling of the hydraulic equipment is performed. k Release the remaining pressure from the hydraulic circuit always before performing the work.

•

In the field, there is a risk of dust entering the component during disassembling or maintenance work, and performance check is hardly performed. Replacement of the assembly is recommended.

•

Perform disassembling and maintenance work in the dust proof area.

Seal Openings (Prevention of Flowing Out of Oil) Plug the openings of the piping and the device which have been removed to prevent foreign material from entering and oil from flowing out.

NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.

Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.

REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs.

00-46

WA320-8

00 Index and Foreword

Precautions When You Handle Hydraulic Equipment

Preventing Intrusion of Foreign Materials While You Refill •

During refilling with the hydraulic oil, do not let water enter the electrical components.

•

Clean the oil filler port and its around, refilling pump, oil jug, or etc.

•

Refilling by using an oil cleaning device is better method since it can filtrate the contaminants accumulated in the oil during storage.

Replace Hydraulic Oil While Its Temperature is High •

The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high.

•

Old hydraulic oil needs to be drained as much as possible when replacing.

NOTICE Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludges, and the service life of the hydraulic oil is shortened.

REMARK Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the circuit.

Do Not Use the Hydraulic Oil and Lubricating Oil Again Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.

If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.

Flushing Operation •

Flushing is required to completely dislodge the contaminants and sludges, and existing oil containing those inside the hydraulic circuit after disassembling and assembling, and when replacing the oil with the new one.

•

Normally, flushing is performed twice. Primary flushing is performed by using the flushing oil (1) and the secondary flushing is performed by using the specified hydraulic oil.

Cleaning Operation Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine.

WA320-8

00-47

Precautions When You Handle Hydraulic Equipment

00 Index and Foreword

REMARK The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment cannot remove. So, it is very effective device.

00-48

WA320-8

00 Index and Foreword

Precautions When You Disconnect and Connect Pipings

Precautions When You Disconnect and Connect Pipings When performing “testing and adjusting” of the machine, “removal and installation” and “disassembly and assembly” of the components, observe the following precautions.

Precautions for Removal and Disassembly Work •

If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly.

•

After disconnecting the hoses or tubes, plug them to prevent dust from entering.

•

When draining oil, prepare a container with sufficient capacity.

•

Check the matchmarks which indicate the installing position, and put matchmarks on the places where they seem necessary before removal of the components to prevent any mistake when assembling.

•

To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.

•

Attach the tags to wires and hoses so that installation is done to the correct installing positions.

•

Check the thickness and number of shims when storing shims.

•

When hoisting the components, prepare the slings with sufficient strength.

•

When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.

•

Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal.

•

To disconnect the face seal type hose from the cylinder tube, loosen the joint by gripping the two wrenches together, one is the wrench (1) on the hose side, and another is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only.Check after disconnecting the hose that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient.

NOTICE Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.

•

After disconnecting the piping or removing a pipe joint, install the following plugs.

NOTICE When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions.

REMARK The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine.

WA320-8

00-49

Precautions When You Disconnect and Connect Pipings

00 Index and Foreword

Introduction of Parts for the Disassembly of the Face Seal Type Hoses and Tubes

Hose side

Pipe joint side

Plug (1)

Nut (2)

02

07376-70210

02789-00210

02896-11008

03

07376-70315

02789-00315

02896-11009

04

07376-70422

02789-00422

02896-11012

05

07376-70522

02789-00522

02896-11015

06

07376-70628

02789-00628

02896-11018

Nominal No.

O-ring (3)

Introduction of Parts for the Disconnection of the Taper Seal Type Hoses and Tubes

Hose side

Pipe joint side

Plug (1)

Nut (2)

02

07376-50210

07222-00210

03

07376-50315

07222-00312

04

07376-50422

07222-00414

05

07376-50522

07222-00515

06

07376-50628

07222-00616

10

07376-51034

07222-01018

12

07376-51234

07222-01219

14

07376-51443

07222-01422

Nominal No.

00-50

WA320-8

00 Index and Foreword

Precautions When You Disconnect and Connect Pipings

Introduction of Parts for the Disconnection of the Split Flange Type Hoses and Tubes

Nomi nal No.

Bolt pitch (mm) a

b

Flange (1)

04

38.1

17.5

07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823

05

42.9

19.8

07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823

06

47.6

22.2

07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032

10

52.4

26.2

07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032

58.7

30.2

07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032

66.7

31.8

07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232

69.9

35.8

07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232

79.4

36.5

07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445

77.8

42.8

07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232

96.8

44.5

07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845

24

88.9

50.8

07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232

30

106.4

62

07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645

34

120.6

69.8

07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645

40

130.2

77.8

07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645

50

152.4

92

07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645

12

14

20

Hose side

Tube side Split flange (2)

Sleeve head (3)

O-ring (4)

Bolt (5)

Washer (6)

Introduction of Parts for the Removal of O-Ring Boss Type Joint

WA320-8

00-51

Precautions When You Disconnect and Connect Pipings

00 Index and Foreword

Nominal No.

Plug (1)

O-ring (2)

08

07040-10807

07002-10823

10

07040-11007

07002-11023

12

07040-11209

07002-11223

14

07040-11409

07002-11423

16

07040-11612

07002-11623

18

07040-11812

07002-11823

20

07040-12012

07002-12034

24

07040-12412

07002-12434

30

07041-13012

07002-13034

33

07040-13316

07002-13334

36

07041-13612

07002-13634

42

07040-14220

07002-14234

52

07040-15223

07002-15234

Introduction of Parts for the Removal of Taper Pipe Thread Type Joint

Plug (1)

Nominal No.

Nominal thread size

Square head type (A)

Hexagonal socket head (B)

01

R1/8

07042-00108

07043-00108

02

R1/4

07042-00211

07043-00211

03

R3/8

07042-00312

07043-00312

04

R1/2

07042-00415

07043-00415

06

R3/4

07042-00617

07043-00617

10

R1

07042-01019

07043-01019

12

R11/4

07042-01222

07043-01222

14

R11/2

07042-01422

07043-01422

20

R2

07042-02026

07043-02026

Precautions for Installation and Assembly Work •

Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.

•

Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.

00-52

WA320-8

00 Index and Foreword

Precautions When You Disconnect and Connect Pipings

•

Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.

•

Bend the cotter pins and lock plates securely.

•

When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to the threaded portion.

•

When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dust or damage.

•

Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.

•

Apply engine oil to the rotating parts and sliding surface.

•

Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.

•

After installing the snap ring, check that the snap ring is settled in the ring groove completely.

•

When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then connect them securely.

•

Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook.

•

When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.

•

As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure.

REMARK If the threaded portion is difficult to degrease, you may use a seal tape.

When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the third thread in the advancing direction of the threads seeing from the screw end.

NOTICE If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come off. If the sealed tip is pushed outside, it may cause oil leakage.

•

To connect the face seal type hose to the cylinder tube, tighten the joint by gripping the two wrenches together, one is the wrench (1) on the hose side, and another is the wrench (2) on the cylinder tube reaction force point at the same time as shown in the following figure. Use the grip strength only.Check after connecting the hose that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient.

NOTICE Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.

NOTICE When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed, be sure to bleed air from the hydraulic circuit before operating it for the first time according to the following procedure.

1. Start the engine, and run it at low idle.

2.

Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximately 100 mm before the stroke end for 4 or 5 times.

3.

Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke end for 3 or 4times.

WA320-8

00-53

Precautions When You Disconnect and Connect Pipings

00 Index and Foreword

NOTICE After repair is finished, when operating the machine which has been stored for a long period, bleed air from the hydraulic circuit according to the same procedure.

Precautions at the End Time of Work Refilling of coolant or water or oil, greasing, and adding of DEF •

For machines with urea SCR system, fill DEF to the specified level before starting the engine.

•

Supply the specified amount of grease to the work equipment parts.

•

When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.

•

When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.

•

If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system. See “TESTING AND ADJUSTING”.

Testing installed condition of cylinder heads and manifolds •

Check the cylinder head and intake and exhaust manifold mountings for looseness.

•

If there is any looseness, retighten the part.

REMARK For the tightening torques, see “50 Disassembly and Assembly”.

Test engine piping for damage and looseness Intake and exhaust system Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak of air or exhaust gas from connecting portion.

If there is any looseness, damage, or gas leak, retighten or repair the part.

Cooling system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water leak from connecting portion.

If there is any looseness, damage, or water leak, retighten or repair the part.

Fuel system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion.

If there is any looseness, damage, or fuel leak, retighten or repair the part.

Check the exhaust equipment and its installation portion for looseness and damage.

REMARK When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.)

• KDPF • DEF mixing tube • SCR assembly • KDOC muffler • Muffler • Exhaust pipe • KDPF & SCR Ass'y • Parts which connects the above, or etc.

00-54

WA320-8

00 Index and Foreword

Precautions When You Disconnect and Connect Pipings

Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there is any damage, replace the part.

Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the installation portion.

If there is any looseness, retighten the part.

Check of function of muffler in exhaust system REMARK When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.)

• KDPF • DEF mixing tube • SCR assembly • KDOC muffler • Muffler • Exhaust pipe • KDPF & SCR Ass'y • Parts which connects the above, or etc.

Check that there is no unusual noise by comparing to it of the time when the machine was new.

If there is any unusual noise, repair KDPF or muffler, referring to “Troubleshooting” and “Disassembly and Assembly”.

WA320-8

00-55

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DOWNLOAD THE COMPLETE MANUAL

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Precautions When You Handle Electrical Equipment

00 Index and Foreword

Precautions When You Handle Electrical Equipment To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed.

This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical equipment”.

Handle Wiring Harnesses and Connectors •

Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires.

•

Compared with other electrical components fitted in boxes or cases, wiring harnesses are likely to be directly affected by rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling and maintenance of the wiring harnesses.

•

If DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact. Be careful not to spill it over electrical equipment, wiring harness and connectors since DEF is strongly corrosive to metal.

Main Causes of Failure in Wiring Harness Defective contact of connectors (defective contact between male and female connectors) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.

Defective crimping or soldering of connectors The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage.

00-56

WA320-8

00 Index and Foreword

Precautions When You Handle Electrical Equipment

Disconnection in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the soldering, or break the wiring harness.

Water entering the connector by high-pressure jetting The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet.

Do not spray water directly on the connector.

If the connector is waterproof, intruded water is hardly drained.

Once water enters into the connector, water goes through pins to cause short-circuit. Drying the drenched connector or take appropriate actions before providing electricity.

Entry of water, dirt, or dust when disconnecting a connector If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a dry cloth or blow it with compressed air.

Oil, mud, or dust stuck to connector If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through resulting in defective contact. If any oil, grease, dirt or dust is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air, and wash it with electrical contact restorer.

NOTICE • When wiping the jointed portion of the connector, do not apply excessive force or deform the pins.

• If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from.

WA320-8

00-57

Precautions When You Handle Fuel System Equipment

00 Index and Foreword

Precautions When You Handle Fuel System Equipment The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.

Select an Applicable Workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.

Seal the Opening Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.

NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.

Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.

How to Clean Parts When Dirt is Stuck If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.

Precautions When You Replace Fuel Filter Cartridge Be sure to use the Komatsu genuine fuel filter cartridge.

NOTICE The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter other than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.

00-58

WA320-8

00 Index and Foreword

Precautions When You Handle Intake System Equipment

Precautions When You Handle Intake System Equipment The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the intake system.

Select an Applicable Workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.

Seal the Opening Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.

NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter it.

WA320-8

00-59

Practical Use of KOMTRAX

00 Index and Foreword

Practical Use of KOMTRAX Various information which KOMTRAX system transmits by using the radio communication is useful for KOMTRAX operator to provide various services for the customers.

When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.

Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.

REMARK (KOMTRAX may not be installed to the machine in some countries or areas.)

Advantage to Use KOMTRAX •

The location where the machine is working at can be checked on the map in a personal computer.

•

Operation information such as service meter, operating hours, fuel consumption, and occurred caution as well as failure code can be checked.

•

The operator can check the hours used and replacement interval of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.

•

Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be checked, and it is used to presume the machine operating condition.

•

Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is utilized as an advice tool for the user and operator.

•

KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the soundness of machine, in addition to KOMTRAX function described above. These data can be used on personal computer screens.

How to Make a Full Use of KOMTRAX Making use of KOMTRAX enables the following activities.

•

•

Quick response to a request for immediate repair 1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair request from a user.

2.

To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.

3.

To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.

Proactive maintenance 1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure code indicated by a red or yellow flag.

2. To check the condition of the machine with the customer and to make a plan to visit.

3.

•

To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.

Practice of periodic maintenance and periodic inspection service 1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits for the consumable parts indicated by red flags are over.

2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer.

3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.

How to Operate KOMTRAX For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.

00-60

WA320-8

00 Index and Foreword

Disconnect and Connect Push-Pull Type Coupler

Disconnect and Connect Push-Pull Type Coupler REMARK • Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.

• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.

How to Disconnect and Connect Type 1 Push-Pull Type Coupler Disconnection 1.

Hold adapter (1), and push hose joint (2) into mating adapter (3).

REMARK • Push it in approximately 3.5 mm.

• Do not hold rubber cap portion (4).

2.

While having adapter (3) inserted into hose side joint (2), insert rubber cap (4) to adapter (3) side until it clicks.

3.

Hold hose adapter (1) or hose (5), and pull it out.

REMARK Provide an oil container to receive a quantity of hydraulic oil which may flow out.

Connection 1.

Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis.

REMARK Do not hold rubber cap portion (4).

WA320-8

00-61

Disconnect and Connect Push-Pull Type Coupler

2.

00 Index and Foreword

After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition.

REMARK When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a problem.

How to Disconnect and Connect Type 2 Push-Pull Type Coupler Disconnection 1.

Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.

2.

While keeping the condition of step 1, turn lever (3) to the right (clockwise).

3.

While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.

REMARK Provide an container to receive a quantity of hydraulic oil which may flow out.

00-62

WA320-8

00 Index and Foreword

Disconnect and Connect Push-Pull Type Coupler

Connection Hold the tightening adapter part, and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.

How to Disconnect and Connect Type 3 Push-Pull Type Coupler Disconnection 1.

Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.

2.

While keeping the condition of step 1, push cover (3) straight until it contacts contact surface (a) of the hexagonal portion on the male side.

3.

While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.

REMARK Provide an container to receive a quantity of hydraulic oil which may flow out.

WA320-8

00-63

Disconnect and Connect Push-Pull Type Coupler

00 Index and Foreword

Connection Hold the tightening adapter part, and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.

00-64

WA320-8

00 Index and Foreword

Foreword, Safety, Basic Information

Precautions for Disconnection and Connection of Connectors Disconnect Connectors 1.

Hold the connectors when disconnecting.

When disconnecting the connectors, always hold the connecting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel.

NOTICE Do not pull the connectors with one hand.

REMARK If it is a lock stopper type connector, pull it out as pushing the stopper (1) with your thumb.

2.

When removing a connector from a clip •

Both of the connector and clip have stoppers (2), which are engaged with each other when the connector is connected.

•

When removing a connector from a clip, pull the connector in parallel with the clip as removing stoppers.

NOTICE If the connector is pried up and down or to the right or left, it may break the housing.

3.

Action to be taken after removing connectors After removing the connector, cover it with plastic bags to prevent entry of dust, dirt, oil, or water in the contact portion.

NOTICE Be sure to cover the connector with plastic bags when leaving the machine disassembled for a long time, otherwise defective contact may occur.

Connect Connectors 1.

Check the connector visually.

•

Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).

WA320-8

00-65

Foreword, Safety, Basic Information

00 Index and Foreword

•

Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.

•

Check that there is no damage or crack on the external surfaces of the connectors.

NOTICE • If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is any water intrusion into the connector, warm the inside of the connector and harness with a dryer. Do not overheat the connector, otherwise short circuit may occur.

• If there is any damage or breakage, replace the connector.

2.

Connecting the connector securely Position connector (1) correctly, and fit it in securely.

REMARK If the connector is lock stopper type, insert it until it clicks.

3.

Correct the protrusion of the boot and misalignment of the wiring harness.

•

If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position.

REMARK If the protrusion of the boot and misalignment of the wiring harness cannot be fixed, remove the clamp to adjust them.

•

If the connector clamp is removed, be sure to return it to its original position. Check that there is no looseness.

Dry Wiring Harness REMARK If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.

If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.

00-66

WA320-8

00 Index and Foreword

1.

Foreword, Safety, Basic Information

Disconnect the connector and wipe off the water with a dry cloth.

NOTICE If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow.

2.

Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry the connector.

NOTICE Hot air from a dryer can be used, but limit the time of using a dryer to prevent the connector or related parts from becoming too hot, as this will cause deformation or damage to the connector.

3.

Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected, connect T-adapter(1), and perform a continuity test to check for any short circuits between pins caused by water or etc.

REMARK After the connector is completely dried, blow the contact restorer, and reassemble them.

Handle Controller

k When performing arc welding on the machine body, disconnect all of the wiring harness connectors

connected to the controller. Fit an arc welding ground close to the welding point.

WA320-8

00-67

Foreword, Safety, Basic Information

00 Index and Foreword

NOTICE • Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine.

• Do not leave things on the controller.

• Cover the connector portion of the controller with a tape and a plastic bag. Do not touch the connecting portion of connector.

• Do not leave the controller in a place where it is exposed to rain.

• Do not place the controller on oil, water, soil or any places where the temperature is likely to be high even for a short period of time (Place it on a suitable dry stand).

Precautions for Troubleshooting Electrical Circuits •

Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.

•

Before performing troubleshooting, check all the related connectors for loose connection.

REMARK Check the related connectors for their performance by disconnecting and connecting them several times.

•

Be sure to connect all the disconnected connectors before proceeding to the next step.

NOTICE If the starting switch is turned to ON position while the connectors are disconnected, an unrelated failure beside the actual failed part may be displayed.

•

When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change.

NOTICE If the value changes on the multimeter, there may be a defective contact in the circuit.

00-68

WA320-8

00 Index and Foreword

Foreword, Safety, Basic Information

How to Disconnect and Connect Deutsch Connector Disconnect DEUTSCH Connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2).

Connect DEUTSCH Connector 1.

Push in female connector (2) horizontally, and insert it straight until it clicks. (Arrow: x)

2.

In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z) REMARK Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.

WA320-8

00-69

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Foreword, Safety, Basic Information

00 Index and Foreword

How to Disconnect and Connect Slide Lock Type Connector How to Disconnect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2) 1.

Slide lock (L1) to the right.

2.

While pressing lock (L2), pull out connector (1) toward you.

REMARK If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward you, push up portion A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.

How to Connect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2) Insert it straight until it clicks.

How to Disconnect Slide Lock Type Connector (FRAMATOME-24) 1.

Slide down lock (red) (L1).

00-70

WA320-8

00 Index and Foreword

2.

Foreword, Safety, Basic Information

While pressing lock (L2), pull out connector (1).

REMARK Lock (L2) is located behind connector (1) in the figure.

How to Connect Slide Lock Type Connector (FRAMATOME-24) Insert it straight until it clicks.

WA320-8

00-71

Foreword, Safety, Basic Information

00 Index and Foreword

How to Disconnect and Connect Connector with Lock to Pull How to Disconnect Connector with Lock to Pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.

How to Connect Connector with Lock to Pull Insert the connector securely until it “clicks”.

00-72

WA320-8

00 Index and Foreword

Foreword, Safety, Basic Information

How to Disconnect and Connect Connector with Lock to Push How to Disconnect Connector with Lock to Push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow.

• 114 series

•

107 series

REMARK If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.

While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

How to Connect Connector with Lock to Push (BOSCH-3) Insert it straight until it clicks.

WA320-8

00-73

Foreword, Safety, Basic Information

00 Index and Foreword

How to Disconnect Connector with Lock to Push (AMP-3) While pressing lock (E), pull out connector (5) in the direction of the arrow.

How to Connect Connector with Lock to Push (AMP-3) Insert it straight until it clicks.

How to Disconnect Connector with Lock to Push (SUMITOMO-3) While pressing lock (E), pull out connector (5) in the direction of the arrow.

REMARK Pull up the connector straight.

How to Connect Connector with Lock to Push (SUMITOMO-3) Insert it straight until it clicks.

How to Disconnect Connector with Lock to Push (SUMITOMO-4) While pressing lock (D), pull out connector (4) in the direction of the arrow.

How to Connect Connector with Lock to Push (SUMITOMO-4) Insert it straight until it clicks.

00-74

WA320-8

00 Index and Foreword

Foreword, Safety, Basic Information

How to Disconnect and Connect Connector with Housing to Rotate How to Disconnect Connector with Housing to Rotate Turn housing (H1) to the left, and pull it out.

REMARK Housing (H1) is left on the wiring harness side.

Connect Connector with Housing to Rotate 1.

Insert the connector to the end while aligning its groove to the other.

2.

Turn housing (H1) clockwise until it clicks.

WA320-8

00-75

How to Read the Codes for Electric Cable

00 Index and Foreword

How to Read the Codes for Electric Cable In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.

The electrical wire code is helpful in understanding the electrical circuit diagram.

Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85 Indicates type of wire by symbol.

AEX

0.85 L

Type, symbol, and material of wire are shown in (Table 1).

(Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on the diagram.)

Indicates size of wire by nominal No. Sizes (Nominal Nos.) are shown in (Table 2).

Indicates color of wire by color code.

Color codes are shown in (Table 3).

Type, Symbol, and Material AV and AVS are different in only thickness and outside diameter of the coating. The conductors of CAVS and AVSS are round compressed conductors. And the outside diameter of the conductor and the thickness of the coating are different from those of AV and AVS. As for AEX, the thickness and outside diameter of the coating are similar to those of AV, but the coating material is different from that of AV and AVS. (Table 1) Type

Symbol

Low-voltage wire for automobile

AV

Thin-cover low-voltage wire for automobile

Conductor material

Insulator material

Temperature range (°C) in use

Example of use For large current wiring (nominal No. 5 and above)

General wiring

AVS -30 to +60

(nominal No. 3 and lower)

(Type 1) Thin-cover low-voltage wire for automobile

Soft polyvinyl chloride CAVS

(nominal No. 1.25 and lower)

(Type 2) Ultra-thin-cover low-voltage power supply AVSS for automobiles Heat-resistant low-voltage wire for automobile

Annealed copper for electric appliance -40 to +80

For industrial vehicles (for forklift trucks) Nominal No.0.5f to 2f General wiring for extremely cold weather specification

AEX

Heat-resistant ultra-thin lowAESS voltage elecX trical wire for automobiles

00-76

For mid- to small-size excavators

Heat-resistant crosslinked polyethylene

Wiring at high-temperature place -50 to +110 Extremely cold area and heat resistance specifications Thin-cover wiring

WA320-8

00 Index and Foreword

How to Read the Codes for Electric Cable

Dimensions

(Table 2) Nominal No.

Coating D

Conductor

0.5f

(0.5)

0.75f

(0.85)

1.25f

(1.25)

2f

2

3f

3

5

Number of strands

20

7

30

11

50

16

37

26

58

41

65

Diameter of strand

0.18

0.32

0.18

0.32

0.18

0.32

0.26

0.32

0.26

0.32

0.32

Cross-sectional area (mm2)

0.51

0.56

0.76

0.88

1.27

1.29

1.96

2.09

3.08

3.30

5.23

d (approx.)

1.0

1.2

1.5

1.9

1.9

2.3

2.4

3.0

AVS

Standard

2.0

2.2

2.5

2.9

2.9

3.5

3.6

-

AV

Standard

-

-

-

-

-

-

-

4.6

AEX

Standard

2.0

2.2

2.7

3.0

3.1

-

3.8

4.6

Nominal No.

8

15

20

30

40

50

60

85

100

Number of strands

50

84

41

70

85

108

127

169

217

Diameter of strand

0.45

0.45

0.80

0.80

0.80

0.80

0.80

0.80

0.80

Cross-sectional area (mm2)

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

d (approx.)

3.7

4.8

6.0

8.0

8.6

9.8

10.4

12.0

13.6

AVS

Standard

-

-

-

-

-

-

-

-

-

AV

Standard

5.3

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

AEX

Standard

5.3

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

Coating D

Conductor

Nominal No.

Conductor

WA320-8

0.5f

0.5

0.75f

0.85

1.25f

1.25

Number of strands

-

7

-

11

-

16

Diameter of strand

-

round compression

-

round compression

Cross-sectional area (mm2)

-

0.56

-

0.88

-

1.29

d (approx.)

-

0.9

-

1.1

-

1.4

round compression

00-77

Coating D

How to Read the Codes for Electric Cable

00 Index and Foreword

Nominal No.

0.5f

0.5

0.75f

0.85

1.25f

1.25

CAVS Standard

-

1.6

-

1.8

-

2.1

Nominal No.

Coating D

Conductor

AVSS

0.5f

0.75f

1.25f

2f

Number of strands

19

19

37

37

Diameter of strand

0.19

0.23

0.21

0.26

Cross-sectional area (mm2)

0.54

0.79

1.28

2

d (approx.)

1

1.2

1.5

1.8

Standard

1.6

1.8

2.1

2.6

0.5f

0.75f

1.25f

2f

Number of strands

19

19

37

37

Diameter of strand

0.19

0.23

0.21

0.26

Cross-sectional area (mm2)

0.5387

0.7894

1.282

1.964

d (approx.)

1

1.2

1.5

1.8

Standard

1.6

1.8

2.1

2.6

Nominal No.

Coating D

Conductor

AESSX

REMARK “f” of nominal No. denotes “flexible”.

Color Code Table (Table 3) Color Code

00-78

Color of wire

Color Code

Color of wire

B

Black

LgW

Light green and White

Br

Brown

LgY

Light green and Yellow

BrB

Brown and Black

LR

Blue and Red

BrR

Brown and Red

LW

Blue and White

BrW

Brown and White

LY

Blue and Yellow

BrY

Brown and Yellow

O

Orange

Ch

Charcoal

P

Pink

Dg

Dark green

R

Red

G

Green

RB

Red and Black

GB

Green and Black

RG

Red and Green

GL

Green and Blue

RL

Red and Blue

Gr

Gray

RW

Red and White

GR

Green and Red

RY

Red and Yellow

WA320-8

00 Index and Foreword

Color Code

How to Read the Codes for Electric Cable

Color of wire

Color Code

Color of wire

GW

Green and White

Sb

Sky Blue

GY

Green and Yellow

Y

Yellow

L

Blue

YB

Yellow and Black

LB

Blue and Black

YG

Yellow and Green

Lg

Light green

YL

Yellow and Blue

LgB

Light green and Black

YR

Yellow and Red

LgR

Light green and Red

YW

Yellow and White

REMARK In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking.

Example) GW indicates that the background is “Green” and marking is “White”.

Circuit Type and Color Code Type of wire

AVS, AV, CAVS, AVSS

AEX,AESSX

Charge

R

WG

-

-

-

-

R

-

Ground

B

-

-

-

-

-

B

-

Start

R

-

-

-

-

-

R

-

Light

RW

RB

RY

RG

RL

-

O

-

Instrument

Y

YR

YB

YG

YL (*1)

YW (*1)

Y

Gr

Signal

G

GW

GR

GY

GB

GL (*1)

G

Br

L

LW

LR

LY

LB

-

L

-

Br

BrW (*2)

BrR (*2)

BrY (*2)

BrB (*2)

-

-

-

Lg

LgR (*2)

LgY (*1)

LgB (*2)

LgW (*1)

-

-

-

O (*1)

-

-

-

-

-

-

-

Gr

-

-

-

-

-

-

-

P

-

-

-

-

-

-

-

Sb

-

-

-

-

-

-

-

Dg (*1)

-

-

-

-

-

-

-

Ch (*1)

-

-

-

-

-

-

-

Type of circuit

Others

*1: This item is not set to AVSS. *2: This item is not set to 0.75f to 2f of AVSS.

WA320-8

00-79

Explanation of Terms for Maintenance Standard

00 Index and Foreword

Explanation of Terms for Maintenance Standard The maintenance standard section shows the judgment criteria whether the equipment or parts should be replaced or can be reused when the machine is disassembled for the maintenance. The following terms are the descriptions of the judgment criteria.

Standard Dimension and Tolerance •

The finished dimension of a part is slightly different from one to another actually.

•

A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the part.

•

The dimension set as the standard is called the standard dimension and the allowable range of difference from this standard dimension is called “tolerance”.

•

An indication example of a standard dimension and tolerance is shown in the following table.

(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side)

Example: Standard dimension

Tolerance -0.022

120

-0.126

•

The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/ lower limit of tolerance).”

Example) 120 (-0.022/ -0.126)

•

Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is determined by the tolerance.

•

A dimension indication example of a shaft and hole is shown in the following table.

(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Standard dimension

60

00-80

Tolerance Shaft

Hole

-0.030

+0.046

-0.076

0

WA320-8

00 Index and Foreword

Explanation of Terms for Maintenance Standard

Standard Clearance and Standard Value •

The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance.

•

When some parts are repaired, the clearance is generally adjusted to the standard clearance.

•

The values indicating performance and function of new products or equivalent are called “standard value”, which is indicated by a range or a target value.

•

When some parts are repaired, the value of performance/ function is set to the standard value.

Standard Interference •

When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called “interference”.

•

Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is “standard interference”.

•

After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.

Allowable Limit, Allowable Value, or Allowable Dimension •

The dimension of parts changes due to the wear or deformation while they are used. When the dimension changes exceeding certain value, parts cannot be used any longer. This value is called “repair limit”.

•

If a part is worn to the repair limit, it must be replaced or repaired.

•

The performance and function of products lower while they are used. A value with which the product can be used without causing a problem is called “allowable value” or “allowable dimension”.

•

A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgment must be made in consideration of the operating condition and customer's requirement.

Allowable Clearance •

Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called “allowable clearance”.

•

If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.

Allowable Interference •

The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called “allowable interference”.

•

The allowable interference shows the repair limit of the part of smaller tolerance.

WA320-8

00-81

Explanation of Terms for Maintenance Standard

•

00 Index and Foreword

The parts whose interferences are out of the allowable interference must be replaced or repaired.

00-82

WA320-8

00 Index and Foreword

Standard Tightening Torque Table

Standard Tightening Torque Table Table of Tightening Torque for Bolts and Nuts REMARK Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.

Thread diameter (mm) 6

8

10

12 14 16

Width across flats (mm) 10 (*2) 10 13 (*2) 12 17 (*1, *2) 14 19 (*1, *2) 17 22 24 (*1) 22

Tightening torque (Nm {kgfm} ) 11.8 to 14.7 {1.2 to 1.5}

27 to 34 {2.8 to 3.5}

59 to 74 {6 to 7.5}

98 to 123 {10 to 12.5} 153 to 190 {15.5 to 19.5} 235 to 285 {23.5 to 29.5}

18

27

320 to 400 {33 to 41}

20

30

455 to 565 {46.5 to 58}

22

32

610 to 765 {62.5 to 78}

24

36

785 to 980 {80 to 100}

27

41

1150 to 1440 {118 to 147}

30

46

1520 to 1910 {155 to 195}

33

50

1960 to 2450 {200 to 250}

36

55

2450 to 3040 {250 to 310}

39

60

2890 to 3630 {295 to 370}

*1: Split flange bolt *2: Flanged bolt REMARK Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in the table below.

WA320-8

00-83

CLICK HERE TO

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Standard Tightening Torque Table

Thread diameter (mm)

00 Index and Foreword

Width across flats (mm)

Tightening torque (Nm {kgfm} )

6

10

5.9 to 9.8 {0.6 to 1.0}

8

12

13.7 to 23.5 {1.4 to 2.4}

10

14

34.3 to 46.1 {3.5 to 4.7}

12

17

74.5 to 90.2 {7.6 to 9.2}

REMARK Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise specified.

Type of bolt Nominal size threads per inch

A

B

Tightening torque (Nm {kgfm} )

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

9.8 to 14.7 {1 to 1.5}

12.7 {1.3}

2.9 to 3.9 {0.3 to 0.4}

3.43 {0.35}

5/

16-18UNC

24.5 to 34.3 {2.5 to 3.5}

29.4 {3}

6.9 to 8.8 {0.7 to 0.9}

7.8 {0.8}

3/ -16UNC 8

44.1 to 58.8 {4.5 to 6}

52.0 {5.3}

9.8 to 14.7 {1 to 1.5}

11.8 {1.2}

7/

16-14UNC

73.5 to 98.1 {7.5 to 10}

86.3 {8.8}

19.6 to 24.5 {2 to 2.5}

21.6 {2.2}

1/ -13UNC 2

108 to 147 {11 to 15}

127 {13}

29.4 to 39.2 {3 to 4}

34.3 {3.5}

9/

16-12UNC

157 to 216 {16 to 22}

186 {19}

44.1 to 58.8 {4.5 to 6}

51.0 {5.2}

5/ -11UNC 8

226 to 294 {23 to 30}

265 {27}

63.7 to 83.4 {6.5 to 8.5}

68.6 {7}

3/ -10UNC 4

392 to 530 {40 to 54}

461 {47}

108 to 147 {11 to 15}

127 {13}

7/ -9UNC 8

637 to 853 {65 to 87}

745 {76}

177 to 235 {18 to 24}

206 {21}

1/ -20UNC 4

00-84

WA320-8

00 Index and Foreword

Standard Tightening Torque Table

Type of bolt Nominal size threads per inch

A

B

Tightening torque (Nm {kgfm} )

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

1-8UNC

883 to 1196 {90 to 122}

1040 {106}

245 to 333 {25 to 34}

284 {29}

11/8-7UNC

1187 to 1608 {121 to 164}

1393 {142}

333 to 451 {34 to 46}

392 {40}

11/4-7UNC

1598 to 2157 {163 to 220}

1873 {191}

451 to 608 {46 to 62}

530 {54}

11/2-6UNC

2354 to 3177 {240 to 324}

2765 {282}

657 to 892 {67 to 91}

775 {79}

REMARK Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise specified.

Type of bolt Nominal size threads per inch

A

B

Tightening torque (Nm {kgfm} )

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

1/ -28UNF 4

14.7 to 19.6 {1.5 to 2}

17.7 {1.8}

3.9 to 4.9 {0.4 to 0.5}

4.41 {0.45}

5/

16-24UNF

34.3 to 39.2 {3.5 to 4}

34.3 {3.5}

7.8 to 9.8 {0.8 to 1}

8.8 {0.9}

3/ -24UNF 8

53.9 to 68.6 {5.5 to 7}

61.8 {6.3}

14.7 to 19.6 {1.5 to 2}

16.7 {1.7}

7/

16-20UNF

83.4 to 108 {8.5 to 11}

96.1 {9.8}

24.5 to 29.4 {2.5 to 3}

26.5 {2.7}

1/ -20UNF 2

127 to 167 {13 to 17}

147 {15}

34.3 to 49.0 {3.5 to 5}

41.2 {4.2}

9/

16-18UNF

186 to 245 {19 to 25}

216 {22}

49.0 to 68.6 {5 to 7}

58.8 {6}

5/ -18UNF 8

255 to 343 {26 to 35}

294 {30}

73.5 to 98.1 {7.5 to 10}

83.4 {8.5}

3/ -16UNF 4

441 to 598 {45 to 61}

520 {53}

127 to 167 {13 to 17}

147 {15}

7/ -14UNF 8

716 to 961 {73 to 98}

843 {86}

196 to 265 {20 to 27}

226 {23}

1-14UNF

1020 to 1373 {104 to 140}

1196 {122}

284 to 382 {29 to 39}

333 {34}

11/8-12UNF

1353 to 1844 {138 to 188}

1598 {163}

382 to 520 {39 to 53}

451 {46}

11/4-12UNF

1804 to 2432 {184 to 248}

2118 {216}

510 to 686 {52 to 70}

598 {61}

11/2-12UNF

2707 to 3658 {276 to 373}

3177 {324}

765 to 1030 {78 to 105}

892 {91}

WA320-8

00-85

Standard Tightening Torque Table

00 Index and Foreword

Table of Tightening Torque for O-Ring Boss Piping Joints REMARK Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.

Nominal No.

Thread di- Width across flats (mm) ameter (mm)

02

14

-

18

03, 04

20

05, 06

24

10, 12

33

14

42

Varies depending on type of connector.

Tightening torque (Nm {kgfm} ) Range

Target

35 to 63 {3.5 to 6.5}

44 {4.5}

59 to 98 {6.0 to 10.0}

78 {8.0}

84 to 132 {8.5 to 13.5}

103 {10.5}

128 to 186 {13.0 to 19.0}

157 {16.0}

363 to 480 {37.0 to 49.0}

422 {43.0}

746 to 1010 {76.0 to 103}

883 {90.0}

Table of Tightening Torque for O-Ring Boss Plugs REMARK Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.

Nominal No.

00-86

Thread diam- Width across eter (mm) flats (mm)

Tightening torque (Nm {kgfm} ) Range

Target

08

8

14

5.88 to 8.82 {0.6 to 0.9}

7.35 {0.75}

10

10

17

9.8 to 12.74 {1.0 to 1.3}

11.27 {1.15}

12

12

19

14.7 to 19.6 {1.5 to 2.0}

17.64 {1.8}

14

14

22

19.6 to 24.5 {2.0 to 2.5}

22.54 {2.3}

16

16

24

24.5 to 34.3 {2.5 to 3.5}

29.4 {3.0}

WA320-8

00 Index and Foreword

Nominal No.

Standard Tightening Torque Table

Tightening torque (Nm {kgfm} )

Thread diam- Width across eter (mm) flats (mm)

Range

Target

18

18

27

34.3 to 44.1 {3.5 to 4.5}

39.2 {4.0}

20

20

30

44.1 to 53.9 {4.5 to 5.5}

49.0 {5.0}

24

24

32

58.8 to 78.4 {6.0 to 8.0}

68.6 {7.0}

30

30

32

93.1 to 122.5 {9.5 to 12.5}

107.8 {11.0}

33

33

-

107.8 to 147.0 {11.0 to 15.0}

127.4 {13.0}

36

36

36

127.4 to 176.4 {13.0 to 18.0}

151.9 {15.5}

42

42

-

181.3 to 240.1 {18.5 to 24.5}

210.7 {21.5}

52

52

-

274.4 to 367.5 {28.0 to 37.5}

323.4 {33.0}

Table of Tightening Torque for Hose (Taper Seal Type and Face Seal Type) REMARK • Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table unless otherwise specified.

• The table is applied to the threaded portion coated with engine oil (wet threaded portion).

Nominal No. of hose

Width across flats (mm)

02

19

Tightening torque (Nm {kgfm} )

Taper seal

Face seal Nominal size - Thread root diameter(mm) threads per inch (reference)

Range

Target

Thread size (mm)

34 to 54 {3.5 to 5.5}

44 {4.5}

-

34 to 63 {3.5 to 6.5}

44 {4.5}

14

22

54 to 93 {5.5 to 9.5}

74 {7.5}

-

24

59 to 98 {6.0 to 10.0}

78 {8.0}

04

27

84 to 132 {8.5 to 13.5}

05

32

06

36

(10)

41

(12) (14)

03

WA320-8

9/

16-18UN

14.3

-

-

16-16UN

17.5

18

-

-

103 {10.5}

22

13/ -16UN 16

20.6

128 to 186 {13.0 to 19.0}

157 {16.0}

24

1 -14UNS

25.4

177 to 245 {18.0 to 25.0}

216 {22.0}

30

13/16-12UN

30.2

177 to 245 {18.0 to 25.0}

216 {22.0}

33

-

-

240 to 300 {24.5 to 30.5}

270 {27.5}

-

17/16-12UN

36.5

46

197 to 294 {20.0 to 30.0}

245 {25.0}

36

-

-

55

246 to 343 {25.0 to 35.0}

294 {30.0}

42

-

-

11/

00-87

Standard Tightening Torque Table

00 Index and Foreword

Table of Tightening Torque for Face Seal Joints REMARK • The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated low pressure piping which is used for engine.

• The table is applied to the threaded portion coated with engine oil (wet threaded portion).

• Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.

Outside diameter of adequate pipe (mm)

Width across flats (mm)

8

Tightening torque (Nm {kgfm} )

Face seal Nominal size threads per inch

Thread root diameter(mm) (reference)

Range

Target

19

14 to 16 {1.4 to 1.6}

15 {1.5}

9/

16-18UN

14.3

10

22

24 to 27 {2.4 to 2.7}

25.5 {2.6}

11/ -16UN 16

17.5

12

24 (27)

43 to 47 {4.4 to 4.8}

45 {4.6}

13/

16-16UN

20.6

15 (16)

30 (32)

60 to 68 {6.1 to 6.8}

64 {6.5}

1 -14UNS

25.4

22 (20)

36

90 to 95 {9.2 to 9.7}

92.5 {9.4}

13/16-12UN

30.2

Tightening Torque Table for Bolts and Nuts on 102, 107 and 114 Series Engines REMARK Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table unless otherwise specified.

Thread diameter (mm)

Tightening torque (Nm {kgfm} )

6

10±2 {1.02±0.20}

8

24±4 {2.45±0.41}

10

43±6 {4.38±0.61}

12

77±12 {7.85±1.22}

14

-

Tightening Torque Table for 102, 107, and 114 Series Engines (Joint Bolts) REMARK Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following table unless otherwise specified.

00-88

WA320-8

00 Index and Foreword

Standard Tightening Torque Table

Thread diameter (mm)

Tightening torque (Nm {kgfm} )

6

8±2 {0.81±0.20}

8

10±2 {1.02±0.20}

10

12±2 {1.22±0.20}

12

24±4 {2.45±0.41}

14

36±5 {3.67±0.51}

Tightening Torque Table for Tapered Screws on 102, 107, and 114 Series Engines (National Taper Pipe Thread (NPT)) REMARK Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the following table unless otherwise specified.

Material of female screw

In cast iron or steel

In aluminum

Nominal thread size

Tightening torque (Nm {kgfm} )

Tightening torque (Nm {kgfm} )

1/

16

15±2 {1.53±0.20}

5±1 {0.51±0.10}

1/

8

20±2 {2.04±0.20}

15±2 {1.53±0.20}

1/

4

25±3 {2.55±0.31}

20±2 {2.04±0.20}

8

35±4 {3.57±0.41}

25±3 {2.55±0.31}

2

55±6 {5.61±0.61}

35±4 {3.57±0.41}

4

75±8 {7.65±0.82}

45±5 {4.59±0.51}

3/ 1/ 3/

WA320-8

00-89

Conversion Table

00 Index and Foreword

Conversion Table How to Use the Conversion Table The conversion table is provided to enable simple conversion of the numerical numbers between the different units. For further details of the method of using the conversion table, see the examples given below.

Examples to Use the Conversion Table to Change a Unit from mm to in.

When converting 55 mm to in 1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).

2.

Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).

3.

Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit from mm to in. Accordingly, 55 mm = 2.165 in.

When converting 550 mm to in 1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left) to get 55 mm.

2. Convert 55 mm to 2.165 in according to the preceding procedure.

3.

The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point one place to the right) to restore the target value. This gives 550 mm = 21.65 in

mm to in (B) 1 mm = 0.03937 in 0

1

2

3

4

5

6

7

8

9

0

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

(C) (A)

50

1.969

2.008

2.017

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.847

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.780

3.819

3.858

3.898

mm to in 1 mm = 0.03937 in 0

1

2

3

4

5

6

7

8

9

0

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

00-90

WA320-8

00 Index and Foreword

Conversion Table

1 mm = 0.03937 in 0

1

2

3

4

5

6

7

8

9

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.847

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

kg to lb 1 kg = 2.2046 lb 0

1

2

3

4

5

6

7

8

9

0

0

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

ℓ to U.S.Gal 1 ℓ = 0.2642 U.S.Gal 0

1

2

3

4

5

6

7

8

9

0

0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

ℓ to U.K.Gal 1 ℓ = 0.21997 U.K.Gal 0

1

2

3

4

5

6

7

8

9

0

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

WA320-8

00-91

Conversion Table

00 Index and Foreword

1 ℓ = 0.21997 U.K.Gal 0

1

2

3

4

5

6

7

8

9

30

6.599

6.819

7.039

7.259

7.479

7.699

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

kgfm to lbft 1 kgfm = 7.233 lbft 0

1

2

3

4

5

6

7

8

9

0

0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

kgf/cm2 to lb/in2 1 kgf/cm2 = 14.2233 lb/in2 0

1

2

3

4

5

6

7

8

9

0

0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

00-92

WA320-8

00 Index and Foreword

Conversion Table

1 kgf/cm2 = 14.2233 lb/in2 0

1

2

3

4

5

6

7

8

9

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

Temperature Conversion of Fahrenheit to Celsius •

A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures in the center of the following table show the temperatures in both Fahrenheit and Celsius.

•

When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.

•

When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.

1 °C = 33.8 °F °C

°F

°C

°F

°C

°F

°C

°F

-40.4

-40

-40.0

-11.7

11

51.8

7.8

46

114.8

27.2

81

177.8

-37.2

-35

-31.0

-11.1

12

53.6

8.3

47

116.6

27.8

82

179.6

-34.4

-30

-22.0

-10.6

13

55.4

8.9

48

118.4

28.3

83

181.4

-31.7

-25

-13.0

-10.0

14

57.2

9.4

49

120.2

28.9

84

183.2

-28.9

-20

-4.0

-9.4

15

59.0

10.0

50

122.0

29.4

85

185.0

-28.3

-19

-2.2

-8.9

16

60.8

10.6

51

123.8

30.0

86

186.8

WA320-8

00-93

Conversion Table

00 Index and Foreword

1 °C = 33.8 °F °C

°F

°C

°F

°C

°F

°C

°F

-27.8

-18

-0.4

-8.3

17

62.6

11.1

52

125.6

30.6

87

188.6

-27.2

-17

1.4

-7.8

18

64.4

11.7

53

127.4

31.1

88

190.4

-26.7

-16

3.2

-7.2

19

66.2

12.2

54

129.2

31.7

89

192.2

-26.1

-15

5.0

-6.7

20

68.0

12.8

55

131.0

32.2

90

194.0

-25.6

-14

6.8

-6.1

21

69.8

13.3

56

132.8

32.8

91

195.8

-25.0

-13

8.6

-5.6

22

71.6

13.9

57

134.6

33.3

92

197.6

-24.4

-12

10.4

-5.0

23

73.4

14.4

58

136.4

33.9

93

199.4

-23.9

-11

12.2

-4.4

24

75.2

15.0

59

138.2

34.4

94

201.2

-23.3

-10

14.0

-3.9

25

77.0

15.6

60

140.0

35.0

95

203.0

-22.8

-9

15.8

-3.3

26

78.8

16.1

61

141.8

35.6

96

204.8

-22.2

-8

17.6

-2.8

27

80.6

16.7

62

143.6

36.1

97

206.6

-21.7

-7

19.4

-2.2

28

82.4

17.2

63

145.4

36.7

98

208.4

-21.1

-6

21.2

-1.7

29

84.2

17.8

64

147.2

37.2

99

210.2

-20.6

-5

23.0

-1.1

30

86.0

18.3

65

149.0

37.8

100

212.0

-20.0

-4

24.8

-0.6

31

87.8

18.9

66

150.8

40.6

105

221.0

-19.4

-3

26.6

0

32

89.6

19.4

67

152.6

43.3

110

230.0

-18.9

-2

28.4

0.6

33

91.4

20.0

68

154.4

46.1

115

239.0

-18.3

-1

30.2

1.1

34

93.2

20.6

69

156.2

48.9

120

248.0

-17.8

0

32.0

1.7

35

95.0

21.1

70

158.0

51.7

125

257.0

-17.2

1

33.8

2.2

36

96.8

21.7

71

159.8

54.4

130

266.0

-16.7

2

35.6

2.8

37

98.6

22.2

72

161.6

57.2

135

275.0

-16.1

3

37.4

3.3

38

100.4

22.8

73

163.4

60.0

140

284.0

-15.6

4

39.2

3.9

39

102.2

23.3

74

165.2

62.7

145

293.0

-15.0

5

41.0

4.4

40

104.0

23.9

75

167.0

65.6

150

302.0

-14.4

6

42.8

5.0

41

105.8

24.4

76

168.8

68.3

155

311.0

-13.9

7

44.6

5.6

42

107.6

25.0

77

170.6

71.1

160

320.0

-13.3

8

46.4

6.1

43

109.4

25.6

78

172.4

73.9

165

329.0

-12.8

9

48.2

6.7

44

111.2

26.1

79

174.2

76.7

170

338.0

-12.2

10

50.0

7.2

45

113.0

26.7

80

176.0

79.4

175

347.0

00-94

WA320-8

01 Specifications

WA320-8

01-1

Table of Contents

01 Specifications

Table of Contents Abbreviation List ............................................................................................................................................ 01-3 Specifications................................................................................................................................................. 01-9 Specification Drawing.............................................................................................................................. 01-9 Specification Drawing: WA320-8 ...................................................................................................... 01-9 Specifications.........................................................................................................................................01-11 Specifications: WA320-8 .................................................................................................................01-11 Weight Table ......................................................................................................................................... 01-16 Weight Table: WA320-8.................................................................................................................. 01-16 Table of Fuel, Coolant, and Lubricants .................................................................................................. 01-18

01-2

WA320-8

01 Specifications

Abbreviation List

Abbreviation List •

This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.

•

Abbreviations that are used in general society may not be included.

•

Special abbreviations which appear infrequently are noted in the text.

•

This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of Abbreviations Used in the Text Purpose of use (major applicable machine (*1), or component/system)

Abbreviation

Actual word spelled out

ABS

Antilock Brake System

AISS

Automatic Idling Setting Engine System

This is a function that automatically sets the idle speed.

Steering AJSS

Advanced Joystick Steering System

This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.

ARAC

Automatic Retarder Accelerator Control

Travel and brake (HD, HM)

(WA) Travel and brake (HD, HM) Travel and brake

Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.

This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill.

This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.

ARSC

Automatic Retarder Speed Control

ASR

Travel and brake Automatic Spin Regulator (HD, HM)

This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.

ATT

Attachment

A function or component that can be added to the standard specification.

BCV

BRAKE Brake cooling oil control valve (HD)

CAN

Controller Area Network

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

CDR

Crankcase Depression Regulator

Engine

This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.

CLSS

Closed-center Load Sensing System

Hydraulic system

This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).

WA320-8

(HD, HM)

Work equipment

This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.

01-3

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Abbreviation List

Abbreviation

Actual word spelled out

01 Specifications

Purpose of use (major applicable machine (*1), or component/system)

Explanation

Engine

This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.

Electronic control system

This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)

CRI

Common Rail Injection

ECM

Electronic Control Module

ECMV

Electronic Control Modulation Valve

ECSS

Travel Electronically Controlled Suspension System (WA)

This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.

ECU

Electronic Control Unit

This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)

EGR

Exhaust Gas RecirculaEngine tion

This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.

EMMS

Equipment ManageMachine monitor ment Monitoring System

This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).

EPC

Electromagnetic ProporHydraulic system tional Control

Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.

FOPS

Falling Object Protective Cab and canopy Structure

Transmission (D, HD, WA, etc)

Electronic control system

This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.

This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.

F-N-R

Forward-Neutral-Reverse

GPS

Global Positioning System

GNSS

Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)

HSS

Hydrostatic Steering System

HST

Hydro Static Transmission

Operation Communication (KOMTRAX, KOMTRAX Plus)

Steering

01-4

(D Series) Transmission (D, WA)

Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.

This is a general term for system uses satellites such as GPS, GALILEO, etc.

This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft.

Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.

WA320-8

01 Specifications

Abbreviation List

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*1), or component/system)

Explanation

ICT

Information and Communication Technology

Communication and electronic control

A general term for the engineering and its socially applied technology of information processing and communication.

IMA

Inlet Metering Actuator

Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)

IMU

Inertial Measurement Unit

Engine

This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.

IMV

Inlet Metering Valve

Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)

KCCV

Komatsu Closed CrankEngine case Ventilation

This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.

KCSF

Komatsu Catalyzed Soot Filter

KDOC

Komatsu Diesel Oxidation Catalyst

KDPF

Engine

Engine

Komatsu Diesel ParticuEngine late Filter

This is a filter that captures soot in exhaust gas.

It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas.

It is built in to KDPF or assembled with the muffler.

This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it.

It is installed instead of the conventional muffler.

Travel and brake

This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.

KTCS

Komatsu Traction Control System

(HM)

LCD

Liquid Crystal Display

Machine monitor

This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.

LED

Light Emitting Diode

Electronic parts

This is a semiconductor element that emits light when the voltage is applied in forward direction.

LIN

Local Interconnect Network

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

LS

Load Sensing

Hydraulic system

This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.

LVDS

Low Voltage Differential Signaling

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

Engine

This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.

MAF

WA320-8

Mass Air Flow

01-5

Abbreviation List

01 Specifications

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*1), or component/system)

MMS

Multimedia Messaging Service

Communication

NC

Normally Closed

This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.

NO

Normally Open

This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.

OLSS

Open-center Load Sensing System

Hydraulic system

PC

Pressure Compensation Hydraulic system

PCCS

Palm command control system

PCV

Pre-stroke Control Valve Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.

PPC

Proportional Pressure Control

This is a system that operates actuators in proportion to the oil pressure.

PPM

Piston Pump and Motor

PTO

Power Take Off

PTP

Power Tilt and power Pitch dozer

Steering

ROPS

Roll-Over Protective Structure

(D Series)

Hydraulic system Hydraulic system (D, PC, etc)

Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.

This is a hydraulic system that can operate multiple actuators at the same time regardless of the load.

This is a function that corrects the oil pressure.

This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.

Piston type hydraulic pump and motor.

Power train system

Power take-off mechanism

Work equipment

This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.

(D Series)

Cab and canopy

ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2.

This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.

SCR

Selective Catalytic Reduction

SI

Le Systeme International d' Unites (Internation- Unit al unit system)

Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.

SOL

Solenoid

This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.

01-6

Urea SCR system

Electrical system

WA320-8

01 Specifications

Abbreviation

TOPS

Abbreviation List

Purpose of use (major applicable machine (*1), or component/system)

Actual word spelled out

Tip-Over Protective Structure

Cab and canopy

Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.

TWV

2-Way Valve

Hydraulic system

This is a solenoid valve that switches over direction of flow.

VGT

Variable Geometry Turbocharger

Engine

This is a turbocharger on which the cross-section area of the exhaust passage is variable.

VHPC

Variable Horse Power Control

Engine control

This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.

*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader

List of Abbreviations Used in the Circuit Diagrams Abbreviation

Actual word spelled out

A/C

Air Conditioner

A/D

Analogue-to-Digital

A/M

Air Mix Damper

ACC

Accessory

ADD

Additional

AUX

Auxiliary

BR

Battery Relay

CW

Clockwise

CCW

Counter Clockwise

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actuator

NC

No Connection

WA320-8

01-7

Abbreviation List

01 Specifications

Abbreviation S/T STRG

Steering

SIG

Signal

SOL

Solenoid

STD

Standard

OPT OP

01-8

Actual word spelled out

Option

PRESS

Pressure

SPEC

Specification

SW

Switch

TEMP

Temperature

T/C

Torque Converter

T/M

Transmission

WA320-8

01 Specifications

Specification Drawing

Specifications Specification Drawing Specification Drawing: WA320-8

D

I C

H B

G

E F

A 9 J W0 1 4 5 6

Item

Unit

WA320-8

Machine weight (with BOC) North America specification EU Specification Operating load

kg kg

15400 15370 4480

Bucket capacity (heaped, with BOC) North America specification EU Specification Engine model

m3 -

2.8 2.9 KOMATSU SAA6D107E-3 diesel engine

Engine rated horsepower •

Gross (SAE J1995) (*1)

kW {HP} /

127 {170}/2100 {2100}

•

ISO 14396

min-1 {rpm}

127 {170}/2100 {2100}

•

Net (ISO 9249/SAE J1349) (*2)

123 {165}/2100 {2100}

Overall length (with BOC) A

North America specification EU Specification

B

Overall height

mm mm

7690 7755 3200

Overall height when bucket is raised to the maximum height C

North America specification EU Specification

WA320-8

mm

5375 5395

01-9

Specification Drawing

01 Specifications

Item

Unit

WA320-8

D

Overall width

mm

2590

E

Minimum ground clearance

mm

425

Bucket width F

North America specification

mm

EU Specification

2740 2750

Bucket tip/ BOC tip G

Dumping clearance (*3)

North America specification

mm

EU Specification

2970/2880 2905/2835

Bucket tip/ BOC tip H

Dumping reach (*3)

North America specification

mm

EU Specification I

Forward tilt angle of the bucket (maximum height)

960/1000 985/1020

degree

47

Bucket tip/ BOC tip Minimum turning radius

North America specification

mm

EU Specification

6300/6330

Center of outside tire Allowable towing load

mm

5380

kN {kg}

112 {11415}

1st (Forward/Reverse) Travel speed

2nd (Forward/Reverse) 3rd (Forward/Reverse)

6275/6310

1.0 to 13.0/1.0 to 13.0 km/h

4th (Forward/Reverse)

13.0/13.0 18.7/18.7 38.0/38.0

*1: Indicates the value of the bare engine (without cooling fan). *2: Indicates the value at the minimum cooling fan speed.

REMARK • The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit. Net denotes the value of an engine which is measured under the condition almost the same as that of the time when it would be installed on a machine.

•

The rated horsepower (net) at the maximum cooling fan speed is the following value.

112 kW/151 HP{2100 min-1/2100 rpm}

*3: Indicates the value when the forward tilt angle of the bucket is 45 °.

BOC Abbreviation for Bolt On Cutting edge

01-10

WA320-8

01 Specifications

Specifications

Specifications Specifications: WA320-8 Item

Unit

WA320-8

Weight Machine weight (front wheels + rear wheels) North America specification EU Specification

kg

15400 15370

Machine weight (front wheels) in SAE travel posture North America specification EU Specification

kg

6760 6845

Machine weight (rear wheels) in SAE travel posture North America specification EU Specification

kg

8640 8525

Performance Bucket capacity (heaped) North America specification EU Specification Operating load

m3 kg

2.8 2.9 4480

Travel speed Forward 1st

1.0 to 13.0

Forward 2nd

13.0

Forward 3rd

18.7

Forward 4th

km/h

38.0

Reverse 1st

1.0 to 13.0

Reverse 2nd

13.0

Reverse 3rd

18.7

Reverse 4th

38.0

Maximum drawbar pull Forward

kN {kg}

Reverse Gradeability Minimum turning radius (center of outside tire)

120 {12200} 120 {12200}

degree

25

mm

5380

Turning radius (cutting edge/tip of BOC) in SAE travel posture North America specification EU Specification

mm

6275/6310 6300/6330

BOC Abbreviation for Bolt On Cutting edge Dimensions

WA320-8

01-11

Specifications

01 Specifications

Item

Unit

WA320-8

Overall length (with BOC) North America specification EU Specification Overall width (body)

7690

mm

7755

mm

2590

Bucket width (with BOC) North America specification EU Specification Overall height (top of cab)

2740

mm

2750

mm

3200

Overall height when bucket is raised to the maximum height North America specification EU Specification

5375

mm

5395

Wheelbase

mm

3030

Tread

mm

2050

Minimum ground clearance

mm

425

Maximum hinge pin height

mm

4005

Dumping clearance (*1) (Bucket tip/ BOC tip) North America specification EU Specification

2970/2880

mm

2905/2835

Dumping reach (*1) (Bucket tip/ BOC tip) North America specification EU Specification

960/1000

mm

985/1020

Steering angle

degree

38.5

Backward tilt angle of the bucket (travel posture/ maximum height)

degree

50/66

Forward tilt angle of the bucket (maximum height)

degree

47

Digging depth (*2) (Bucket tip/ BOC tip) North America specification EU Specification

330/375

mm

365/405

*1: Indicates the value when the forward tilt angle of the bucket is 45 °. *2: Indicates the value when the forward tilt angle of the bucket is 10 °.

BOC Abbreviation for Bolt On Cutting edge Engine Model Type

01-12

-

SAA6D107E-3

-

4-cycle, water-cooled, in-line, vertical, direct injection, with variable geometry turbocharger, with air-cooled aftercooler, and water-cooled EGR

WA320-8

01 Specifications

Specifications

Item

Unit

WA320-8

No. of cylinders - bore x stroke

mm

6-107 x 124

Total piston displacement

ℓ {cc}

6.69 {6690}

Gross (SAE J1995) (*1)

kW {HP} /

127 {170}/2100 {2100}

•

ISO 14396

min-1 {rpm}

127 {170}/2100 {2100}

•

Net (ISO 9249/SAE J1349) (*2)

Performance Engine rated horsepower •

Maximum torque (*2) Maximum speed with no load Minimum speed with no load

123 {165}/2100 {2100} Nm {kgfm} / min-1 {rpm} min-1 {rpm}

755 {77.005}/1400 {1400} 2250 {2250} 825 {825}

Starting motor

-

24 V, 5.5 kW

Alternator

-

24 V, 90 A

Battery (*3)

-

12 V, 92 Ah x 2

*1: Indicates the value of the bare engine (without cooling fan). *2: Indicates the value at the minimum cooling fan speed. *3: The battery capacity (Ah) is indicated in the 5-hour rate.

REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit. Net denotes the value of an engine which is measured under the condition almost the same as that of the time when it would be installed on a machine.

• The rated horsepower (net) at the maximum cooling fan speed is the following value.

112 kW/151 HP{2100 min-1/2100 rpm}

Power train HST pump Type Discharged volume

-

Variable displacement swash plate piston type

cm3/rev

0 to 110.4

HST motor 1 Type Discharged volume

cm3/rev

Variable displacement bent axis piston type 0 to 115.6

HST motor 2 Type Discharged volume

-

Variable displacement bent axis piston type

cm3/rev

41 to 115.6

-

Counter-shaft double acting planetary type, helical gear constant-mesh type, switching between 2 power trains

Transfer Type Reduction gear system Type Differential Type

WA320-8

-

-

Spiral bevel gear, splash oil lubrication

Straight bevel gear type, torque proportioning

01-13

Specifications

01 Specifications

Item

Unit

WA320-8

-

Planetary gear, single reduction, splash lubrication type

Final drive Type Axle Axle type Drive wheel Front wheel

-

Rear wheel

Front and rear wheel drive Frame fixed, semi floating type Center pin support type, semi floating type

Tire Size Rim size

20.5R25☆

-

25x17.00-1.7

Inflation pressure Front wheel

kPa {kgf/cm2}

425 {4.25}

Rear wheel

400 {4.0}

Brake Main 4-wheel brake type, front and rear wheel separate system brake type

Braking method Brake type

-

Sealed, wet, multiple disc type

Operating system

Hydraulically operated type

Operating method

With foot-operated hydraulic boost device

Parking Braking method Brake type

-

Operating system

Transfer output shaft brake Sealed, wet, multiple disc type Spring-control type, hydraulic release type

Steering Steering method Operating system

-

Articulated frame type Full hydraulic

Hydraulic system Steering and work equipment pump Type Discharged volume

-

Variable displacement swash plate piston type

cm3/rev

90.0

Brake and cooling fan pump Type Discharged volume

-

Gear type

cm3/rev

25.7

Transfer lubrication pump Type Discharged volume

01-14

cm3/rev

Gear type 12.5

WA320-8

01 Specifications

Specifications

Item

Unit

WA320-8

Steering cylinder Type

-

Double-acting piston type

Cylinder bore

mm

70

Piston rod diameter

mm

40

Stroke

mm

453

Max. distance between pins

mm

1271

Min. distance between pins

mm

818

Type

-

Double-acting piston type

Cylinder bore

mm

120

Piston rod diameter

mm

75

Stroke

mm

729

Max. distance between pins

mm

2056

Min. distance between pins

mm

1327

Type

-

Double-acting piston type

Cylinder bore

mm

150

Piston rod diameter

mm

110

Stroke

mm

558

Max. distance between pins

mm

1912

Min. distance between pins

mm

1354

Lift cylinder

Bucket cylinder

Control valve Type Set pressure

-

2-spool type

MPa {kgf/cm2}

30.4 {310}

Steering valve Type Set pressure

-

Orbitrol type

MPa {kgf/cm2}

20.6 {210}

Cooling fan motor Type Capacity

-

Fixed displacement, swash plate, piston type (With reverse function and flow control valve)

cm3/rev

23.0

Work equipment Link type Shape of bucket cutting edge

-

PZ link With flat cutting edge BOC

BOC Abbreviation for Bolt On Cutting edge

WA320-8

01-15

Weight Table

01 Specifications

Weight Table Weight Table: WA320-8

k This weight table is provided for your reference for when handling the components or when trans-

porting.

k This weight table shows the dry weight.

Unit: kg Item

WA320-8

Engine assembly

680

Cooling assembly (including fan, cooling fan motor, and frame)

216

•

Cooling sub-assembly (excluding fan, cooling fan motor, and frame)

127

•

Radiator

19

•

Aftercooler

15

•

Hydraulic oil cooler

14

•

Air conditioner condenser

3

•

Transfer oil cooler

5

•

Cooling fan motor

14

HST pump

88

HST motor 1

46

HST motor 2

47

Transfer

247

Front drive shaft

18

Rear drive shaft

6

Front axle With torque proportioning differential

714

With limited slip differential

718

Rear axle With torque proportioning differential

677

With limited slip differential

666

Tire and rim assembly (20.5R25☆ L-3) (1 piece)

341

•

Tire (20.5R25☆ L-3) (1 piece)

215

•

Rim (25 x 17.00-1.7) (1 piece)

126

Brake and cooling fan pump and transfer lubrication pump

8.6

Steering and work equipment pump

88

Control valve 2-spool valve

72

3-spool valve

84

Work equipment PPC valve

4

Priority valve

10

Orbitrol valve

7

01-16

WA320-8

01 Specifications

Weight Table

Unit: kg Item

WA320-8

Cushion valve

4

Brake accumulator charge valve

14

Brake valve

12

Steering cylinder assembly (1 piece)

21

Lift cylinder assembly (1 piece)

111

Bucket cylinder assembly (1 piece)

196

Front frame

1223

Rear frame

1213

Rear axle pivot

101

Counterweight

1485

Additional weight (1 piece)

125

Engine hood assembly (including side panel, excluding mirror)

256

•

Hood (including frame)

81

•

Side door (1 piece)

42

•

Grille

38

Hydraulic tank

129

Fuel tank

133

Boom (including bushing)

1313

Bucket link

68

Bell crank

300

Bucket (2.8 m3 wide, including BOC, bucket hinge pin)

1328

Bucket (2.9 m3 wide, including BOC, bucket hinge pin)

1326

Operator cab (including floor assembly)

808

Operator's seat

78

Air conditioner unit

5

Battery (1 piece)

30

BOC Abbreviation for Bolt On Cutting edge

WA320-8

01-17

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Table of Fuel, Coolant, and Lubricants

01 Specifications

Table of Fuel, Coolant, and Lubricants For details of notes (Note 1, Note 2...) in the table, see “Operation and Maintenance Manual”.

Ambient Temperature Reservoir

Fluid Type

Engine oil for KDPF used in cold terrain (Oil Change interval 250 hours)

-22 -4 14 32 -30 -20 -10 0

50 10

68 20

86 104 122 F 30 40 50 C

Recommended Komatsu Fluids EOS5W30-LA

(Note.1)

(KES Diesel Engine Oil)

(Note.1)

EOS5W40-LA (KES Diesel Engine Oil)

Engine oil pan EO10W30-LA

Engine oil for KDPF (Oil Change interval 500 hours)

Transfer case

(KES Diesel Engine Oil)

EO15W40-LA (KES Diesel Engine Oil)

TO10 (KES)

Power train oil (Note.2)

TOS0W30 (KES)

Power train oil

TOS5W30 (KES)

Hydraulic system

Axle

Pin / Bushing Grease fitting

Cooling system

Engine oil

EO10W30-DH (KES)

Axle oil (Note.3)

AXO80 (KES)

Power train oil (Note.4 )

TO50 (KES)

Hyper grease (Note.5)

G2-TE (KES)

Lithium EP grease

G2-LI (KES) AF-NAC (KES)

Non-Amine Engine Coolant

(AF-NAC) (Note.6)

ASTM D975 No.1-D S15 Fuel tank

Diesel fuel

ASTM D975 No.2-D S15 DEF tank

DEF

(Note.7)

DEF AJD03470

Unit: ℓ Location

Specified capacity

Refill capacity

Engine oil pan

25.5

23

Transfer case

8.6

6.1

01-18

WA320-8

01 Specifications

Table of Fuel, Coolant, and Lubricants

Unit: ℓ Location

Specified capacity

Refill capacity

Hydraulic oil system

146

92

Axle (front wheel)

27

27

Axle (rear wheel)

25.5

25.5

Cooling system

34.9

-

Fuel tank

245

-

DEF tank

21.1

-

WA320-8

01-19

10 Structure and Function

WA320-8

10-1

Table of Contents

10 Structure and Function

Table of Contents Abbreviation List ............................................................................................................................................ 10-6 Urea SCR System........................................................................................................................................ 10-12 Layout Drawing of Urea SCR System ................................................................................................... 10-12 Urea SCR System Diagram .................................................................................................................. 10-14 Function of Urea SCR System .............................................................................................................. 10-15 Function of DEF System ................................................................................................................ 10-15 Inducement Strategy ...................................................................................................................... 10-18 Component Parts of Urea SCR System ................................................................................................ 10-32 DEF Mixing Tube ........................................................................................................................... 10-32 SCR Assembly............................................................................................................................... 10-33 DEF Tank ....................................................................................................................................... 10-35 DEF Pump ..................................................................................................................................... 10-37 DEF Injector ................................................................................................................................... 10-38 DEF Hose ...................................................................................................................................... 10-39 DEF Tank Heating Valve ................................................................................................................ 10-40 Boot-up System ........................................................................................................................................... 10-41 Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) .............................................. 10-41 Layout Drawing of Boot-up System (Machine with Gateway Function Controller) ................................. 10-43 System Operating Lamp System........................................................................................................... 10-45 System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) ............ 10-45 System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) ......... ................................................................................................................................................... 10-45 Function of System Operating Lamp System (Machine with KOMTRAX Terminal)......................... 10-45 Function of System Operating Lamp System (Machine with Gateway Function Controller)............ 10-46 Battery Disconnect Switch..................................................................................................................... 10-48 Function of Battery Disconnect Switch ........................................................................................... 10-48 Preheating System................................................................................................................................ 10-49 System Diagram of Preheating System.......................................................................................... 10-49 Function of Automatic Preheating System...................................................................................... 10-49 Operation of Automatic Preheating System.................................................................................... 10-49 Function of Manual Preheating System.......................................................................................... 10-50 Operation of Manual Preheating System........................................................................................ 10-50 Engine System............................................................................................................................................. 10-51 Layout Drawing of Engine System ........................................................................................................ 10-51 Function of Engine System ............................................................................................................ 10-53 Engine Control System ......................................................................................................................... 10-54 System Diagram of Engine Control System (Machine with KOMTRAX Terminal)........................... 10-54 System Diagram of Engine Control System (Machine with Gateway Function Controller) .............. 10-56 Function of Engine Control System (Machine with KOMTRAX Terminal) ....................................... 10-58 Function of Engine Control System (Machine with Gateway Function Controller) .......................... 10-59 Operation of Engine Control System (Machine with KOMTRAX Terminal) ..................................... 10-62 Operation of Engine Control System (Machine with Gateway Function Controller) ........................ 10-64 Automatic Idle Stop System .................................................................................................................. 10-66 Function of Automatic Idle Stop System......................................................................................... 10-66 Component Parts of Engine System ..................................................................................................... 10-67 Damper .......................................................................................................................................... 10-67 VGT ............................................................................................................................................... 10-69 EGR System .................................................................................................................................. 10-73 EGR Valve ..................................................................................................................................... 10-75 EGR Cooler ................................................................................................................................... 10-77 KCCV System ................................................................................................................................ 10-79 KCCV Ventilator ............................................................................................................................. 10-81 KDPF ............................................................................................................................................. 10-83 Cooling System............................................................................................................................................ 10-87 Layout Drawing of Cooling System ....................................................................................................... 10-87 Specifications of Cooling System ................................................................................................... 10-88 10-2

WA320-8

10 Structure and Function

Table of Contents

Cooling Fan Control System ................................................................................................................. 10-89 System Diagram of Cooling Fan Control System ........................................................................... 10-89 Function of Cooling Fan Control System ........................................................................................ 10-89 Component Parts of Cooling System .................................................................................................... 10-94 Cooling Fan Motor ......................................................................................................................... 10-94 Control System ...........................................................................................................................................10-107 Layout Drawing of Control System (Machine with KOMTRAX Terminal) ..............................................10-107 Layout Drawing of Control System (Machine with Gateway Function Controller) .................................10-109 Machine Monitor System...................................................................................................................... 10-111 System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) ....................... 10-111 System Diagram of Machine Monitor System (Machine with Gateway Function Controller) ..........10-112 Function of Machine Monitor System ............................................................................................10-112 Rearview Monitor System ....................................................................................................................10-114 System Diagram of Rearview Monitor System ..............................................................................10-114 Function of Rearview Monitor System ...........................................................................................10-114 KOMTRAX System ..............................................................................................................................10-115 KOMTRAX System Diagram (Machine with KOMTRAX Terminal) ................................................10-115 System Diagram of KOMTRAX System (Machine with Gateway Function Controller)...................10-115 Function of KOMTRAX System .....................................................................................................10-116 Component Parts of Control System ....................................................................................................10-117 Machine Monitor ...........................................................................................................................10-117 Switch Panel .................................................................................................................................10-135 Rearview Monitor ..........................................................................................................................10-136 Rearview Camera .........................................................................................................................10-138 KOMTRAX Terminal......................................................................................................................10-139 Gateway Function Controller.........................................................................................................10-141 Communication Terminal...............................................................................................................10-144 Monitor Controller .........................................................................................................................10-146 HST Controller ..............................................................................................................................10-151 CAN Terminating Resistor .............................................................................................................10-156 Engine Controller ..........................................................................................................................10-157 Accelerator Pedal..........................................................................................................................10-164 Hydraulic System ........................................................................................................................................10-166 Layout Drawing of Hydraulic System....................................................................................................10-166 CLSS ...................................................................................................................................................10-167 Structure of CLSS .........................................................................................................................10-167 Function of CLSS..........................................................................................................................10-168 Component Parts of Hydraulic System.................................................................................................10-170 Hydraulic Tank ..............................................................................................................................10-170 Hydraulic Oil Filter.........................................................................................................................10-173 Steering and Work Equipment Pump ............................................................................................10-174 Brake and Cooling Fan Pump and Transfer Lubrication Pump ......................................................10-187 Control Valve.................................................................................................................................10-188 Power Train System ....................................................................................................................................10-218 Layout Drawing of Power Train System ...............................................................................................10-218 Operation of Power Train System ........................................................................................................10-220 Directional Selector Switch Control Function........................................................................................10-221 HST Control System ............................................................................................................................10-223 System Diagram of HST Control System ......................................................................................10-223 Engine Overrun Prevention Function ............................................................................................10-224 Neutralizer Function ......................................................................................................................10-224 HST Charge System ............................................................................................................................10-225 System Diagram of HST Charge System ......................................................................................10-225 Function of HST Charge System...................................................................................................10-225 HST Pump Control System ..................................................................................................................10-226 System Diagram of HST Pump Control System ............................................................................10-226 Directional Selection Function.......................................................................................................10-226 Absorbing Torque Control Function ...............................................................................................10-227 WA320-8

10-3

Table of Contents

10 Structure and Function

Inching Control Function ...............................................................................................................10-227 Travel Speed Adjustment Function (at Low Speed).......................................................................10-227 HST Controller Gear Shift Control Function .........................................................................................10-228 Gear Shift Function .......................................................................................................................10-228 Gear Shift Display Function...........................................................................................................10-230 Travel Speed Adjustment Function................................................................................................10-230 Transfer Clutch Control Function..........................................................................................................10-231 HST System Protection Function .........................................................................................................10-232 Transfer Protection Function .........................................................................................................10-232 Direction Protection Function ........................................................................................................10-232 HST Motor 1 Overrun Prevention Function 1 (Machine with KOMTRAX Terminal)........................10-232 HST Motor 1 Overrun Prevention Function 1 (Machine with Gateway Function Controller) ...........10-233 HST Motor 1 Overrun Prevention Function 2 ................................................................................10-235 Travel Speed Limitation Function (Machine with KOMTRAX Terminal) .........................................10-235 Travel Speed Limitation Function Machine with Gateway Function Controller)..............................10-236 Maximum Speed Low Fuel Consumption Control.................................................................................10-237 Function of Maximum Speed Low Fuel Consumption Control .......................................................10-237 Komatsu Traction Control System (KTCS) ...........................................................................................10-240 Komatsu Traction Control System (KTCS) Diagram......................................................................10-240 Function of Komatsu Traction Control System (KTCS)..................................................................10-240 Component Parts of Power Train System.............................................................................................10-246 Drive Shaft ....................................................................................................................................10-246 HST Pump ....................................................................................................................................10-248 HST Charge Pump........................................................................................................................10-261 HST Motor ....................................................................................................................................10-263 Transfer ........................................................................................................................................10-269 Axle...............................................................................................................................................10-277 Torque Proportioning Differential ...................................................................................................10-279 Limited Slip Differential .................................................................................................................10-284 Final Drive.....................................................................................................................................10-288 Combination Switch ......................................................................................................................10-290 Work Equipment System.............................................................................................................................10-294 Layout Drawing of Work Equipment System ........................................................................................10-294 Work Equipment Control System .........................................................................................................10-296 Work Equipment Lever Operation Function...................................................................................10-296 PZ Auto Tilt-in Compensation Control Function.............................................................................10-296 Work Equipment Lock System .............................................................................................................10-297 Work Equipment Lock System Diagram (Applicable Machine: 85001 to 87648)............................10-297 Work Equipment Lock System Diagram (Applicable Machine: 87649 and Up) ..............................10-297 Function of Work Equipment Lock System ....................................................................................10-298 Bucket Positioner System ....................................................................................................................10-299 Bucket Positioner System Diagram ...............................................................................................10-299 Function of Bucket Positioner System ...........................................................................................10-299 Operation of Bucket Positioner System .........................................................................................10-301 Fork Positioner System ........................................................................................................................10-303 Fork Positioner System Diagram...................................................................................................10-303 Function of Fork Positioner System...............................................................................................10-303 Operation of Fork Positioner System.............................................................................................10-304 Remote Positioner System...................................................................................................................10-307 Remote Boom Positioner System Diagram ...................................................................................10-307 Function of Remote Boom Positioner System ...............................................................................10-307 ECSS ...................................................................................................................................................10-310 ECSS Diagram..............................................................................................................................10-310 Function of ECSS .........................................................................................................................10-310 Operation of ECSS .......................................................................................................................10-310 Component Parts of Work Equipment System .....................................................................................10-312 Self-Pressure Reducing Valve.......................................................................................................10-312 Work Equipment Lock Solenoid Valve...........................................................................................10-317 10-4

WA320-8

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