SERIAL
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00Indexandforeword
100Indexandforeword
00Indexandforeword.......................................................................................................................00-1
Index.........................................................................................................................................00-2
Foreword,safetyandgeneralinformation...................................................................................00-17
Importantsafetynotice.......................................................................................................00-17
Howtoreadtheshopmanual..............................................................................................00-24
Explanationoftermsformaintenancestandard....................................................................00-26
Handlingequipmentoffuelsystemdevices..........................................................................00-28
Handlingofintakesystemparts...........................................................................................00-29
Handlingofhydraulicequipment..........................................................................................00-30
Methodofdisconnectingandconnectingofpush-pulltypecoupler.........................................00-32
Handlingofelectricalequipment..........................................................................................00-35
Howtoreadelectricwirecode.............................................................................................00-43
Precautionswhenperformingoperation...............................................................................00-46
PracticaluseofKOMTRAX.................................................................................................00-51
Standardtighteningtorquetable..........................................................................................00-52
Listofabbreviation.............................................................................................................00-58
Conversiontable................................................................................................................00-63
01Specification.................................................................................................................................01-1
Tableofcontents........................................................................................................................01-2 Specifications.............................................................................................................................01-3 Specificationdrawing...........................................................................................................01-3 Specifications......................................................................................................................01-5
Weighttable......................................................................................................................01-11
Tableoffuel,coolant,andlubricants....................................................................................01-12
10Structureandfunction...................................................................................................................10-1
Tableofcontents........................................................................................................................10-2
Engineandcoolingsystem..........................................................................................................10-4
Enginerelatedparts.............................................................................................................10-4
EGRsystempipingdrawing................................................................................................10-13
EGRsystemcircuitdiagram................................................................................................10-15
EGRvalve.........................................................................................................................10-16
EGRcooler........................................................................................................................10-18
KCCVlayoutdrawing.........................................................................................................10-20
KCCVventilator.................................................................................................................10-22
KDPF................................................................................................................................10-24
Coolingsystem..................................................................................................................10-30
Radiatorfanpump..............................................................................................................10-32
Aftercoolerfanmotor..........................................................................................................10-41
Radiatorfanmotor.............................................................................................................10-52
Centerbrakecoolingremotemotor......................................................................................10-61
Centerbrakecoolingremotepump......................................................................................10-65
Oilcoolerbypassvalve.......................................................................................................10-66
Powertrain...............................................................................................................................10-67
Powertrainsystem.............................................................................................................10-67
Driveshaft.........................................................................................................................10-69
Torqueconverterandtransmissionhydraulicpiping..............................................................10-70
Torqueconverter................................................................................................................10-71
Transmission.....................................................................................................................10-77
Transmissioncontrolvalve................................................................................................10-102
ForwardandreverseclutchECMVandgearspeedclutchECMV.........................................10-105
LockupclutchECMV........................................................................................................10-112
DifferentiallockclutchECMV............................................................................................10-116
Mainreliefvalve,torqueconverterreliefvalve,andmainflowselectorvalve..........................10-120
Axle................................................................................................................................10-126
Differential.......................................................................................................................10-129
Finaldrive.......................................................................................................................10-133
Testingblowbypressure.....................................................................................................30-24
Testingengineoilpressure.................................................................................................30-26
Testing EGR valve and VGT driving oil pressure 30-28
Testingfuelpressure..........................................................................................................30-29
Handlingcylindercutoutmodeoperation..............................................................................30-30
Handlingno‐injectioncrankingoperation..............................................................................30-31
Testingfuelreturnrateandleakage.....................................................................................30-32
Bleedingairfromfuelcircuit................................................................................................30-35
Testingfuelcircuitforleakage.............................................................................................30-36
Testingradiatorfanandaftercoolerfanspeed.......................................................................30-37
Replacingandadjustingbeltforalternatorandairconditionercompressor..............................30-38
Proceduresforcleaningfueldoser.......................................................................................30-39
Writingcompensationvaluesatreplacementofinjectorandenginecontroller.........................30-42
Bleedingairfrombrakecircuit.............................................................................................30-80
Testingwearofwheelbrakedisc.........................................................................................30-81
Parkingbrakeemergencyreleasingprocedure.....................................................................30-82
Testingwearofparkingbrakepadandadjustingclearance....................................................30-83
Hydraulicsystem......................................................................................................................30-85
Testingandadjustingsuspensioncylinder............................................................................30-85
Testingandadjustingdumpcircuitoilpressure.....................................................................30-90
Workequipment.......................................................................................................................30-93
Adjustingdumpbodypositionersensor................................................................................30-93
Testingandadjustingbodymount........................................................................................30-95
Cabanditsattachments............................................................................................................30-97
Cabtilt-upprocedure..........................................................................................................30-97
Electricalsystem....................................................................................................................30-101
Settingandadjustingeachequipment................................................................................30-101
Specialfunctionsofmachinemonitor.................................................................................30-112
KOMTRAXterminalstart-upprocedure..............................................................................30-185
Handlingvoltagecircuitofenginecontroller........................................................................30-189
Handlingbatterydisconnectswitch....................................................................................30-190
Pmclinic................................................................................................................................30-191
PmClinicservice.............................................................................................................30-191 40Troubleshooting............................................................................................................................40-1
Tableofcontents........................................................................................................................40-2
Classificationandproceduresfortroubleshooting.................................................................40-36
Informationintroubleshootingtable.....................................................................................40-42
Preparationfortroubleshootingofelectricalsystem...............................................................40-44
Connectorlistandlayout....................................................................................................40-50
Connectorcontactidentification...........................................................................................40-66
T-branchboxandT-branchadaptertable...........................................................................40-105
Fuselocationtable...........................................................................................................40-110
PrecautionsforKDPF(KCSFandKDOC)CleaningandReplacement.................................40-114 Precautionsontroubleshootingofmachinemonitor............................................................40-117
ProcessingprocedureofharnesscheckerfortroubleshootingofmachinemonitorLCD unit....................................................................................................................40-119
Preparationofdummytemperaturesensor(forKDOCandKDPFtemperature sensors).............................................................................................................40-124
Preparationofshortcircuitelectricalconnector(forfailurecodes[CA1883]and [CA3135])..........................................................................................................40-125
Failurecodestable...........................................................................................................40-126
Troubleshootingbyfailurecode(Displayofcode)......................................................................40-148 Failurecode[1500L0]DoubleEngagementofT/MClutches................................................40-148 Failurecode[15B0NX]TransmissionOilFilterClogging......................................................40-149 Failurecode[15F0KM]Abuse1ofGearShiftingfromRtoF................................................40-150 Failurecode[15F0MB]Abuse2ofGearShiftingfromRtoF................................................40-151 Failurecode[15F7KM]AbuseofTMForwardClutchDisk...................................................40-152 Failurecode[15G0MW]FailureofClutch(Reverse)............................................................40-153 Failurecode[15G7KM]AbuseofTMReverseClutchDisk...................................................40-156 Failurecode[15H0MW]FailureofClutch(High).................................................................40-157 Failurecode[15J0MW]FailureofClutch(Low)...................................................................40-160 Failurecode[15K0MW]FailureofClutch(1st)....................................................................40-163 Failurecode[15L0MW]FailureofClutch(2nd)...................................................................40-166 Failurecode[15M0MW]FailureofClutch(3rd)...................................................................40-169 Failurecode[15SBL1]ReleaseTroubleofECMV(Reverse)................................................40-172 Failurecode[15SBMA]MalfunctionofECMV(Reverse)......................................................40-175 Failurecode[15SCL1]ReleaseTroubleofECMV(High).....................................................40-176 Failurecode[15SCMA]MalfunctionofECMV(High)...........................................................40-179 Failurecode[15SDL1]ReleaseTroubleofECMV(Low)......................................................40-180 Failurecode[15SDMA]MalfunctionofECMV(Low)............................................................40-183 Failurecode[15SEL1]ReleaseTroubleofECMV(1st)........................................................40-184 Failurecode[15SEMA]MalfunctionofECMV(1st)..............................................................40-187 Failurecode[15SFL1]ReleaseTroubleofECMV(2nd).......................................................40-188 Failurecode[15SFMA]MalfunctionofECMV(2nd).............................................................40-191 Failurecode[15SGL1]ReleaseTroubleofECMV(3rd).......................................................40-192 Failurecode[15SGMA]MalfunctionofECMV(3rd).............................................................40-195 Failurecode[15SJMA]MalfunctionofECMV(Lockup)........................................................40-196 Failurecode[15SKMA]MalfunctionofECMV(Inter-AxleDiff.).............................................40-198 Failurecode[2F00KM]DraggingofParkingBrake..............................................................40-200 Failurecode[2G42ZG]AccumulatorOilPressureLow(Front).............................................40-202 Failurecode[2G43ZG]AccumulatorOilPressureLow(Rear)..............................................40-203
Failurecode[879AKA]A/CInnerSensorOpenCircuit........................................................40-204 Failurecode[879AKB]A/CInnerSensorShortCircuit.........................................................40-205 Failurecode[879BKA]A/COuterSensorOpenCircuit........................................................40-206 Failurecode[879BKB]A/COuterSensorShortCircuit........................................................40-207
Failurecode[879CKA]VentilatingSensorOpenCircuit.......................................................40-208
Failurecode[879CKB]VentilatingSensorShortCircuit.......................................................40-209
Failurecode[879EMC]VentilationDamperAbnormality......................................................40-210
Failurecode[879FMC]AirMixDamperAbnormality...........................................................40-211
Failurecode[879GKX]RefrigerantAbnormality..................................................................40-212
Failurecode[989D00]TiltCaution.....................................................................................40-213
Failurecode[989L00]EngineControllerLockCaution1.......................................................40-214
Failurecode[989M00]EngineControllerLockCaution2......................................................40-215 Failurecode[989N00]EngineControllerLockCaution3......................................................40-216 Failurecode[A1U0N3]HCDesorbRequest1....................................................................40-217 Failurecode[A1U0N4]HCDesorbRequest2....................................................................40-219 Failurecode[AA10NX]AirCleanerClogging......................................................................40-221 Failurecode[AB00KE]ChargeVoltageLow.......................................................................40-223 Failurecode[AB00KY]HotShortofAlternatorRTerminal...................................................40-225 Failurecode[B@BAZG]EngOilPressLow.......................................................................40-227 Failurecode[B@BAZK]EngineOilLevelLow....................................................................40-228 Failurecode[B@BCNS]EngWaterOverheat....................................................................40-229 Failurecode[B@BCZK]EngWaterLevelLow...................................................................40-230 Failurecode[B@C6NS]RetarderOilOverheat(Front)........................................................40-232 Failurecode[B@C8NS]RetarderOilOverheat(Center).....................................................40-233 Failurecode[B@CENS]T/COilTemp.Overheat................................................................40-234 Failurecode[B@JANS]SteeringOilOverheat...................................................................40-235 Failurecode[CA115]EngNeandBkupSpeedSensError..................................................40-236 Failurecode[CA122]ChgAirPressSensorHighError.......................................................40-237 Failurecode[CA123]ChgAirPressSensorLowError........................................................40-239 Failurecode[CA131]ThrottleSensorHighError.................................................................40-241 Failurecode[CA132]ThrottleSensorLowError.................................................................40-243 Failurecode[CA135]EngOilPressSensorHighError........................................................40-246 Failurecode[CA141]EngOilPressSensorLowError........................................................40-248 Failurecode[CA144]CoolantTempSensHighError..........................................................40-250 Failurecode[CA145]CoolantTempSensLowError...........................................................40-252 Failurecode[CA153]ChgAirTempSensorHighError........................................................40-254 Failurecode[CA154]ChgAirTempSensorLowError.........................................................40-256 Failurecode[CA187]Sensor2SupplyVoltLowError.........................................................40-258 Failurecode[CA221]AmbientPressSensHighError.........................................................40-260 Failurecode[CA222]AmbientPressSensLowError..........................................................40-262 Failurecode[CA227]Sensor2SupplyVoltHighError.........................................................40-264 Failurecode[CA234]EngOverspeed................................................................................40-265 Failurecode[CA238]NeSpeedSensorSupplyVoltError...................................................40-266 Failurecode[CA239]NeSpeedSensSupplyVoltHighError...............................................40-267 Failurecode[CA271]IMV/PCV1ShortError......................................................................40-268 Failurecode[CA272]IMV/PCV1OpenError......................................................................40-269 Failurecode[CA273]PCV2ShortError.............................................................................40-270 Failurecode[CA274]PCV2OpenError.............................................................................40-271 Failurecode[CA322]Inj#1(L#1)Open/ShortError.............................................................40-272 Failurecode[CA323]Inj#5(L#5)Open/ShortError.............................................................40-274 Failurecode[CA324]Inj#3(L#3)Open/ShortError.............................................................40-276 Failurecode[CA325]Inj#6(L#6)Open/ShortError.............................................................40-278 Failurecode[CA331]Inj#2(L#2)Open/ShortError.............................................................40-280 Failurecode[CA332]Inj#4(L#4)Open/ShortError.............................................................40-282 Failurecode[CA343]ECMCriticalInternalFailure..............................................................40-284 Failurecode[CA351]InjectorsDriveCircuitError...............................................................40-285 Failurecode[CA352]Sensor1SupplyVoltLowError.........................................................40-286 Failurecode[CA356]MassAirFlowSensorHighError.......................................................40-288 Failurecode[CA357]MassAirFlowSensorLowError........................................................40-290 Failurecode[CA386]Sensor1SupplyVoltHighError.........................................................40-292 Failurecode[CA431]IdleValidationSwError.....................................................................40-293 Failurecode[CA432]IdleValidationProcessError.............................................................40-296 Failurecode[CA441]BatteryVoltageLowError.................................................................40-299 Failurecode[CA442]BatteryVoltageHighError.................................................................40-301 Failurecode[CA449]RailPressVeryHighError.................................................................40-302 Failurecode[CA451]RailPressSensorHighError.............................................................40-303 Failurecode[CA452]RailPressSensorLowError.............................................................40-305 Failurecode[CA515]RailPressSensSupVoltHighError..................................................40-307 Failurecode[CA516]RailPressSensSupVoltLowError...................................................40-309 Failurecode[CA553]RailPressHighError........................................................................40-311
Failurecode[CA555]CrankcasePressHighError1...........................................................40-312 Failurecode[CA556]CrankcasePressHighError2...........................................................40-313 Failurecode[CA559]RailPressLowError.........................................................................40-314 Failurecode[CA595]TurboSpeedHighError2.................................................................40-318 Failurecode[CA687]TurboSpeedLowError.....................................................................40-319 Failurecode[CA689]EngNeSpeedSensorError..............................................................40-321 Failurecode[CA691]IntakeAirTempSensHighError........................................................40-323 Failurecode[CA692]IntakeAirTempSensLowError.........................................................40-325 Failurecode[CA697]ECMInternalTempSensorHighError................................................40-327 Failurecode[CA698]ECMIntTempSensorLowError........................................................40-328 Failurecode[CA731]EngBkupSpeedSensPhaseError...................................................40-329 Failurecode[CA778]EngBkupSpeedSensorError...........................................................40-330 Failurecode[CA1117]PersistentDataLostError................................................................40-332 Failurecode[CA1664]KDOCMalfunction..........................................................................40-333 Failurecode[CA1691]RegenerationIneffective.................................................................40-336 Failurecode[CA1695]Sensor5SupplyVoltHighError.......................................................40-339 Failurecode[CA1696]Sensor5SupplyVoltLowError.......................................................40-341 Failurecode[CA1843]CrankcasePressSensHighError....................................................40-343 Failurecode[CA1844]CrankcasePressSensLowError....................................................40-345 Failurecode[CA1879]KDPFDeltaPSensorHighError.....................................................40-347 Failurecode[CA1881]KDPFDeltaPSensorLowError......................................................40-349 Failurecode[CA1883]KDPFDeltaPSensInRangeError..................................................40-351 Failurecode[CA1921]KDPFSootLoadHighError1..........................................................40-356 Failurecode[CA1922]KDPFSootLoadHighError2..........................................................40-359 Failurecode[CA1923]DosingFuelValve1HighError........................................................40-364 Failurecode[CA1924]DosingFuelValve1LowError.........................................................40-366 Failurecode[CA1925]DosingFuelValve1InRangeError.................................................40-368 Failurecode[CA1927]DosingFuelPressSensHighError..................................................40-370 Failurecode[CA1928]DosingFuelPressSensLowError...................................................40-372 Failurecode[CA1942]CrankcasePressSensInRangeError.............................................40-374 Failurecode[CA1963]DosingFuelValve1ServoError......................................................40-375 Failurecode[CA1977]FuelDoserOpen/ShortError...........................................................40-379 Failurecode[CA1993]KDPFDeltaPressureLowError......................................................40-381 Failurecode[CA2185]ThrotSensorSupVoltHighError.....................................................40-385 Failurecode[CA2186]ThrotSensorSupVoltLowError......................................................40-387 Failurecode[CA2249]RailPressVeryLowError...............................................................40-389 Failurecode[CA2265]FuelFeedPumpOpenError............................................................40-390 Failurecode[CA2266]FuelFeedPumpShortError............................................................40-392 Failurecode[CA2271]EGRValvePosSensHighError......................................................40-394 Failurecode[CA2272]EGRValvePosSensLowError.......................................................40-396 Failurecode[CA2349]EGRValveSolenoidOpenError......................................................40-398 Failurecode[CA2353]EGRValveSolenoidShortError......................................................40-400 Failurecode[CA2357]EGRValveServoError...................................................................40-402 Failurecode[CA2381]KVGTPosSensHighError.............................................................40-403 Failurecode[CA2382]KVGTPosSensLowError..............................................................40-405
Failurecode[CA2383]KVGTSolenoidOpenError.............................................................40-407 Failurecode[CA2386]KVGTSolenoidShortError.............................................................40-409 Failurecode[CA2387]KVGTServoError..........................................................................40-411 Failurecode[CA2555]GridHtrRelayVoltLowError...........................................................40-412 Failurecode[CA2556]GridHtrRelayVoltHighError..........................................................40-414 Failurecode[CA2637]KDOCFacePlugging.....................................................................40-416 Failurecode[CA2639]ManualStationaryRegenerationRequest.........................................40-418 Failurecode[CA2732]DosingFuelValve2HighError........................................................40-421 Failurecode[CA2733]DosingFuelValve2LowError.........................................................40-423 Failurecode[CA2741]DosingFuelValveSwapError.........................................................40-425 Failurecode[CA2765]InjTrimDataError..........................................................................40-426 Failurecode[CA2878]DosingFuelValve2ServoError......................................................40-427 Failurecode[CA2881]DosingFuelPressureLowError1....................................................40-430 Failurecode[CA3133]KDPFOutletPressSensHighError.................................................40-435
Failurecode[CA3134]KDPFOutletPressSensLowError..................................................40-437 Failurecode[CA3135]KDPFOutletPressSensInRangeError..........................................40-439 Failurecode[CA3167]FuelDoserDegradation..................................................................40-443 Failurecode[CA3251]KDOCInletTempHighError............................................................40-446 Failurecode[CA3253]KDOCTempError-NonRegeneration.............................................40-449 Failurecode[CA3254]KDOCOutletTempHighError1......................................................40-452 Failurecode[CA3255]KDPFTempError-NonRegeneration..............................................40-455 Failurecode[CA3256]KDPFOutletTempHighError1.......................................................40-459 Failurecode[CA3311]KDOCOutletTempHighError2.......................................................40-462 Failurecode[CA3312]KDPFOutletTempHighError2.......................................................40-465 Failurecode[CA3313]KDOCInletTempSensorLowError.................................................40-468 Failurecode[CA3314]KDOCInletTempSensHighError...................................................40-471 Failurecode[CA3315]KDOCInletTempSensInRangeError.............................................40-475 Failurecode[CA3316]KDOCOutletTempSensLowError.................................................40-480 Failurecode[CA3317]KDOCOutletTempSensHighError.................................................40-483 Failurecode[CA3318]KDOCOutletTempSensInRangeError..........................................40-487 Failurecode[CA3319]KDPFOutletTempSensHighError.................................................40-492 Failurecode[CA3321]KDPFOutletTempSensLowError..................................................40-496 Failurecode[CA3322]KDPFOutletTempSensInRangeError...........................................40-499 Failurecode[CA3419]MassAirFlowSensorSupVoltHighError........................................40-504 Failurecode[CA3421]MassAirFlowSensorSupVoltLowError.........................................40-506 Failurecode[D150KB]GroundFaultofEmerg.SteeringRelay............................................40-508 Failurecode[D150KZ]FailureofEmerg.SteeringRelay.....................................................40-509 Failurecode[D151KB]GroundFaultofEmerg.SteeringRelay2.........................................40-510 Failurecode[D151KZ]FailureofEmerg.SteeringRelay2...................................................40-511 Failurecode[D164KY]HotShortofHeadLightHighSelector..............................................40-512 Failurecode[D19HKZ]FailureofStopLamp(R&L)............................................................40-513 Failurecode[D19JKZ]PersonalCodeRelayAbnormality....................................................40-515 Failurecode[D1EHKA]DisconnectionofEngineStartRelay...............................................40-516 Failurecode[D1EHKB]GroundFaultofEngineStartRelay.................................................40-517 Failurecode[D1EHKY]HotShortofEngineStartRelay......................................................40-518 Failurecode[D1EMKA]DisconnectionofParkingInterlockRelay........................................40-519 Failurecode[D1EMKB]GroundFaultofParkingInterlockRelay..........................................40-520 Failurecode[D1EMKY]HotShortofParkingInterlockRelay...............................................40-521 Failurecode[D1FBKB]GroundFaultofSol.Self-HoldingRelay...........................................40-522 Failurecode[D5ZHL6]DisconnectionofKeySWC............................................................40-523 Failurecode[D811MC]KOMTRAXError............................................................................40-525 Failurecode[D862KA]GPSAntennaOpenCircuit.............................................................40-526 Failurecode[D8ALKA]OperatingLampOpenCircuit(KOMTRAX)......................................40-527 Failurecode[D8ALKB]OperatingLampShortCircuit(KOMTRAX)......................................40-529 Failurecode[D8AQK4]CAN2Discon(KOMTRAX)2..........................................................40-531 Failurecode[D8AQKR]CAN2Discon(KOMTRAX)............................................................40-532 Failurecode[DAF0KT]AbnormalityofNon-volatileMemory(MON).....................................40-533 Failurecode[DAF0MB]MonitorROMAbnormality..............................................................40-534 Failurecode[DAF0MC]MonitorError................................................................................40-535 Failurecode[DAF3KK]ControllerPowerSourceLow(MON)...............................................40-536 Failurecode[DAF8KB]CameraPowerSupplyShortCircuit................................................40-538 Failurecode[DAFDKB]Monitor12VPowerOutputShortCircuit..........................................40-539 Failurecode[DAFGMC]GPSModuleError........................................................................40-541 Failurecode[DAFLKA]OperatingLampOpenCircuit(MON)...............................................40-542 Failurecode[DAFLKB]OperatingLampShortCircuit(MON)...............................................40-544 Failurecode[DAFQKR]CAN2Discon(Monitor).................................................................40-546 Failurecode[DAQ0KK]ControllerPowerSourceLow(T/M)................................................40-547
Failurecode[DAQ0KT]AbnormalityofNon-volatileMemory(T/M).......................................40-549 Failurecode[DAQ0MC]T/MConError..............................................................................40-550 Failurecode[DAQ1KA]DisconnectionofKeySWACC(T/M)..............................................40-551 Failurecode[DAQ2KK]SolenoidPowerSourceLow(T/M).................................................40-553
Failurecode[DAQ9KQ]InconsistencyofModelSelection(T/M)..........................................40-555 Failurecode[DAQLKA]OperatingLampOpenCircuit(T/M)................................................40-556
Failurecode[DAQLKB]OperatingLampShortCircuit(T/M)................................................40-558
Failurecode[DAQQKR]CAN2Discon(TransmissionCon).................................................40-560
Failurecode[DAQRKR]CAN1Discon(TransmissionCon).................................................40-561
Failurecode[DAQRMA]InconsistencyofOptionSelection(T/M).........................................40-562 Failurecode[DAZ9KQ]A/CModelSelectionAbnormality....................................................40-563 Failurecode[DAZQKR]CAN2Discon(AirconECU)...........................................................40-564
Failurecode[DB10KT]AbnormalityofNon-volatileMemory(RHC)......................................40-565 Failurecode[DB10MC]RHCError....................................................................................40-566 Failurecode[DB11KA]DisconnectionofKeySWACC(RHC).............................................40-567 Failurecode[DB12KK]SolenoidPowerSourceLow(RHC).................................................40-569 Failurecode[DB13KK]ControllerPowerSourceLow(RHC)...............................................40-571 Failurecode[DB19KQ]InconsistencyofModelSelection(RHC)..........................................40-573 Failurecode[DB1LKA]DisconnectionofSystemOpe.Lamp(RHC).....................................40-574 Failurecode[DB1LKB]ShortCircuitofSystemOpe.Lamp(RHC).......................................40-576 Failurecode[DB1QKR]CAN2Discon(RetarderHoistCon)................................................40-578 Failurecode[DB1QMA]InconsistencyofOptionSelection(RHC)........................................40-579 Failurecode[DB1RKR]CAN1Discon(RetarderHoistCon).................................................40-580 Failurecode[DB2QKR]CAN2Discon(EngineCon)...........................................................40-581 Failurecode[DB2RKR]CAN1Discon(EngineCon)...........................................................40-586 Failurecode[DBSQKR]CAN2Discon(PLM).....................................................................40-591 Failurecode[DBSQKQ]InconsistencyofModelSelection(PLM).........................................40-595 Failurecode[DD1ML4]FailureofARACSW......................................................................40-596 Failurecode[DDAAL6]DisconofEngineShutdownSecondarySwitch................................40-599 Failurecode[DDTHKA]DisconnectionofFillSwitch(High).................................................40-601 Failurecode[DDTJKA]DisconnectionofFillSwitch(Low)...................................................40-603 Failurecode[DDTKKA]DisconnectionofFillSwitch(1st)....................................................40-605 Failurecode[DDTLKA]DisconnectionofFillSwitch(2nd)...................................................40-607 Failurecode[DDTMKA]DisconnectionofFillSwitch(3rd)...................................................40-609 Failurecode[DDTNKA]DisconnectionofFillSwitch(Reverse)............................................40-611 Failurecode[DF10KA]DisconnectionofShiftLeverInput...................................................40-613 Failurecode[DF10KB]GroundFaultofShiftLeverInput.....................................................40-616 Failurecode[DGF1KX]OutofRangeofT/MOilTemp.Sensor............................................40-620 Failurecode[DGR3KB]GroundFaultofRetarderOilTemp.S.(C)........................................40-622 Failurecode[DGR3L8]FailureofRetarderOilTemp.Sensor(C).........................................40-623 Failurecode[DGR4KB]GroundFaultofRetarderOilTemp.S.(F)........................................40-624 Failurecode[DGR4L8]FailureofRetarderOilTemp.Sensor(F)..........................................40-625 Failurecode[DGR6KB]GroundFaultofSteeringOilTemp.S..............................................40-627 Failurecode[DGR6L8]FailureofSteeringOilTemp.Sensor...............................................40-628 Failurecode[DGR7KX]OutofRangeofPistonPumpOilTemp.S.......................................40-630 Failurecode[DGT1KX]OutofRangeofT/COilTemp.Sensor............................................40-632
Failurecode[DHP4KY]HotShortofSuspensionPress.S.(FR)..........................................40-634
Failurecode[DHP4KZ]FailureofSuspensionPress.S.(FR)..............................................40-636
Failurecode[DHP5KY]HotShortofSuspensionPress.S.(FL)...........................................40-638
Failurecode[DHP5KZ]FailureofSuspensionPress.S.(FL)...............................................40-640
Failurecode[DHP6KY]HotShortofSuspensionPress.S.(RR)..........................................40-642
Failurecode[DHP6KZ]FailureofSuspensionPress.S.(RR)..............................................40-644
Failurecode[DHP7KY]HotShortofSuspensionPress.S.(RL)...........................................40-646
Failurecode[DHP7KZ]FailureofSuspensionPress.S.(RL)...............................................40-648 Failurecode[DHQ2KX]OutofRangeofMainFlowSel.ValveS..........................................40-650 Failurecode[DHT5KX]OutofRangeofT/CInputPressureSensor.....................................40-652 Failurecode[DHT5L6]FailureofT/COilPressSensor.......................................................40-654 Failurecode[DHT8KX]OutofRangeofSteeringOilPress.S..............................................40-656 Failurecode[DHT8ZG]SteeringOilPressureLow..............................................................40-658 Failurecode[DHU2KX]OutofRangeofAcc.OilPress.S.(F).............................................40-659 Failurecode[DHU3KX]OutofRangeofAcc.OilPress.S.(R).............................................40-661 Failurecode[DHUAKX]OutofRangeofRetarderPress.S.(CR)........................................40-663 Failurecode[DHUBKX]OutofRangeofRetarderPress.S.(FR).........................................40-665 Failurecode[DHUCKX]OutofRangeofParkingBrakePress.S.........................................40-667 Failurecode[DHUDKX]OutofRangeofEmerg.SteeringPress.S.1...................................40-669
Failurecode[DHUEKX]OutofRangeofEmerg.SteeringPress.S.2...................................40-671 Failurecode[DHUQKX]OutofRangeofRetarderPress.S.(FL).........................................40-673 Failurecode[DHURKX]OutofRangeofRetarderPress.S.(CL).........................................40-675 Failurecode[DJF1KA]DisconnectionofFuelLevelSensor.................................................40-677 Failurecode[DK30KX]OutofRangeofSteeringAnglePot.................................................40-679 Failurecode[DK51L5]FailureofRetarderLeverPot.andRVS............................................40-681 Failurecode[DK52KX]OutofRangeofHoistLeverPotentio...............................................40-684 Failurecode[DK53L8]FailureofHoistLeverPotentio.........................................................40-686 Failurecode[DK54KX]OutofRangeofBodyPotentio........................................................40-687 Failurecode[DK60KX]OutofRangeofAccelerationSensor...............................................40-689 Failurecode[DKH0KX]OutofRangeofInclinationAngleSensor........................................40-691 Failurecode[DKH1KX]OutofRangeofLong.InclinationAngleS.......................................40-693 Failurecode[DLF1KA]DisconnectionofT/MInputSpeedSensor........................................40-695 Failurecode[DLF1LC]FailureofT/MInputSpeedSensor...................................................40-697 Failurecode[DLF2KA]DisconnectionofT/MInter.SpeedSensor........................................40-699 Failurecode[DLF2LC]FailureofT/MIntermediateSpeedSensor........................................40-701 Failurecode[DLF400]T/MDiff.OverrunPreventionActivated.............................................40-703 Failurecode[DLF4KA]DisconnectionofT/MDiff.SpeedSensor.........................................40-704 Failurecode[DLF4LC]FailureofT/MDiff.SpeedSensor....................................................40-706 Failurecode[DLF6LC]FailureofWheelSpeedSensor(FR)................................................40-708 Failurecode[DLF7LC]FailureofWheelSpeedSensor(FL)................................................40-710 Failurecode[DLFDLC]FailureofWheelSpeedSensor(CR)...............................................40-712 Failurecode[DLFELC]FailureofWheelSpeedSensor(CL)...............................................40-714 Failurecode[DLFFLC]FailureofWheelSpeedSensor(Front)............................................40-716 Failurecode[DLFGLC]FailureofWheelSpeedSensor(Center).........................................40-717 Failurecode[DLM3KA]DisconnectionofRadiatorFanSpeedSensor..................................40-718 Failurecode[DLM3LC]FailureofRadiatorFanSpeedSensor.............................................40-720 Failurecode[DLM3MB]RadiatorFanControlMismatch......................................................40-722 Failurecode[DLM4KA]DisconnectionofCACFanSpeedSensor.......................................40-723 Failurecode[DLM4LC]FailureofCACFanSpeedSensor..................................................40-725 Failurecode[DLM4MB]CACFanControlMismatch...........................................................40-727 Failurecode[DLT3KA]DisconnectionofOutputSpeedSens.(Main)....................................40-728 Failurecode[DLT3LC]FailureofOutputSpeedSensor(Main).............................................40-730 Failurecode[DPQ1KR]LINDiscon(SwitchPanel).............................................................40-732 Failurecode[DPQ2KR]LINDiscon(LEDUnit)...................................................................40-735 Failurecode[DPQ3KR]LINDiscon(RearViewMonitor).....................................................40-738 Failurecode[DSJ0KR]CAN2Discon(MeterUnit)..............................................................40-741 Failurecode[DV00KB]GroundFaultofBuzzerOutput........................................................40-742 Failurecode[DW2BKA]DisconnectionofMainFlowSelectorSol........................................40-744 Failurecode[DW2BKB]GroundFaultofMainFlowSelectorSol..........................................40-745 Failurecode[DW2BKY]HotShortofMainFlowSelectorSol...............................................40-746 Failurecode[DW2BL1]ReleaseTroubleofMainFlowSel.Valve.........................................40-747 Failurecode[DW2BLH]MalfunctionofMainFlowSelectorValve.........................................40-748 Failurecode[DW4BK4]ReleaseTroubleofParkingBrakeValve.........................................40-749 Failurecode[DW4BMA]MalfunctionofParkingBrakeValve...............................................40-751 Failurecode[DW72KZ]FailureofKickoutSolenoid............................................................40-752 Failurecode[DW73KA]DisconnectionofHoistSelectorSol................................................40-754 Failurecode[DW73KB]GroundFaultofHoistSelectorSol..................................................40-756 Failurecode[DW73KY]HotShortofHoistSelectorSol.......................................................40-758 Failurecode[DW7BKB]GroundFaultofRadiatorFanRev.Sol...........................................40-760 Failurecode[DW7BKY]HotShortofRadiatorFanRev.Sol.................................................40-762 Failurecode[DW7BKZ]FailureofRadiatorFanRev.Sol.....................................................40-763 Failurecode[DW7LKB]GroundFaultofCACFanRev.Sol.................................................40-765 Failurecode[DW7LKY]HotShortofCACFanRev.Sol.......................................................40-766 Failurecode[DW7LKZ]FailureofCACFanRev.Sol...........................................................40-767 Failurecode[DW7NKZ]FailureofSteeringPumpSelectorSol............................................40-768 Failurecode[DWNJKZ]FailureofTCSShutoffSol.(Front).................................................40-770 Failurecode[DWNKKZ]FailureofTCSShutoffSol.(Center)..............................................40-772 Failurecode[DX13KA]DisconnectionofHoistEPCSolenoid..............................................40-774
Failurecode[DX13KB]GroundFaultofHoistEPCSolenoid................................................40-776 Failurecode[DX13KY]HotShortofHoistEPCSolenoid.....................................................40-778 Failurecode[DX16KA]DisconnectionofRad.FanPumpEPCSol.......................................40-780 Failurecode[DX16KB]GroundFaultofRad.FanPumpEPCSol........................................40-781 Failurecode[DX16KY]HotShortofRadiatorFanPumpEPCSol........................................40-783 Failurecode[DX29KA]DisconnectionofCACFanPumpEPCSol.......................................40-784 Failurecode[DX29KB]GroundFaultofCACFanPumpEPCSol........................................40-785 Failurecode[DX29KY]HotShortofCACFanPumpEPCSol..............................................40-786 Failurecode[DX30K4]ReleaseTroubleofRetarderEPCValve(FL).....................................40-787 Failurecode[DX30KA]DisconnectionofRetarderEPCSol.(FL).........................................40-789 Failurecode[DX30KB]GroundFaultofRetarderEPCSol.(FL)...........................................40-791 Failurecode[DX30KY]HotShortofRetarderEPCSol.(FL)................................................40-793 Failurecode[DX30MA]MalfunctionofRetarderEPCValve(FL)..........................................40-795 Failurecode[DX31K4]ReleaseTroubleofRetarderEPCValve(CR)....................................40-797 Failurecode[DX31KA]DisconnectionofRetarderEPCSol.(CR)........................................40-799 Failurecode[DX31KB]GroundFaultofRetarderEPCSol.(CR)..........................................40-801 Failurecode[DX31KY]HotShortofRetarderEPCSol.(CR)...............................................40-803 Failurecode[DX31MA]MalfunctionofRetarderValve(CR).................................................40-805 Failurecode[DX32K4]ReleaseTroubleofRetarderEPCValve(CL)....................................40-807 Failurecode[DX32KA]DisconnectionofRetarderEPCSol.(CL).........................................40-809 Failurecode[DX32KB]GroundFaultofRetarderEPCSol.(CL)..........................................40-811 Failurecode[DX32KY]HotShortofRetarderEPCSol.(CL)................................................40-813 Failurecode[DX32MA]MalfunctionofRetarderEPCValve(CL)..........................................40-815 Failurecode[DX33K4]ReleaseTroubleofRetarderEPCValve(FR)...................................40-817 Failurecode[DX33KA]DisconnectionofRetarderEPCSol.(FR).........................................40-819 Failurecode[DX33KB]GroundFaultofRetarderEPCSol.(FR)..........................................40-821 Failurecode[DX33KY]HotShortofRetarderEPCSol.(FR)...............................................40-823 Failurecode[DX33MA]MalfunctionofRetarderEPCValve(FR)..........................................40-825 Failurecode[DX34KA]DisconnectionofRemoteCoolingEPCSol......................................40-827 Failurecode[DX34KB]GroundFaultofRemoteCoolingEPCSol........................................40-828 Failurecode[DX34KY]HotShortofRemoteCoolingEPCSol.............................................40-830 Failurecode[DXH0KA]DisconnectionofECMV(Inter-AxleDiff.).........................................40-831 Failurecode[DXH0KB]GroundFaultofECMV(Inter-AxleDiff.)...........................................40-833 Failurecode[DXH0KY]HotShortofECMV(Inter-AxleDiff.)................................................40-835 Failurecode[DXH1KA]DisconnectionofECMVSolenoid(Lockup).....................................40-837 Failurecode[DXH1KB]GroundFaultofECMVSolenoid(Lockup).......................................40-839
Failurecode[DXH1KY]HotShortofECMVSolenoid(Lockup)............................................40-841
Failurecode[DXH2KA]DisconnectionofECMVSolenoid(High).........................................40-843
Failurecode[DXH2KB]GroundFaultofECMVSolenoid(High)...........................................40-845
Failurecode[DXH2KY]HotShortofECMVSolenoid(High)................................................40-847
Failurecode[DXH3KA]DisconnectionofECMVSolenoid(Low)..........................................40-848
Failurecode[DXH3KB]GroundFaultofECMVSolenoid(Low)............................................40-850
Failurecode[DXH3KY]HotShortofECMVSolenoid(Low).................................................40-852
Failurecode[DXH4KA]DisconnectionofECMVSolenoid(1st)............................................40-855
Failurecode[DXH4KB]GroundFaultofECMVSolenoid(1st).............................................40-857
Failurecode[DXH4KY]HotShortofECMVSolenoid(1st)...................................................40-859
Failurecode[DXH5KA]DisconnectionofECMVSolenoid(2nd)...........................................40-862
Failurecode[DXH5KB]GroundFaultofECMVSolenoid(2nd)............................................40-864
Failurecode[DXH5KY]HotShortofECMVSolenoid(2nd)..................................................40-866
Failurecode[DXH6KA]DisconnectionofECMVSolenoid(3rd)...........................................40-869
Failurecode[DXH6KB]GroundFaultofECMVSolenoid(3rd).............................................40-871
Failurecode[DXH6KY]HotShortofECMVSolenoid(3rd)..................................................40-873
Failurecode[DXH7KA]DisconnectionofECMVSolenoid(Reverse)....................................40-876
Failurecode[DXH7KB]GroundFaultofECMVSolenoid(Reverse).....................................40-878
Failurecode[DXH7KY]HotShortofECMVSolenoid(Reverse)...........................................40-880
Failurecode[DY30MA]Malfunction1ofEmerg.SteeringMotor...........................................40-883
Failurecode[DY30MC]Malfunction2ofEmerg.SteeringMotor..........................................40-886
Failurecode[DY30ME]Emerg.SteeringLong-TimeActivated.............................................40-889
Failurecode[DY32MC]Malfunction2ofEmerg.SteeringMotor2........................................40-891
Troubleshootingofelectricalsystem(E-mode)..........................................................................40-894
E-1Enginedoesnotstart(Enginedoesnotrotate)..............................................................40-894
E-2Manualpreheatingsystemdoesnotwork.....................................................................40-900
E-3Automaticpreheatingsystemdoesnotwork.................................................................40-903
E-4Whilepreheatingisworking,preheatingpilotlampdoesnotlightup...............................40-905
E-5AllofLCDunit,LEDunitandmeterunitonmachinemonitordisplaynothing...................40-907
E-6LCDunitonmachinemonitordisplaysnothing..............................................................40-910
E-7BacklightofLCDunitonmachinemonitorisabnormal(Backlightgoesoutor flickers)..............................................................................................................40-912
E-8LCDonmachinemonitordoesnotdisplayproperly.......................................................40-914
E-9Meterunitdisplayonmachinemonitorisabnormal.......................................................40-916
E-10Nightlightinglampofmeterunitonmachinemonitorisabnormal.................................40-919
E-11LEDunitlamponmachinemonitorisabnormal...........................................................40-922
E-12Nightlightinglampofswitchpanelonmachinemonitorisabnormalorswitchesdoesnot operateproperly.................................................................................................40-924
E-132switchesoperationofswitchpanelonmachinemonitordoesnotfunction...................40-926
E-14Switchpanelbuzzerofmachinemonitorisabnormal...................................................40-928
E-15Rearviewmonitordoesnotlightuporbacklightflickers...............................................40-930
E-16Rearviewmonitorimagesarenotdisplayedclearly.....................................................40-932
E-17Rearviewmonitorbrightnesscannotbeadjusted........................................................40-935
E-18Nightlightinglampofrearviewmonitorisabnormal....................................................40-938
E-19Rearviewmonitordoesnotdisplayimageswhilereverselinkeddisplayfunctionis enabled.............................................................................................................40-940
E-20Guidelineonrearviewmonitorisnotdisplayedwhileguidelineisset..........................40-943
E-21Someitemsofgaugesandcautionlampsonmachinemonitorarenotdisplayed properly.............................................................................................................40-945
E-22Fuellevelgaugedoesnotindicatecorrectlevel..........................................................40-946
E-23Seatbeltcautionlampindicationisabnormal..............................................................40-948
E-24MachinemonitorcannotbeoperatedwhenstartingswitchisinOFFposition................40-949
E-25Alarmbuzzerdoesnotsound....................................................................................40-950
E-26Alarmbuzzerdoesnotstopsounding.........................................................................40-952
E-27Enginemodeselectorfunctiondoesnotoperateproperly............................................40-954
E-28AISSfunctiondoesnotoperateproperly.....................................................................40-955
E-29Hoistleverdoesnotoperateproperly.........................................................................40-956
E-30Turnsignallampandwinkerlamp(hazardlamp)donotoperateproperly......................40-958
E-31Noneofheadlamp,clearancelamp,andtaillamplights...............................................40-962
E-32Clearancelampdoesnotlightup...............................................................................40-964
E-33Taillampdoesnotlightup.........................................................................................40-966
E-34Lowbeamofheadlampdoesnotlightup....................................................................40-968
E-35Highbeamofheadlampdoesnotlightup...................................................................40-970
E-36NeitherLowbeamnorHighbeamofheadlamplightsup..............................................40-972
E-37Highbeamsdonotlightupwhilepassingswitchisoperated........................................40-974
E-38KOMTRAXdoesnotoperateproperly........................................................................40-976
E-39 Fuelfeedpumpdoesnotoperateordoesnotstopautomatically.................................... 40-976-1
Troubleshootingofhydraulicandmechanicalsystem(H-mode)..................................................40-977
Information describedintroubleshootingtable(H-mode).....................................................40-977
Systemchartofhydraulicandmechanicalsystems.............................................................40-978
Failuremodeandcausetable...........................................................................................40-980
H-1Machinedoesnotstart...............................................................................................40-984
H-2Machinedoesnottravelsmoothly(enginehunts)..........................................................40-986
H-3Lockupclutchisnotdisengaged..................................................................................40-987
H-4Abnormallylargeshocksresultfromstartingofmachineandgearshifting......................40-988
H-5Machinedoesnotupshift............................................................................................40-989
H-6Machinelackstravelspeedorpowerduringtravelinlockupdrivemodethroughallgear speeds...............................................................................................................40-991
H-7Machinelackstravelspeedorpowerduringtravelintorqueconverterdrive mode.................................................................................................................40-992
H-8Machinelackstravelspeedorpowerduringtravelinspecificgearspeed........................40-993
H-9Machinestartsorgearspeedshiftswithlongtimelag...................................................40-994
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H-11Torqueconverteroilpressureislow...........................................................................40-997
H-12Frontbrakedoesnotworksufficiently........................................................................40-998
H-13Centerbrakedoesnotworksufficiently......................................................................40-999
H-14Steeringwheelisheavytoturn................................................................................40-1000
H-15Steeringwheeldoesnotmove................................................................................40-1001
H-16Steeringwheelswings............................................................................................40-1002
H-17Dumpbodyraisespeedorpowerisslow..................................................................40-1003
H-18Dumpbodydoesnotmove.....................................................................................40-1005
H-19Hydraulicdriftofdumpbodyislarge........................................................................40-1006
H-20Radiatorfanspeedisabnormal(high,low,orstationary)...........................................40-1007
H-21Aftercoolerfanspeedisabnormal(high,low,orstationary)........................................40-1008
H-22Unusualnoiseisheardfromaroundradiatorfan.......................................................40-1009
H-23Unusualnoiseisheardfromaroundaftercoolerfan...................................................40-1010
Troubleshootingofengine(S-mode)........................................................................................40-1011
Informationmentionedintroubleshootingtable(Smode)....................................................40-1011
S-1WhenstartingswitchisturnedtoSTARTposition,engineisnotcranked.......................40-1012
S-2Theenginecranksbutexhaustsmokedoesnotcomeout...........................................40-1013
S-3Fuelisinjectedbutenginedoesnotstart(incompletecombustion,engineseemstostart butdoesnot)....................................................................................................40-1014
S-4Enginestartabilityispoor..........................................................................................40-1015
S-5Enginedoesnotpick-upsmoothly.............................................................................40-1017
S-6Enginestopsduringoperation...................................................................................40-1019
S-7Enginerunsroughorisunstable...............................................................................40-1021
S-8Enginelackspower..................................................................................................40-1022
S-9KDPFgetscloggedinashorttime.............................................................................40-1024
S-10Engineoilconsumptionisexcessive........................................................................40-1026
S-11Engineoilbecomescontaminatedearly....................................................................40-1027
S-12Fuelconsumptionisexcessive................................................................................40-1028
S-13Oilisincoolant(orcoolantspurtsorcoolantlevelgoesdown)....................................40-1029
S-14Oilpressuredrops..................................................................................................40-1030
S-15Fuelmixesintoengineoil........................................................................................40-1031
S-16Watermixesintoengineoil(milky)...........................................................................40-1032
S-17Coolanttemperaturerisestoohigh(overheating)......................................................40-1033
S-18Unusualnoiseisheard...........................................................................................40-1034
S-19Vibrationisexcessive.............................................................................................40-1035
S-20Aircannotbebledfromfuelcircuit...........................................................................40-1036
S-21Activeregenerationisexecutedfrequently...............................................................40-1037
S-22Activeregenerationtakesalongtime.......................................................................40-1038
S-23Whitesmokeisexhaustedduringactiveregeneration...............................................40-1039
Circuitdiagramandarrangementofconnectorpins...............................................................80-23
Systemdiagram.................................................................................................................80-25
Inputandoutputsignalsoftheairconditionercontroller.........................................................80-26
Partsandconnectorslayout................................................................................................80-28
Testingairleakage(duct)....................................................................................................80-33
Testingwithself-diagnosisfunction......................................................................................80-36
Howtoopentheelectricalsystemabnormalityrecordscreeninservicemodeofthemachine
monitor.........................................................................................................................80-37
Testingvent(mode)changeover..........................................................................................80-39
TestingFRESH/RECIRCairchangeover..............................................................................80-40
Testing(dual)pressureswitchforrefrigerant.........................................................................80-41
Testingrelays....................................................................................................................80-43
Troubleshootingchart1......................................................................................................80-45
Troubleshooting chart 2............................................................................................................. 80-46
Informationintroubleshootingtable.....................................................................................80-49
Failurecodelistrelatedtoairconditioner..............................................................................80-50
Failurecode[879AKA]A/CInnersensorOpenCircuit...........................................................80-51
Failurecode[879AKB]A/CInnersensorShortCircuit...........................................................80-52
Failurecode[879BKA]A/COutersensorOpenCircuit..........................................................80-53
Failurecode[879BKB]A/COutersensorShortCircuit..........................................................80-55
Failurecode[879CKA]VentilatingsensorOpenCircuit.........................................................80-57
Failurecode[879CKB]VentilatingsensorShortCircuit..........................................................80-58
Failurecode[879EMC]VentilatingDamperAbnormality........................................................80-59
Failurecode[879FMC]AirMixDamperAbnormality.............................................................80-60
Failurecode[879GKX]RefrigerantAbnormality....................................................................80-61
A-1Troubleshootingforpowersupplysystem(Airconditionerdoesnotoperate).....................80-63
A-2Troubleshootingforcompressorandrefrigerantsystem(Airisnotcooled)........................80-65
A-3Troubleshootingforblowermotorsystem(Noaircomesoutorairflowis abnormal)............................................................................................................80-68
A-4TroubleshootingforFRESH/RECIRCairchangeover......................................................80-70
Troubleshootingwithgaugepressure...................................................................................80-72
Connectionofservicetool...................................................................................................80-75
Precautionsfordisconnectingandconnectingairconditionerpiping.......................................80-77
Handlingofcompressoroil..................................................................................................80-79
90Diagramsanddrawings.................................................................................................................90-1
Tableofcontents........................................................................................................................90-2
Hydrauliccircuitdiagram.............................................................................................................90-3
Symbolsinhydrauliccircuitdiagram......................................................................................90-3
Powertrainhydrauliccircuitdiagram......................................................................................90-7
Hydrauliccircuitdiagram.......................................................................................................90-9
Electriccircuitdiagram..............................................................................................................90-11
Symbolsinelectriccircuitdiagram.......................................................................................90-11
Insidecabelectriccircuitdiagram........................................................................................90-15
Outsidecabelectriccircuitdiagram.....................................................................................90-29
Circuitdiagramrelatedtopayloadmeter..............................................................................90-43
Index....................................................................................................................................................................1
(ALL-0370-001-A-00-A)
• Appropriateservicingandrepairareextremelyimportanttoensuresafeoperationofthemachine.The shopmanualdescribestheeffectiveandsafeservicingandrepairmethodsrecommendedbyKomatsu. SomeofthesemethodsrequiretheuseofthespecialtoolsdesignedbyKomatsuforthespecificpurpose.
• Thesymbolmark k isusedforsuchmattersthatrequirespecialcautionsduringthework.Thework indicatedbythecautionmarkshouldbeperformedaccordingtotheinstructionswithspecialattentionto thecautions.Shouldhazardoussituationoccurorbeanticipatedduringsuchwork,besuretokeepsafe firstandtakeeverynecessarymeasure.
Safetypoints
• Goodarrangement
• Correctworkclothes
• Observanceofworkstandard
• Practiceofmakingandcheckingsignals
• Prohibitionofoperationandhandlingby unlicensedworkers
• Safetycheckbeforestartingwork
• Wearingprotectivegoggles(forcleaningor grindingwork)
• Wearingshieldinggogglesandprotectors(for weldingwork)
• Goodphysicalconditionandpreparation
• Precautionsagainstworkwhichyouarenot usedtooryouareusedtotoomuch
Generalprecautions
kk
Inappropriatehandlingcausesanextreme danger.Readandunderstandwhatis describedintheoperationandmaintenance manualbeforeoperatingthemachine.Read andunderstandwhatisdescribedinthis manualbeforestartingthework.
• Beforeperforminganygreasingorrepairs,read allthesafetylabelsstucktothemachine.For thelocationsofthesafetylabelsanddetailed explanationofprecautions,seetheoperation andmaintenancemanual.
• Locateaplaceintherepairworkshoptokeep thetoolsandremovedparts.Alwayskeepthe toolsandpartsintheircorrectplaces.Always keeptheworkareacleanandmakesurethat thereisnodirt,wateroroilonthefloor.Smoke onlyintheareasprovidedforsmoking.Never smokewhileworking.
• Whenperforminganywork,alwayswearthe safetyshoesandhelmet.Donotwearloose workcloths,orclotheswithbuttonsmissing.
1.Alwaysweartheprotectiveeyeglasseswhen hittingpartswithahammer.
2.Alwaysweartheprotectiveeyeglasseswhen grindingpartswithagrinder,etc.
• Whenperforminganyworkwith2ormore workers,alwaysagreeontheworkingprocedure
beforestarting.Whileworking,alwayskeep conversationsoftheworkbetweenyourfellow workersandyourselfonanystepofthework. Duringthework,hangthewarningtagof "UNDERWORKING"intheoperator's compartment.
• Only the approved personnel can do the work in a closed environment or in a prohibited area.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performingwelding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
• When you work in high places, use a platform.
• Beforeyou startthe work, use the personalfallarrestequipmentto preventfalling.Thereis a dangerof 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.
• Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving.
• Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them.
• When performingthe disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
• Remove all of mud and oil from the steps or other places used to get on and off the machine completely.Always use the handrails, ladders of steps when getting on or off the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing.
• For the machine equipped with the battery disconnect switch, check that the system operating lamp is turned off before starting the work. Then, turn the battery disconnect switch to OFF (Q) position and remove the switch key. For the machine not equipped with the battery disconnect switch, remove the cable from the battery before starting the work. Be sure to remove the negative end (-) of the battery cable first.
• Release the remaining pressure in the circuits completely before the work when the parts in the circuits of oil, fuel, coolant and air are disconnected or removed. When the cap of the oil filter, drain plug or oil pressure pickup plug is removed, loose them slowly to prevent the oil from spurting out.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.
• Immediatelyafter the engine is shut down, the coolant and oil in the circuits are hot. Be careful not to get scalded by the hot coolant and oil. Start the work after checking that the coolant and oil are cooled down sufficiently.
• Start the work after the engine is shut down. Be sure to shut down the engine when working on or around the rotating parts in particular.When checking the machine without shutting down the engine (measuring oil pressure, rotational speed, oil or coolant temperature),take extreme care not to get caught in the rotating parts or the working equipment.
• The hoist or crane must be used to sling the components weighing 20 kg or heavier. Check the slings (wire rope, nylon sling, chain and hook) for damage before the work. Use the slings with ample capacity and install them to the proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
• When removing the part which is under internal pressure or reaction force of the spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately and release the pressure, then, remove the part.
• When removing the part, be careful not to break or damage the electrical wiring. The damaged wiring may cause electrical fires.
• When removing piping, prevent the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
• As a general rule, do not use gasoline to wash parts. Do not use gasoline to clean the electrical parts, in particular.
• Reinstall the parts removed to their original places. Replace the damaged parts and the parts which must not be used with new ones. When installing the hoses and wiring harnesses, be careful that they are not damaged by contacting with other parts when the machine is operated.
• When connecting the high pressure hoses and tubes, make sure that they are not twisted. The damaged high pressure hoses and tubes are very dangerous when they are installed. So, be extremely careful when connecting the high pressure pipings. In addition, check that their connections are correct.
• When assembling or installing the parts, be sure to tighten the bolts to the specified torque. When installing the protective parts such as guards, or the parts which vibrate violently or rotate at high speeds, be sure to check that they are installed correctly.
• When aligning 2 holes, never insert your fingers or hand into the holes. Align the holes with care so that your fingers are not caught in the hole.
• When measuring hydraulic pressure, check that the measuring tools are correctly installed.
• Pay attention to safety when removing and installing the tracks of the track type machines. When removing the track, it separates suddenly. The workers should not stand at either end of the track.
• If the engine is operated for a long time in a closed place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate the place well.
Precautions for slinging work and making signals
• Only one appointed worker must make signals and co-worker must communicate with each other frequently.The appointed signaler must make specified signals clearly at the place where the signaler is well seen from the operator's seat and where the signaler can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely.
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.
q 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.
q 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 the gloves during sling work. (Put on the leather gloves, if available.)
• Measuretheweightoftheloadbytheeyeand checkitscenterofgravity.
• Usetheproperslingaccordingtotheweightof theloadandmethodofslinging.Iftoothickwire ropesareusedtoslingalightload,theloadmay slipandfall.
• Donotslingaloadwith1wireropeonly.Ifdoso, theloadmayrotateortheslinggetslooseand theslingmayslipoff.Install2ormorewireropes symmetrically.
k Slingingwithoneropemaycauseturning oftheloadduringhoisting,untwistingof therope,orslippingoftheropefromits originalslingingpositionontheload, whichcanresultinadangerousaccident.
• Hanging angle must be 60 deg. or smaller as a rule.
• When hanging a heavy load (20 kg or heavier), the hanging angle of the rope must be narrower than that of the hook.
a When slinging a load with 2 ropes or more, thelargerthehangingangleis,thelargerthe tensionofeachrope.Thefigurebellow showsthevariationofallowableloadinkg whenhoistingismadewith2ropes,eachof whichisallowedtoslingupto9.8kN {1,000kg}aloadvertically,atvarious hangingangles.Whenthe2ropesslinga loadvertically,upto2,000kgoftotalweight canbesuspended.Thisweightisreducedto 1,000kgwhenthe2ropesmakeahanging angleof120deg..Ifthe2ropesslinga2,000 kgloadatahangingangleof150deg.,each ropeissubjectedtoaforceaslargeas4,000 kg.
• Wheninstallingwireropestoanangularload, applypadstoprotectthewireropes.Iftheload isslippery,applypropermaterialtopreventthe wireropefromslipping.
• Usethespecifiedeyeboltsandfixwireropes, chains,etc.tothemwithshackles,etc.
• Applywireropestothemiddlepartofthehook.
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a Slingingnearthetipofthehookmaycause theropetoslipoffthehookduringhoisting. Thestrengthofthehookismaximumatits centralpart.
• Donotusetwistedorkinkedwireropes.
• Whenslingingupaload,observethefollowing.
1.Winduptheropeslowlyuntilthewirerope tensions.Whenputtingyourhandsonthe wireropes,donotgraspthembutpressthem downfromabove.Ifyougraspthem,your fingersmaybecaught.
2.Afterthewireropesarestretched,stopthe craneandchecktheconditionoftheslung load,wireropes,andpads.
3.Iftheloadisunstableorthewireropeor chainsaretwisted,lowertheloadandliftit upagain.
4.Donotliftuptheloadatanangle.
• Whenloweringaload,payattentiontothe following.
1.Whenliftingdownaload,stopittemporarily at30cmabovethefloor,andthenlowerit slowly.
2.Checkthattheloadisstable,andthen removethesling.
3.Removekinksanddirtfromthewireropes andchainsusedfortheslingwork,andput theminthespecifiedplace.
Precautionsforusingmobilecrane
a ReadtheOperationandMaintenanceManualof thecranecarefullyinadvanceandoperatethe cranesafely.
Precautionsforusingoverheadtravelingcrane
kk Thehoistorcranemustbeusedtoslingthe components weighing 20 kg or heavier. A part weighing 20 kg or heavier in "Disassembly and assembly" section is indicatedwiththesymbolof 44.
a The symbol shows the weight of the parts with weight of 20 kg or more for convenience of workers. But the weight can possibly be shown even if it is less than 20 kg 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 you start work, examine the wire ropes, brake, clutch, controller, rails, over hoisting, ground fault interrupter for electric shock prevention, crane collision prevention device, and power application caution lamp, and examine the items about the safety. 4 4
• Beforestartingwork,checkthewireropes, brake,clutch,controller,rails,overwinding preventiondevice,groundfaultcircuitinterrupter
forelectricshockprevention,cranecollision preventiondevice,andenergizingwarninglamp, andcheckthefollowingsafetyitems.
• 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.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it will not be an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emergency.
• Shut down the main switch when the hoist stops because of a blackout. When turning on a switch which is turned OFF by the ground fault circuit interrupterfor electric shock prevention, check that the devices related to that switch are not in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 meters above the floor. Do not leave the sling attached to the hook.
Selectingwireropes
• Selectadequateropesdependingontheweight ofthepartstobehoisted,referringtothetable below Wirerope(JISG3525,6x37-TypeA) (StandardZtwistwireropeswithoutgalvanizing)
a Theallowableloadiscalculatedasonesixthof thebreakingloadoftheropetobeused(safety coefficient:6).
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
Disconnection
k k When replacing the air conditioner unit, air conditionercompressor,condenseror receiverdrier,etc.,collecttherefrigerant(air conditionergas:R134a)fromtheair conditionercircuitbeforedisconnectingthe airconditionerhoses.
a Askaqualifiedpersonforcollecting,addingand fillingoperationsoftherefrigerant(air conditionergas:R134a).(Onlyregistered personscanwork.)
a Neverreleasetherefrigerant(airconditioner gas:R134a)totheatmosphere.
kk Ifrefrigerantgas(airconditionergas:R134a) getsinyoureyes,youmayloseyoursight. Andifittouchesyourskin,youmaysuffer fromfrostbite.Putonprotectiveeyeglasses, glovesandworkingclotheswithlong sleeveswhilecollectingtherefrigerantor fillingtheairconditionercircuitwiththe refrigerant.
• Whenlooseningthenutsfixingairconditioner hosesandtubes,besuretouse2wrenches; useonewrenchtofixandusetheotheroneto loosenthenut.
Connection
• Wheninstallingthehosefortheairconditioner circuit,takecarenottoallowinvasionofdirt, dustsandwaterintothehose.
• CheckthattheO-ringsarefittedtothejoints whenconnectingtheairconditionerpiping.
• OnceanO-ringisused,itisdeformedand deteriorated.Accordingly,donotreuseit.
• • WhenremovingtheO-rings,useasofttoolso thatthepipingisnotdamaged. CheckthattheO-ringisnotdamagedor deteriorated.
• Applycompressoroilforrefrigerant(R134a)to theO-ring.
a However,donotapplyoiltothethreaded partofabolt,nutorunion.
Manufacturer Partname
DENSO ND-OIL8
VALEOTHERMAL SYSTEMS ZXL100PG(equivalentto PAG46)
SANDEN SP-10
• Whentighteningnutsoftheairconditioner hosesandtubes,besuretouse2wrenches. Useonewrenchtofixandtightenthenutwith theotherwrenchtothespecifiedtorque(Usea torquewrenchfortightening).
a ExampleoffittingofO-ring
• AnO-ringisfittedtoeveryjointoftheair conditionerpiping.
Fortighteningtorques,see"Others", "Precautionsfordisconnectionandconnection ofairconditionerpiping".
Precautionstopreventfire (ALL-0000-17B-K-03-A)
• Firecausedbyfuel,oil,coolantorwindow washerfluid
Donotbringanyflameorfireclosetoflammable substancessuchasfuel,oil,coolantorwindow washerfluid.Thereisdangerthattheymaycatch fire.Alwaysobservethefollowing.
• Donotsmokeoruseanyflamenearfuelor otherflammablesubstances.
• Shutdowntheenginebeforeaddingfuel.
• Donotleavethemachinewhenaddingfuel oroil.
• Tightenallthefuelandoilcapssecurely.
• Becarefulnottospillfuelonoverheated surfacesoronpartsoftheelectricalsystem.
• Afteraddingfueloroil,wipeupanyspilled fueloroil.
• Putgreasyragsandotherflammable materialsintoasafecontainertomaintain safetyattheworkplace.
• Whenwashingpartswithoil,useanonflammableoil.Donotusedieseloilor gasoline.Thereisdangerthattheymaycatch fire.
• Donotweldoruseacuttingtorchtocutany pipesortubesthatcontainflammableliquids.
• Determinewell-ventilatedareasforstoringoil andfuel.Keeptheoilandfuelinthe specifiedplaceanddonotallow unauthorizedpersonstoenter.
• Whenperforminggrindingorweldingwork onthemachine,moveanyflammable materialstoasafeplacebeforestarting.
• Firecausedbyaccumulationorattachment offlammablematerial
• Removeanydryleaves,chips,piecesof paper,coaldust,oranyotherflammable materialsaccumulatedorattachedtoor aroundtheengineexhaustmanifold,muffler, orbattery,orontheundercovers.
• Topreventfiresfrombeingcaught,remove anyflammablematerialssuchasdryleaves, chips,piecesofpaper,coaldust,orany otherflammablematerialsaccumulated aroundthecoolingsystem(radiator,oil cooler)orontheundercover.
• Firecomingfromelectricwiring
Shortcircuitsintheelectricalsystemcancause fire.Alwaysobservethefollowing.
• Keepalltheelectricwiringconnectionsclean andsecurelytightened.
• Checkthewiringeverydayforloosenessor damage.Reconnectanylooseconnectorsor refastenwiringclamps.Repairorreplaceany damagedwiring.
• Firecausedbypiping
Checkthatalltheclampsforthehosesand tubes,guards,andcushionsaresecurelyfixed inposition.
Iftheyareloose,theymayvibrateduring operationandrubagainstotherparts.Thereis dangerthatthismayleadtodamagetothe hosesandcausehigh-pressureoiltospurtout, leadingtofireandseriouspersonalinjuryor death.
• Firearoundthemachineduetohighlyheated exhaustgas
SomemachinesareequippedwithKDPF (KomatsuDieselParticulateFilter).
KDPFisasystemforpurifyingsootinexhaust gas.Itsexhaustgasdischargedduring purificationprocess(regeneration)canbeat highertemperaturethanthatfromexisting models.Donotbringanyflammablematerial closetotheoutletoftheexhaustpipe.
• Whentherearethatchedhouses,dryleaves orpiecesofpaperneartheworksite,setthe systemtodisabletheregenerationbefore startingworktopreventfirehazardsdueto highlyheatedexhaustgas.
Seetheoperationandmaintenancemanual forthesettingprocedure.
• Explosioncausedbylightingequipment
• Whencheckingfuel,oil,batteryelectrolyte, orcoolant,alwaysuselightingequipment withanti-explosionspecifications.
• Whentakingtheelectricalpowerforthe lightingequipmentfromthemachineitself, followtheinstructionsintheoperationand maintenancemanual.
(ALL-0000-17A-K-01-A)
• TurnthestartingswitchtoOFFpositiontostop theengine.
• Usethehandrailsandstepstogetoffthe machine.
• Donotjumpoffthemachine.Youmayfallor sufferseriousinjury.
• Thefumegeneratedbyafirecontainsharmful materialswhichhaveabadinfluenceona humanbodywhentheyaresucked. Don'tbreatheafume.
• Afterafire,theremaybeharmfulcompounds left.Ifittouchesyourskinitmayhaveabad influenceonyourbody.
Besuretowearrubbergloveswhenhandlethe materialsleftafterthefire.
Thematerialofthegloves,whichis recommendedispolychloroprene(Neoprene)or polyvinylchloride(inthelowertemperature environment).
Whenwearingcotton-work-gloves,wearrubber glovesunderthem.
(ALL-0000-99A-K-02-A)
Topreventpollution,payfullattentiontothewayto disposeofwastematerials.
• Alwaysputtheoilandcoolantdrainedfromthe machineincontainers.Neverdraintheoiland coolantdirectlyontothegroundordumpintothe sewagesystem,rivers,thesea,orlakes.
• Observetherelatedlawsandregulationswhen disposingofharmfulobjectssuchasoil,fuel, coolant,solvent,filters,andbatteries.
Somekindsofrubberandplasticsmayproduce poisonousgasharmfultohumanbodywhenthey areburned.
• Asforrubber,plastics,orparts(hoses,cables, andwiringharnesses,etc.)whichcontainthose materials,asktheindustrialwastetreatment firmsfortheirdisposalsinaccordancewiththe localregulations.
00Indexandforeword
Foreword,safetyandgeneralinformation
• Some attachmentsandoptionalpartsdescribedinthisshopmanualmaynotbearrangedforcertain areas.ContactyourKomatsudistributorifoneorsomeofthemarerequired.
• Materialsandspecificationsaresubjecttochangewithoutnotice.
• Theshopmanualsareavailablefor"Machinepart"and"Enginepart".Fortheengine,seetheshop manualforthesamemodeloftheengineastheonewhichismountedonthemachine.
Compositionofshopmanual
• Thisshopmanualdescribesthetechnicalinformationrequiredfortheservicesperformedinaworkshop. Theshopmanualisdividedintothefollowingchaptersfortheconvenienceofuse.
00.Indexandforeword
• Thissectionincludestheindex,foreword,safetyandbasicinformation.
01.Specification
• Thissectionexplainsthespecificationsofthemachine.
10.Structureandfunction
• Thissectionexplainsthestructureandfunctionofthemachine.Thesectionof"Structureandfunction" servesnotonlytogiveanunderstandingforthestructureofeachcomponent,butalsoservesas referencematerialfortroubleshooting.
20.Standardvaluetable
• Thestandardvaluesforanewmachineandtroubleshootingareindicated.Thisstandardvaluetableis usedfortestingandadjusting,anddeterminingafailureattroubleshooting.
30.Testingandadjusting
• Thissectiondescribesthemeasuringtoolsandhowtomeasure,andhowtoadjustvariousparts.Asfor thestandardvalueandfailurecriterion,seethestandardvaluetable.
40.Troubleshooting
• Thissectiondescribesthetroubleshootinginasuspectedareawhenafailureoccursandtheremedyfor thefailure.Troubleshootingisdescribedbyeachfailuremode.
50.Disassemblyandassembly
• Thissectionexplainstheproceduresforremoving,installing,disassembling,andassemblingeachpartor componentandthespecialtoolsfortheworksaswellasprecautionsfordoingthemsafely.Inaddition, tighteningtorque,andquantityandweightofcoatingmaterial,oil,grease,andcoolantrequiredforthe worksarealsoexplained.
60.Maintenancestandard
• Thissectiondescribesthemaintenancestandardvaluesforeachcomponent.Thissectiongivesthe criterionvaluesforeachcomponentandrequiredremedyatdisassemblyormaintenance.
80.Appendix
• Thestructureandfunction,testingandadjusting,andtroubleshootingforalloftheothercomponentsor equipmentwhichcannotbeseparatelyclassifiedareexplainedtogetherintheappendix.
90.Diagramsanddrawings
• Thissectiongiveshydrauliccircuitdiagramsandelectricalcircuitdiagrams.
Symbol
Importantsafetyandqualityportionsaremarkedwiththefollowingsymbolssothattheshopmanualisused practically.
Remarks
Thespecialsafetyprecautionsrequiredforperformingworkare described. a Caution
Safety
Thespecialtechnicalprecautionsorotherprecautionsforpreserving standardsrequiredwhenperformingworkaredescribed. 4 Weight
The weight of parts or component 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.
Thetighteningtorquesthatrequirespecialattentionduringassembly workareindicated.
Theplacestobecoatedwithadhesives,grease,etc.duringassembling areindicated. 5 Oil,coolant
Theplaceswhereoil,coolant,etc.mustbeaddedandthequantitytobe addedareindicated. 6 Drain
Placeswhereoil,coolant,etc.mustbedrainedandthequantitytobe drainedareindicated.
• Inthisshopmanual,theunitsareindicatedwithInternationalSystemofunits(SI).
• Forreference,GravitationalSystemofunitswhichisusedtobeusedisindicatedinparenthesesof{}.
Foreword,safetyandgeneralinformation
Explanationoftermsformaintenancestandard (ALL-0330-006-A-01-A) (Rev.2012/10)
• Thechapterofmaintenancestandardshowsjudgementcriteriatodeterminetheproductstobereplaced ortobereused.Thejudgementcriteriaaredescribedbyusingthefollowingterms.
Standarddimensionandtolerance
• Tobeaccurate,thefinisheddimensionofapart isslightlydifferentfromonetoanother.
• Thefinisheddimensionofapartspecifiesthe allowabledifferencefromthestandard dimensionwhichissetfirst.
• Thedimensionsetasthestandardiscalledthe standarddimensionandtherangeofdifference fromthisstandarddimensioniscalledthe "tolerance".
• Anindicationexampleofastandarddimension andtoleranceisshowninthefollowingtable.
(Thestandarddimensionisenteredontheleft sideandthetoleranceisenteredwithapositive ornegativesymbolontherightside)
Example:
StandarddimensionTolerance
• Thetolerancemaybeindicatedinthetextanda tableas"standarddimension(upperlimitof tolerance/lowerlimitoftolerance)."
Example:120(-0.022/-0.126)
• Usually,thedimensionofaholeandthe dimensionofashafttobeinsertedintothehole areindicatedbythesamestandarddimension anddifferenttolerancesoftheholeandshaft. Thetightnessoffitisdecidedbythetolerance.
• Anindicationexampleofashaftandholeis showninthefollowingtable.
(Thestandarddimensionisenteredontheleft sideandthetoleranceoftheshaftisentered withapositiveornegativesymbolatthecenter andthatoftheholeontherightside)
• Theclearancemadewhennewpartsare assemblediscalledthestandardclearance, whichisindicatedbytherangefromthe minimumclearancetothemaximumclearance.
• Whensomepartsarerepaired,theclearanceis generallyadjustedtothestandardclearance.
• Thevaluesindicatingperformanceandfunction ofnewproductsorequivalentarecalledthe "standardvalue",whichisindicatedbyarange oratargetvalue.
• Whensomepartsarerepaired,thevalueof performance/functionissettothestandard value.
Standardinterference
• Whenthediameterofaholeofapartshownin thegivenstandarddimensionandtolerance tableissmallerthanthatoftheshafttobe inserted,thedifferencebetweenthose diametersiscalledthe"interference".
• Subtractthemaximumdimensionofthehole fromtheminimumdimensionoftheshaftand callit(A).Subtracttheminimumdimensionof theholefromthemaximumdimensionofthe shaftandcallit(B).Therangebetween(A)and (B)isthe"standardinterference".
• Afterrepairingorreplacingsomeparts,measure thedimensionoftheirholeandshaftandcheck thattheinterferenceisinthestandardrange.
Repairlimitandallowablevalueorallowable dimension
• Thedimensionsofpartschangebecauseofthe wearordeformationwhiletheyareused.When thedimensionchangesexceedingcertainvalue,
thepartscannotbeusedanylonger.Thisvalue iscalled"repairlimit".
• Ifapartisworntotherepairlimit,itmustbe replacedorrepaired.
• Theperformanceandfunctionoftheproducts lowerwhiletheyareused.Whenthevalueofthe performanceandfunctionlowersexceedinga certainlimitanditinfluencestheoperationetc., thisvalueiscalledtheallowablevalueor allowabledimension.
• Aproductwhosedimensionisoutofthe allowablevalue,mustberepaired.However, sincetheallowablevaluesaregenerally estimatedthroughvarioustestsorexperiences inmostcases,thejudgementmustbemadein considerationoftheoperatingconditionand customer'srequirement.
Allowableclearance
• Partscanbeuseduntiltheclearancebetween themisincreasedtoacertainlimit.Thelimitat whichthosepartscannotbeusediscalledthe "allowableclearance".
• Iftheclearancebetweenthepartsexceedsthe allowableclearance,theymustbereplacedor repaired.
Allowableinterference
• Theallowablemaximuminterferencebetween theholeofapartandtheshaftofanotherpartto beassemblediscalledthe"allowable interference".
• Theallowableinterferenceshowstherepairlimit ofthepartofsmallertolerance.
• Thepartswhoseinterferencesareoutofthe allowableinterferencemustbereplacedor repaired.
Handlingequipmentoffuelsystemdevices (PC-AD00-2A4-K-00-A)
(Rev.2012/01)
• Thecommonrailfuelinjectionsystem(CRI) consistsofmoreprecisepartsthantheparts usedintheconventionalfuelinjectionpumpand nozzle.Ifforeignmaterialentersthissystem,it maycauseafailure.Usespecialcaretoprevent entryoftheforeignmaterialwhenservicingthe fuelsystem.
Usecareforworkingenvironment
• Avoidfilterchangeorrepairingthemachinein rainorhighwinds,oratplaceswherethereisa lotofdust.
Sealingopenings
• Plugthepipesandtheopeningsofthe componentswhichareremovedwiththecaps, tapes,vinylbags,etc.topreventforeignmaterial fromentering.Neverperformrepairworksunder theconditionthattheopeningsareleftasthey areorpluggedwithclothsasforeignmaterial mayenterorenvironmentmaybepollutedby theoilleaked.Donotdiscardthewasteoil somewhereorother.Handitovertoyour customerfordisposal,ordisposeitbyyourself.
Howtocleanpartswhendirtisstuck
• Ifanydirtorduststicksthepartsofthefuel system,cleanitoffthoroughlywithcleanfuel.
Precautionsforreplacingfuelfiltercartridge
• BesuretousetheKomatsugenuinefuelfilter cartridge.
• Thecommonrailfuelinjectionsystem(CRI) consistsofmoreprecisepartsthantheparts usedintheconventionalfuelinjectionpumpand nozzle.Inordertopreventforeignmaterialfrom enteringthissystem,thefilteremploysa speciallyhighperformanceoffilterelement.Ifa filterelementotherthanthegenuineoneisused, thefuelsystemmayhaveafailure.Accordingly, neverusesuchafilterelement.
Handlingofintakesystemparts (PC220-A900-2A4-K-00-A) (Rev.2013/10)
• TheKomatsuVariableGeometryTurbocharger consistsofmorepreciseparts(variable mechanism)thanthepartsusedinthe conventionalturbocharger.Ifforeignmaterial entersthissystem,itmaycauseafailure.Use specialcaretoprevententryoftheforeign materialwhenservicingtheairintakesystem.
Becarefulofworkingenvironment
• Avoidtherepairworkofthemachineinrainor strongwindorattheplaceswherethereisalot ofdust.
Sealingopenings
• Plugthepipesandtheopeningsofthe componentswhichareremoved,withthecaps, tapes,vinylbags,etc.topreventforeignmaterial fromentering.Neverperformrepairworksunder theconditionthattheopeningsareleftopenor pluggedwithragsinceforeignmaterialmay enter.
Foreword,safetyandgeneralinformation
(Rev.2012/10)
• Withtheincreaseinpressureandprecisionofthehydrauliccomponents,themostcommoncauseofa failureisdirt(foreignmaterial)inthehydrauliccircuit.Therefore,thespecialcaremustbetakenwhen addinghydraulicoil,orwhendisassemblingorassemblingthehydrauliccomponents.
Becarefulofworkingenvironment
• Avoidaddinghydraulicoil,replacingfilters,or repairingthemachineinrainorhighwinds,orat placeswherethereisalotofdust.
Disassemblyandmaintenanceworkinthefield
• Whendisassemblyormaintenanceworkofthe hydraulicisperformedinthefield,thereis dangerofdustenteringthecomponents.Itis alsodifficulttochecktheperformanceofthe componentsafterrepairs,soitisdesirableto usethecomponentexchangeservice.The disassemblyandassemblyofthehydraulic componentsmustbeperformedinthespecially arrangeddustproofworkshopandthe performancetestofthecomponentsmustbe performedwiththespecialtestingequipment.
Preventingintrusionofforeignmaterialsduring refillingoperations.
• Caremustbetakenwhenaddinghydraulicoilso thatforeignmaterialdoesnotenter.Keeptheoil fillerportandtheareaaroundit,oilsupplypump andoilcontainerclean.Ifanoilcleaningdevice isused,itispossibletoremovethedirtthatis collectedduringstorage.Itisasurermeans.
Pluggingofopening(preventionofflowingout ofoil)
• Plugthepipesandtheopeningsofthe componentswhichareremoved(whenplugs arenotprepared,sealwithcaps,tapes,vinyl bags,etc.)toprevententryofforeignmaterial andflowingoutofoil.Neverleavetheopenings ofthepipesandhoseswithoutbeingcoveredor pluggedwithclothasforeignmaterialmayenter themorenvironmentmaybepollutedbytheoil leaked.Donotdiscardthewasteoilsomewhere orother.Handitovertoyourcustomerfor disposal,ordisposeitbyyourself.
Replacinghydraulicoilwhileitstemperatureis high
• Whenthehydraulicoiliswarm,itflowseasily.In addition,sludgecanalsobedrainedfromthe circuittogetherwiththeoil.So,itisbetterto changethehydraulicoilwhileitiswarm.When changingthehydraulicoil,theoldoilmustbe drainedasmuchaspossible.(Draintheoilnot onlyfromthehydraulictank,butalsofromthe filterhousingandthedrainplugholeinthe circuit.)Iftheoldoilisleftinthesystem,the contaminantandsludgeintheoilmixwiththe newoilandshortenthelifeofthenewhydraulic oil.
• Afterdisassemblingtheequipmentorwhen changingthehydraulicoilwithnewone,flush thesystemtoremovethecontaminantand sludgeleftinthehydrauliccircuitaswellasthe oilwhichincludesthem.Normally,flushingis performedtwice.Primaryflushingisperformed byuseoftheflushingoilandthesecondary flushingisperformedbyuseofthespecified hydraulicoil.
• Afterrepairingthehydraulicequipment(pump, controlvalve,etc.)orwhenthemachineisin operation,performoilcleaningtoremovethe sludgeorcontaminantinthehydraulicoilcircuit. Theoilcleaningequipmentcanremovetheultra fine(approximately3 μm)particlesthatthefilter builtinthehydraulicequipmentcannotremove. So,itisanextremelyeffectivedevice.
00Indexandforeword
Foreword,safetyandgeneralinformation
Methodofdisconnectingandconnectingofpush-pulltypecoupler (ALLC930-001-P-00-A)
(Rev.2012/01)
kk Loosentheoilfillercapofthehydraulictankslowlytoreleasetheremainingpressureinthe hydraulictank.
kk Eveniftheremainingpressureisreleasedfromthehydraulictank,somehydraulicoilflowsout whenthehoseisdisconnected.Accordingly,prepareanoilcontainer.
Type1 (ALL-C930-925-P-01-A)
Disconnection
1.Holdadapter(1)andpushhosejoint(2)into matingadapter(3).(Fig.1)
a Itcanbepushedinbyapproximately3.5mm.
a Donotholdrubbercapportion(4).
2.Whilepushinghosejoint(2)intoadapter(3), pushrubbercap(4)againstadapter(3)until "click"isheard.(Fig.2)
3.Holdhoseadapter(1)orhose(5)andpullitout. (Fig.3)
a Sincesomehydraulicoilflowsout,prepare anoilcontainer.
Connection
1.Holdhoseadapter(1)orhose(5)andinsertitin matingadapter(3)aligningthemwitheachother. (Fig.4)
a Donotholdrubbercappart(4).
2.Afterinsertingthehosefittingintheadapteron theothersideperfectly,pullitbacktocheckthe connectingcondition.(Fig.4)
a Whenthehosefittingispulledback,the rubbercapwillmoveapproximately3.5mm towardthehose,however,itisnotaproblem.
Type2 (ALL-C930-925-P-02-A)
Disconnection
1.Whileholdingthefitting,pushbody(7)instraight untilslidingpreventionring(6)hitscontact surface(a)atthehexagonalpartonthemale side.(Fig.6)
2.WhilekeepingtheconditionofStep1,turnlever (8)totheright(clockwise).(Fig.7)
3.WhilekeepingtheconditionsofSteps1and2, pulloutwholebody(7)todisconnectit.(Fig.8)
Connection
1.Whileholdingthefitting,pushbody(7)instraight untilslidingpreventionring(6)hitscontact surface(a)atthehexagonalpartonthemale sidetoconnectit.(Fig.9)
Type3 (ALL-C930-925-P-03-A)
Disconnection
1.Whileholdingthefitting,pushbody(9)instraight untilslidingpreventionring(8)hitscontact surface(b)atthehexagonalportiononthemale side.(Fig.10)
2.WhilekeepingtheconditionofStep1,push cover(10)straightuntilithitscontactsurface(b) ofthehexagonalportiononthemaleside.(Fig. 11)
3.WhilekeepingtheconditionsofSteps1and2, pulloutwholebody(9)todisconnectit.(Fig.12)
Connection
1.Whileholdingthefitting,pushbody(9)instraight untilslidingpreventionring(8)hitscontact surface(a)atthehexagonalportiononthemale sidetoconnectthem.(Fig.13)
Handlingofelectricalequipment (ALL-E000-2A4-P-01-A)
(Rev.2012/11)
• Tomaintaintheperformanceofthemachineoveralongperiod,andtopreventfailuresortroublesbefore theyoccur,correct"operation","maintenanceandinspection""troubleshooting",and"repairs"mustbe performed.Thissectiondealsparticularlywithcorrectrepairproceduresformechatronicscomponents andisaimedatimprovingthequalityofrepairs.Forthispurpose,itdescribestheworkingproceduresin "Handlingofelectricalequipment".
Precautionsforhandlingelectricequipment
Handlingwiringharnessesandconnectors
• Wiringharnessesconsistofwiresconnecting onecomponenttoanothercomponent, connectorsusedforconnectingand disconnectingonewirefromanotherwire,and protectorsortubesusedforprotectingthewires.
• Comparedwithotherelectricalcomponents fittedinboxesorcases,wiringharnessesare morelikelytobeaffectedbythedirecteffectsof rainwater,heat,orvibration.Furthermore, duringinspectionandrepairoperations,theyare frequentlyremovedandinstalledagain,sothey arelikelytosufferdeformationordamage.For thisreason,itisnecessarytobeextremely carefulwhenhandlingthewiringharnesses.
Defectivecrimpingorsolderingofconnectors
• Thepinsofthemaleandfemaleconnectorsare attachedtowiresbycrimpingorsoldering.If excessiveforceisappliedtothewire,thejoining areamaybecomeloose,whichmayresultina defectiveconnectionorbreakage.
Mainfailuresoccurringinwiringharness
Defectivecontactofconnectors(defective contactbetweenmaleandfemaleconnectors)
• Problemswithdefectivecontactarelikelyto occurbecausethemaleconnectorisnot properlyinsertedintothefemaleconnector,or becauseoneorbothofconnectorsare deformedorthepositionisnotcorrectlyaligned, orbecausethereiscorrosionoroxidizationof thecontactsurfaces.Thecorrodedoroxidized contactsurfacesmaybecomeshinyagain(and contactmaybecomenormal)byconnectingand disconnectingtheconnectorsapproximately10 times.
• Ifthewiringharnessispulledtodisconnectthe connector,orthecomponentsareliftedwitha cranewhilethewiringharnessisstillconnected, oraheavyobjecthitsthewiringharness,the crimpingoftheconnectormayseparate,orthe solderingmaybedamaged,orthewiring harnessmaybebroken.
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blowitwithcompressedairandsprayitwith electricalcontactrestorer.
a Whenwipingthejointportionofthe connector,becarefulnottoapplyexcessive forceordeformthepins.
a Ifthereisoilorwaterinthecompressedair,it causesthecontactstobecomedirtier.So, removetheoilandwaterfromthe compressedaircompletelybeforecleaning theconnectorwiththecompressedair.
High-pressurewaterenteringconnector
• Theconnectorisdesignedtomakeitdifficultfor watertoenter(drip-proofstructure),butifhighpressurewaterissprayeddirectlyonthe connector,watermayentertheconnector, dependingonthedirectionofthewaterjet. Accordingly,takecarenottospraywaterover theconnector.
Theconnectorisdesignedtopreventwaterfrom entering,butoncewaterdoesenter,itisdifficult todrainit.Ifwatershouldgetintotheconnector, thepinswillbeshort-circuitedbythewater.Soif anywatergetsin,immediatelydrytheconnector ortakeotherappropriateactionbeforepassing electricitythroughit.
1.Holdtheconnectorswhendisconnecting.
• Disconnectconnectorsbyholdingthe connectorbodies.Fortheconnectorsheldby ascrew,loosenthescrewfully,thenholdthe maleandfemaleconnectorswitheachhand respectivelyandpullthemaparthorizontally. Fortheconnectorswithlockstopper,press downthestopperwithyourthumbandpull theconnectorsapart.
a Neverpulltheconnectorwithonehand.
Entryofwater,mudordirtwhendisconnectinga connector
• Ifanywater,mudordirtisstucktotheoutside surfaceofaconnector,itcanenterinsidethe connectorwhentheconnectorisdisconnected. Beforedisconnectingtheconnector,wipeoffany stuckwaterordirtbyusingapieceofdrycloth orblowitwithcompressedair.
Oil,mudordirtstucktoconnector
• Ifanyoilorgreaseisstucktotheconnectorand anoilfilmisformedonthematingsurfaceofthe maleandfemalepins,theoilpreventselectricity frompassingthrough,resultingindefective contact.Ifanyoilorgrease,mudordirtisstuck totheconnector,wipeitoffwithadryclothor
• Bothoftheconnectorandcliphavestoppers, whichareengagedwitheachotherwhenthe connectorisconnected.
• Whenremovingaconnectorfromaclip,pull theconnectorinaparalleldirectiontotheclip forremovingstoppers.
a Iftheconnectorispriedupanddownor totherightandleft,thehousingmay break.
3.Actiontotakeafterremovingconnectors
• Afterremovingtheconnector,coveritwith thevinylbagtoprevententryofdust,dirt,oil orwaterinthecontactportion.
a Ifthemachineisleftdisassembledfora longtime,itisparticularlyeasyfor impropercontacttooccur,soalways covertheconnector.
1.Checktheconnectorvisually.
• Checkthatthereisnooil,dirtorwaterstick totheconnectorpins(jointportion).
• Checkthattheconnectorpinsarefreefrom deformation,defectivecontact,corrosion,or damage.
• Checkthatexternalsurfacesofthe connectorsarefreefromdamageor breakage.
a Ifanyoil,waterordirtisstucktothe connector,wipeitoffwithadrycloth.Ifany waterisinsidetheconnector,warmthe connectorandtheinsideofthewiring harnesswithadryer.Butbecarefulnotto makeittoohotasitcausesshortcircuit.
a Ifthereisanydamageorbreakage,replace theconnector.
2.Fixtheconnectorsecurely.
• Aligntheconnectorscorrectly,andfitthem securely.Fortheconnectorswiththelock stopper,pushintheconnectorsuntil"click"is heard.
3.Correcttheprotrusionofthebootand misalignmentofthewiringharness
• Forconnectorsfittedwiththeboot,correct anyextrusionoftheboot.Inaddition,ifthe wiringharnessortheclampisoutofthe position,putitinitsoriginalposition.
a Iftheconnectorcannotbecorrected easily,removetheclampandadjustthe position.
• Iftheconnectorclampisremoved,besureto returnittoitsoriginalposition.Andcheck thatitissecurelyinstalled.
• Ifthereisanyoilordirtonthewiringharness, wipeitoffwithadrycloth.Avoidwashingby usingsteam.Ifthewireharnessmustbe washedinwater,donotapplyhighpressure waterorsteamdirectlytothewiringharness.If watergetsdirectlyontheconnector,doas follows.
1.Disconnecttheconnectorandwipeoffthewater withadrycloth.
a Iftheconnectoristobeblownwithdry compressedair,thereisariskthatoilinthe airmaycausedefectivecontactofthe conditioner,removeoilandwaterintheair beforestartingairblow.
Disconnection
1.Whilepressinglocks(a)and(b)fromeachside respectively,pulloutfemaleconnector(2).
Connection
1.Pushinfemaleconnector(2)horizontallyuntil thelockclicks.(Arrow:x)
2.Sincelocks(a)and(b)maynotbeset completely,pushinfemaleconnector(2)with curvingmovementuntilthelocksareset normally.(Arrow:x,y,andz)
a Lock(a)inthefigureispulleddown(notset completely),andlock(b)issetcompletely.
2.Drytheinsideoftheconnectorwithadryer. Ifwatergetsinsidetheconnector,useadryerto drytheconnector.
a Hotairfromthedryercanbeused,but regulatethetimetousehotairinorderto preventtheconnectororrelatedpartsfrom becomingtoohot,asitcausesdeformation ordamagetotheconnector.
3.Performacontinuitytestontheconnector. Afterdrying,leavethewiringharness disconnectedandperformacontinuitytestto checkforanyshortcircuitsbetweenpinscaused bywater.
a Aftertheconnectoriscompletelydried,blow thecontactrestorerandreassemblethem.
2.Whilepressinglock(L2),pulloutconnector(1).
Handlingofconnectorsusedonengine
Slide,locktype (FRAMATOME-3,FRAMATOME-2)
Disconnection
1.Slidelock(L1)totheright.
2.Whilepressinglock(L2),pulloutconnector(1) towardyou.
a Inthecasethateveniflock(L2)ispressed, connector(1)cannotbepulledouttoward youunlesspartAfloats,floatpartAwitha smallflat-headscrewdriverwhilepressing lock(L2),andthenpulloutconnector(1) towardyou.
Connection
1.Inserttheconnectorsecurelyuntilaclickis heard.
(FRAMATOME-24)
Disconnection
1.Slidedownlock(red)(L1).
a Lock(L2)islocatedinthebackofconnector (1).
Connection
1.Inserttheconnectorsecurelyuntilaclickis heard.
Pulllocktype (PACKARD-2)
Disconnection
1.Disconnecttheconnector(2)bypullinglock(B) (onthewiringharnessside)ofconnector(2) outward.
00Indexandforeword
Foreword,safetyandgeneralinformation
Connection
1.Inserttheconnectorsecurelyuntilaclickis heard.
Pushlocktype (BOSCH-3)
Disconnection
1.Whilepressinglock(C),pulloutconnector(3)in thedirectionofthearrow.
• 114series
• 107series
a Ifthelockislocatedontheunderside,use flat-headscrewdriver[1]sinceyoucannot insertyourfingers.
Whilepushinguplock(C)oftheconnector withflat-headscrewdriver[1],pullout connector(3)inthedirectionofthearrow.
Connection
1.Inserttheconnectorsecurelyuntilaclickis heard.
(AMP-3)
Disconnection
1.Whilepressinglock(E),pulloutconnector(5)in thedirectionofthearrow.
Connection
1.Inserttheconnectorsecurelyuntilaclickis heard. (SUMITOMO-2)
Disconnection
1.Whilepressinglock(E),pulloutconnector(5)in thedirectionofthearrow.
Connection
1.Inserttheconnectorsecurelyuntilaclickis heard.
(SUMITOMO-3)
Disconnection
1.Whilepressinglock(E),pulloutconnector(5)in thedirectionofthearrow. a Pulltheconnectorstraightup.
Connection
1.Inserttheconnectorsecurelyuntilaclickis heard. (SUMITOMO-4)
Disconnection
1.Whilepressinglock(D),pulloutconnector(4)in thedirectionofthearrow.
Connection
1.Inserttheconnectortotheendwhilealigningits grovetotheother.
2.Turnhousing(H1)inthedirectionofthearrow untilit"clicks".
Connection
1.Inserttheconnectorsecurelyuntilaclickis heard.
Turn-housingtype(Roundgreenconnector) (CANNON-4)
Disconnection
1.Turnhousing(H1)inthedirectionofthearrow. a Unlocktheconnectorbyturninghousing(H1). Whenthelockisreleasethehousingisfelt tighttoturn.
2.Pullouthousing(H1)inthedirectionofthe arrow.
a Housing(H1)isleftonthewiringharness side.
• Theelectroniccircuitsforcontrolincludingthe microcomputersareassembledinthecontroller. Theseelectroniccircuitsinthecontrollermust behandledwithcareastheycontrolthe machine.
• Donotplaceobjectsontopofthecontroller.
• Coverthecontrolconnectorswithtapeoravinyl bag.Nevertouchtheconnectorcontacts.
• Duringrainyweather,donotleavethecontroller inaplacewhereitisexposedtorain.
• Donotplacethecontrolleronoil,water,orsoil, orinaplacethatcanbeheatedtoahigh
temperatureevenforashortperiodoftime. (Placeitonasuitabledrystand.)
• Precautionswhenperformingarcwelding Whenperformingarcweldingonthemachine body,disconnectallthewiringharness connectorsconnectedtothecontroller.Putthe arcweldinggroundtotheplaceclosetothe weldingpoint.
Precautionsfortroubleshootingelectrical circuits
• Besuretoturnthestartingswitchto"OFF" positionbeforedisconnectingorconnectingthe connectors.
• Beforeperformingtroubleshooting,checkallthe relatedconnectorsforlooseconnection.
a Checktherelatedconnectorsfortheir performancebydisconnectingand connectingthemseveraltimes.
• Besuretoconnectallthedisconnected connectorsbeforeproceedingtothenextstep.
a Ifthestartingswitchisturnedto"ON" positionwiththeconnectorsdisconnected, thefailurewhichisnotrelatedtothepart whichisactuallyfailed.
• Whenperformingthetroubleshootingforthe circuit(measurementofvoltage,resistance, continuity,current,etc.),shaketherelatedwiring harnessesandconnectorsseveraltimesand checkthatthemultimeterreadingdoesnot change.
a Ifthereisanyvaluechangeonthe multimeter,theremaybeadefectivecontact inthecircuit.
Howtoreadelectricwirecode (ALL-E500-030-P-00-A)
(Rev.2012/10)
• Intheelectricalcircuitdiagram,material,thicknessandcolorofeachelectricwireareindicatedby symbols.Thewirecodeishelpfulinunderstandingtheelectricalcircuitdiagram.
Example)AEX0.85L:Indicatesblue,heat-resistant,low-voltagewireforautomobile,havingnominalNo.of 0.85
AEX
0.85
Indicatestypeofwirebysymbol. Type,symbol,andmaterialofwireareshowninTable1. (SincetheuseofAVandAVSwiresdependsonsize(nominalNo.),theirsymbolsarenot indicatedonthediagram.)
IndicatessizeofwirebynominalNo. Size(NominalNo.)isshowninTable2.
L Indicatescolorofwirebycolorcode. ColorcodesareshowninTable3.
Type,symbol,andmaterial
• AVandAVSaredifferentinthicknessandoutsidediameterofthecoating.CAVChasacircular compressedconductor.ItdiffersfromAVandAVSintheoutsidediameterofconductorandthicknessof thecoating.AndAEXissimilartoAVinthicknessandoutsidediameterofthecoatingbutdifferentfromAV andAVSinmaterialofthecoating.
(Table1)
Type Symbol Conductor material Insulatormaterial
Low-voltage wirefor automobile AV
Thin-cover low-voltage wirefor automobile (Type1) AVS
Thin-cover low-voltage wirefor automobile (Type2) CAVS
Heatresistantlowvoltagewire for automobile AEX
Annealed copperfor electric appliance
Temperature range(°C)in use Exampleofuse
Forlargecurrentwiring (nominalNo.5andabove)
Generalwiring (nominalNo.3andlower)
Softpolyvinylchloride -30to+60
Heat-resistantcross linkedpolyethylene -50to+110
Formid-tosmall-size excavators (nominalNo.1.25andlower)
Generalwiringforextremely coldweatherspecification
Wiringathighambient temperatureplace
Dimensions (Table2)
NominalNo.815203040506085100 Conductor
NominalNo.0.5f0.50.75f0.851.25f1.25
a "f"ofnominalNo.denotes"flexible".
Colorcodestable (Table3)
ColorCodeColorofwireColorCodeColorofwire
BBlack LgWLightgreen&White
BrBrown LgYLightgreen&Yellow
BrBBrown&BlackLRBlue&Red
BrRBrown&RedLWBlue&White
BrWBrown&WhiteLYBlue&Yellow
BrYBrown&YellowO Orange
ChCharcoalPPink
DgDarkgreen RRed
GGreenRBRed&Black
GBGreen&BlackRGRed&Green
GLGreen&BlueRLRed&Blue
Gr Gray RWRed&White
GRGreen&RedRYRed&Yellow
GWGreen&WhiteSb SkyBlue
GYGreen&YellowYYellow
LBlueYBYellow&Black
LBBlue&BlackYGYellow&Green
LgLightgreen YLYellow&Blue
LgBLightgreen&Black YRYellow&Red
LgRLightgreen&Red YWYellow&White
a Remarks:Inacolorcodeconsistingof2colors,thefirstcoloristhecolorofthebackgroundandthe secondcoloristhecolorofthemarking. Examples)
GWmeansthatthebackgroundis"Green"andmarkingis"White".
Typesofcircuitsandcolorcodes
(Rev.2012/11)
• Whenperforming"testingandadjusting"ofthemachine,"removalandinstallation"and"disassemblyand assembly"ofthecomponents,observethefollowinggeneralcautions.
• Ifthecoolingwatercontainscoolant,disposeofitcorrectlyaschemicals.Donotdrainittothesewage rashly.
• Afterdisconnectingthehosesortubes,plugthemtopreventdirtordustfromentering.
• Whendrainingoil,prepareacontainerwithsufficientcapacity.
• Checkthematchmarkswhichindicatetheinstallingposition,andputmatchmarksontheplaceswhere theyseemnecessarybeforeremovalofthecomponentstopreventanymistakewhenassembling.
• Topreventanyexcessiveforcefrombeingappliedtothewiring,alwaysholdtheconnectorswhen disconnectingtheconnectors.Donotpullthewires.
• Attachthetagstowiresandhosestoshowtheirinstallingpositionstopreventanymistakewhen installing.
• Checkthenumberandthicknessoftheshims,andkeeptheminasafeplace.
• Whenhoistingthecomponents,preparetheslingswithsufficientstrength.
• Whenusingforcingscrewstoremoveanycomponent,tightentheforcingscrewsuniformlyand alternately.
• Beforeremovinganycomponent,cleanthesurroundingareaandcoverthecomponenttopreventany foreignmaterialfromenteringafterremoval.
• Afterdisconnectingthepipingorremovingapipejoint,installthefollowingplugs.
a TheO-ringsinthetableareemergencypartsusedfordisassemblyortransportationofthemachine. Whenassembling,confirmthepartnumbersinthepartsbookandusethepartsconformingtothe usingcondition.
Disconnectionoffacesealtypehosesandtubes
0207376-7021002789-0021002896-11008 0307376-7031502789-0031502896-11009 0407376-7042202789-0042202896-11012 0507376-7052202789-0052202896-11015 0607376-7062802789-0062802896-11018
Disconnectionoftapersealtypehosesandtubes
00Indexandforeword
Foreword,safetyandgeneralinformation
Nominal No.
Boltpitch(mm) HosesideTubeside O-ring(4)Bolt(5)Washer(6) a b Flange(1) Splitflange (2) Sleevehead (3)
79.436.5 0737901470 07371-5147007378-1141007000-13048 0101081455 01643-31445
77.842.8 0737902071 07371-3207607378-1200007000-12060 0737251240 01643-51232
20
96.844.5 0737902080 07371-5208007378-1201007000-12060 0101081865 01643-31845
2488.950.8 0737902484 07371-1248407378-1240007000-12070 0737251240 01643-51232
30106.462 0737903010 07371-1301007378-1300007000-12085 0737251650 01643-51645
34120.669.807379-0341107371-1341107378-1340007000-12100 0737251650 01643-51645
40130.277.8 0737904012 07371-1401207378-1400007000-12110 0737251650 01643-51645
50152.49207379-0501107371-1501107378-1500007000-12135 0737251655 01643-51645
RemovalofpipejointsofO-ringbosstype
NominalNo. Plug(1)O-ring(2) 0807040-1080707002-10823 1007040-1100707002-11023 1207040-1120907002-11223 1407040-1140907002-11423 1607040-1161207002-11623 1807040-1181207002-11823 2007040-1201207002-12034
2407040-1241207002-12434
3007041-1301207002-13034 3307040-1331607002-13334 3607041-1361207002-13634 4207040-1422007002-14234 5207040-1522307002-15234
Removalofpipejointsoftaperpipethreadtype
NominalNo.
01R1/8 07042-00108 07043-00108
02R1/4 07042-00211 07043-00211
03R3/8 07042-00312 07043-00312
04R1/2 07042-00415 07043-00415
06R3/4 07042-00617 07043-00617
10R107042-0101907043-01019
12R1 1/4 07042-01222 07043-01222
14R1 1/2 07042-01422 07043-01422 20R207042-0202607043-02026
• Tightentheboltsandnuts(sleevenuts)tothespecifiedtorque(KES),unlessotherwisespecified.
• Installthehoseswithouttwistandinterference,andsecurelyfastentheclampslocatedin-betweenifthey are.
• Replaceallofthegaskets,O-rings,cotterpins,andlockplateswithnewparts.
• Bendthecotterpinsandlockplatessecurely.
• Whenapplyingadhesive,cleananddegreasethepart,andapply2to3dropsofadhesivetothethreaded part.
• Whenapplyingliquidgasket,cleananddegreasethesurface,andapplyituniformlyaftermakingsurethat thesurfaceisfreefromdirtordamage.
• Cleanalloftheparts,andrepairanydamage,dents,burrs,orrustfoundonthem.
• Coattherotatingpartsandslidingpartswithengineoil.
• Coatthesurfacesofthepress-fittingpartswithmolybdenumdisulfidelubricant(LM-P).
• Afterinstallingthesnapring,checkthatthesnapringissettledintheringgroovecompletely.
• Whenconnectingwiringharnessconnectors,cleantheconnectorstoremoveoil,dirt,orwater,then connectthemsecurely.
• Usetheeyeboltswithnofatigueanddeformationandscrewtheminsecurely.Matchthedirectionsofthe eyesandthehook.
• Wheninstallingsplitflanges,tightentheboltsuniformlyandalternatelytopreventexcessivetighteningon oneside.
• Asarule,applyliquidgasket(LG-5)orliquidsealant(LS-2)tothethreadedpartofeachtapermale screwswhichreceivespressure.
However,ifthethreadedpartisdifficulttodegrease,youmayuseasealtape.
• Whenwindingasealtapeontoaright-handedtapermalescrew,winditclockwiseintheadvancing directionofthethreads,seeingfromthescrewendandstartingatthethirdthread.
a Ifyouwindthesealtapeintheoppositedirection,itbecomeslooseandcomesofforitsendpartis pushedout,andthatcancauseoilleakage.
a Whenthehydrauliccylinderisusedforthefirsttimeafterreassemblyofthehydraulicequipmentsuchas thehydrauliccylinder,pump,etc.andpipingafterremovingthemforrepair,besuretoperformairbleeding ofthehydrauliccircuitaccordingtothefollowingprocedure.
1.Starttheengine,andrunitatlowidle.
2.Repeattheoperationtoextendandretracteachcylinderoftheworkequipmenttoapproximately100 mmbeforethestrokeend4to5times.
3.Operatethehydrauliccylinder3to4timestotheendofitsstroke.
a Afterthecompletionofrepairandwhenoperatingthemachinewhichisstoredlongterm,performtheair bleedingwiththesameprocedureastheonedescribedabove.
Precautionsatthetimeofcompletingwork
Refillingofcoolant,oilandgrease
• Whenthecoolantisdrained,tightenthedrainvalvesecurely,thenrefillthecoolantreservoirwiththe coolantKomatsurecommendstothespecifiedlevel.Starttheenginetocirculatethecoolantinthepiping, andaddthecoolanttothespecifiedlevelagain.
• Whenthehydrauliccomponentsareremovedandinstalled,refilltheoilreservoirwiththeoilKomatsu recommendstothespecifiedlevel.Starttheenginetocirculatetheoilinthepiping,andaddtheoiltothe specifiedlevelagain.
• Ifthehydraulicpipingorhydraulicequipmentisremoved,besuretobleedairfromthesystemafter rebuildingtheparts,byreferringto"Testingandadjusting".
• Supplythespecifiedamountofgreasetotheworkequipmentparts.
Testinginstalledconditionofcylinderheadsandmanifolds
• Checkthecylinderheadandintakeandexhaustmanifoldmountingsforlooseness.
• Ifanyboltisloose,retightenit.
a Forthetighteningtorques,seethe"Disassemblyandassembly".
Testingofenginepipingfordamageandlooseness
Intakeandexhaust system
Checkthepipingfordamage,themountingboltsandnutsforlooseness,andthejoints forairsuctionandexhaustgasleakage.
Ifanypartislooselyinstalledordamaged,retightentheboltsorrepairtheparts.
Coolingsystem
Fuelsystem
Checkthepipingfordamage,themountingboltsandnutsforlooseness,andthejoints forwaterleakage.
Ifanypartislooselyinstalledordamaged,retightentheboltsorrepairtheparts.
Checkthepipingfordamage,themountingboltsandnutsforlooseness,andthejoints forfuelleakage.
Ifanypartislooselyinstalledordamaged,retightentheboltsorrepairtheparts.
CheckofKDPFormufflerandexhaustpipefordamageandlooseness
• VisuallychecktheKDPFormuffler,exhaustpipeandtheirmountingpartsforacrackanddamage.Ifany partisdamaged,replaceit.
• Checkthemountingbolts,nuts,andclampsoftheKDPFormuffler,exhaustpipeandtheirmountingparts forlooseness.
Ifanypartislooselyinstalled,retightenthebolts.
CheckofKDPFormufflerfunction
• ChecktheKDPForthemufflerforunusualnoisecomparingtothenoisewhentheyarenew. Ifanyunusualnoiseisheard,repairKDPFormuffler,referringto"Troubleshooting"and"Disassemblyand assembly".
(Rev.2012/10)
KOMTRAXsystemtransmitsvariousmachineinformationbyuseoftheradiocommunicationandKOMTRAX operatorcanreferthisinformationintheofficeandprovidevariousservicestothecustomers.
WhenKOMTRAXisinstalledonthemachine,themachineinformationcanbecheckedthroughthe KOMTRAXsystemandthetestingandtroubleshootingcanbeperformedefficiently.
(KOMTRAXmaynotbeinstalledonthemachineinsomecountriesorareas.)
MeritofusingKOMTRAX
• TheworkingplaceofthemachinecanbecheckedinthemaponPC.
• Operationinformationsuchasservicemeterreading,operatinghours,fuelconsumption,occurredcaution andfailurecodecanbechecked.
• Thehoursusedandreplacementtimeofconsumablepartsofthemachinesuchasfuelfilter,hydraulicoil filter,hydraulicoilandengineoilcanbechecked.
• Theinformationofmachineworkingcondition(idlingtime,travelingtime,diggingtime,relievingtime,etc.) canbecheckedandthemachineoperatingconditioncanbepresumedwiththeseinformation.
• Variousreportssuchas"Fuelsavingoperationsupport","Summaryofoperation",etc.canbegenerated andutilizedasanadviceaswellfortheuserandoperator.
HowtouseKOMTRAXpractically
WithKOMTRAX,followingsupportactivitieswillbeavailable.
1.Quickresponsetosuddenrequestofrepair
1)Whenreceivingarepairrequestfromauser,checkthedisplayedcautionandfailurecode,etc.through KOMTRAX.
2)Arrangethenecessarytools,replacementparts,etc,immediatelyinaccordancewiththedisplayed failurecode.
3)ByusingthemapofKOMTRAX,findthelocationofthefailedmachineandvisitthecustomerthere.
2.Proactivemaintenance
1)ChecktheservicesummaryscreenofKOMTRAX,andfindthemachinewhichhashighpriorityfailure codeindicatedbyaredoryellowflag.
2)Checktheconditionofthemachinewiththecustomerandmakeaplantovisit.
3)Arrangenecessarytools,replacementparts,etc,immediatelyinaccordancewiththedisplayedfailure code.
3.Practiceofperiodicmaintenanceandperiodicinspectionservice
1)ChecktheservicesummaryscreenofKOMTRAX,andfindthemachineofwhichtheusagelimitsfor theconsumablepartsindicatedbyredflagsareover.
2)Submitanestimatesheetfortheconsumablepartstobereplacedandthelaborcostforthe replacementworktothecustomer.
3)Proposetheperiodicinspection(PMclinic,etc.)accordingtotheservicemeterreading.
HowtooperateKOMTRAX
FortheoperatingmethodofeachscreenofKOMTRAX,see"GlobalKOMTRAXWebReferenceManual(For KeyPerson)".
00Indexandforeword Foreword,safetyandgeneralinformation
Standardtighteningtorquetable (ALL-M140-03B-P-01-A)
Tableoftighteningtorqueforboltsandnuts
(Rev.2012/10)
Unlessotherwisespecified,tightenthemetricboltsandnutstothetorqueshowninthetablebelow.
Threaddiameter (mm)
6 10 (*2)10 11.8to14.7{1.2to1.5}
8 13 (*2)12 27to34{2.8to3.5} 10 17 (*1,*2)14 59to74{6.0to7.5} 12 19 (*1,*2)17 98to123{10.0to12.5} 14 22 157to196{16to20}
16 24 (*1)22 245to309{25to31.5} 18
343to427{35to43.5}
490to608{50to62}
662to829{67.5to84.5}
824to1,030{84to105}
2,450to3,040{250to310} 39 60 2,890to3,630{295to370}
*1:Splitflangebolt.
*2:Flangedbolt.
a Tightenthefollowingflangedboltonwhich"7"isstampedonitstoptothetighteningtorqueshowninthe followingtable.
Threaddiameter
Unlessotherwisespecified,tightentheunifiedcoarsethreadedboltsandnutstothetorqueshowninthetable below.
Typeofbolt A B
NominalNo.threadsperinch, typeofthread Tighteningtorque(Nm{kgm})Tighteningtorque(Nm{kgm})
1/4-20UNC 9.8to14.7{1to1.5}12.7{1.3}2.9to3.9{0.3to0.4}3.43{0.35}
5/16-18UNC 24.5to34.3{2.5to3.5}29.4{3}6.9to8.8{0.7to0.9}7.8{0.8}
3/8-16UNC 44.1to58.8{4.5to6}52.0{5.3}9.8to14.7{1to1.5}11.8{1.2}
7/16-14UNC 73.5to98.1{7.5to10}86.3{8.8}19.6to24.5{2to2.5}21.6{2.2}
1/2-13UNC 108to147{11to15}127{13}29.4to39.2{3to4}34.3{3.5}
9/16-12UNC 157to216{16to22}186{19}44.1to58.8{4.5to6}51.0{5.2}
5/8-11UNC 226to294{23to30}265{27}63.7to83.4{6.5to8.5}68.6{7} 3/4-10UNC 392to530{40to54}461{47}108to147{11to15}127{13} 7/8-9UNC 637to853{65to87}745{76}177to235{18to24}206{21} 1-8UNC 883to1,196{90to122}1,040{106}245to333{25to34}284{29}
1 1/8-7UNC 1,187to1,608{121to164}1,393{142}333to451{34to46}392{40} 1 1/4-7UNC 1,598to2,157{163to220}1,873{191}451to608{46to62}530{54} 1 1/2-6UNC 2,354to3,177{240to324}2,765{282}657to892{67to91}775{79}
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Unlessotherwisespecified,tightentheunifiedfinethreadedboltsandnutstothetorqueshowninthetable below.
Typeofbolt
NominalNo.threadsperinch, typeofthread
1/4-28UNF 14.7to19.6{1.5to2}17.7{1.8}3.9to4.9{0.4to0.5}4.41{0.45} 5/16-24UNF 34.3to39.2{3.5to4}37.3{3.8}7.8to9.8{0.8to1}8.8{0.9}
3/8-24UNF 53.9to68.6{5.5to7}61.8{6.3}14.7to19.6{1.5to2}16.7{1.7}
7/16-20UNF 83.4to108{8.5to11}96.1{9.8}24.5to29.4{2.5to3}26.5{2.7}
1/2-20UNF 127to167{13to17}147{15}34.3to49.0{3.5to5}41.2{4.2} 9/16-18UNF 186to245{19to25}216{22}49.0to68.6{5to7}58.6{6}
5/8-18UNF 255to343{26to35}294{30}73.5to98.1{7.5to10}83.4{8.5}
3/4-16UNF 441to598{45to61}520{53}127to167{13to17}147{15}
7/8-14UNF 716to961{73to98}843{86}196to265{20to27}226{23} 1-14UNF 1,020to1,373{104to140}1,196{122}284to382{29to39}333{34}
1 1/8-12UNF 1,353to1,844{138to188}1,598{163}382to520{39to53}451{46}
1 1/4-12UNF 1,804to2,432{184to248}2,118{216}510to686{52to70}598{61}
1 1/2-12UNF 2,707to3,658{276to373}3,177{324}765to1,030{78to105}892{91}
TableoftighteningtorqueforO-ringbosspipingjoints
a Unlessotherwisespecified,tightenthepipejointforO-ringbosstothetorqueshowninthetablebelow.
NominalNo.
diameter (mm)
acrossflats (mm)
10,12 33 363to480{37.0to49.0}
1442 746to1,010{76.0to103}
TableoftighteningtorqueforO-ringbossplugs
a Unlessotherwisespecified,tightentheplugforO-ringbosstothetorqueshowninthetablebelow.
NominalNo.
(mm)
(mm)
08814 5.88to8.82{0.6to0.9}7.35{0.75} 101017 9.8to12.74{1.0to1.3}11.27{1.15} 121219 14.7to19.6{1.5to2.0}17.64{1.8} 141422 19.6to24.5{2.0to2.5}22.54{2.3} 161624 24.5to34.3{2.5to3.5}29.4{3.0} 181827 34.3to44.1{3.5to4.5}39.2{4.0} 202030 44.1to53.9{4.5to5.5}49.0{5.0} 242432 58.8to78.4{6.0to8.0}68.6{7.0} 303032 93.1to122.5{9.5to12.5}107.8{11.0} 3333 107.8to147.0{11.0to15.0}127.4{13.0} 363636 127.4to176.4{13.0to18.0}151.9{15.5} 4242 181.3to240.1{18.5to24.5}210.7{21.5} 5252 274.4to367.5{28.0to37.5}323.4{33.0}
Tableoftighteningtorqueforhose(tapersealtypeandfacesealtype)
a Unlessotherwisespecified,tightenthehosefittings(tapersealtypeandfacesealtype)tothetorque showninthetablebelow.
a Thetableisappliedtothethreadscoatedwithengineoil(wetthreads)
00Indexandforeword
Foreword,safetyandgeneralinformation
Nominal No.of hose Width across flats (mm)
Tighteningtorque(Nm{kgm})Taperseal Faceseal
RangeTarget
Threadsize (mm)
NominalNo.threadsper inch,typeof thread Threadroot diameter (mm) (reference)
0219 34to54{3.5to5.5}44{4.5} 9/16-18UN14.3 34to63{3.5to6.5}44{4.5} 14 03 22 54to93{5.5to9.5}74{7.5} 11/16-16UN17.5 24 59to98{6.0to10.0}78{8.0} 18 0427 84to132{8.5to13.5}103{10.5} 22 13/16-16UN20.6 0532 128to186{13.0to19.0}157{16.0} 241-14UNS25.4 0636 177to245{18.0to25.0}216{22.0} 301 3/16-12UN30.2 (10) 41 177to245{18.0to25.0}216{22.0} 33 (12) 46 197to294{20.0to30.0}245{25.0} 36 (14) 55 246to343{25.0to35.0}294{30.0} 42
Tableoftighteningtorqueforfacesealjoints a Thetighteningtorquetablebelowappliestothesealjoint(sleevenuttype) a Thetableisappliedtothethreadscoatedwithengineoil(wetthreads).
Outside diameterof pipe(mm) Width acrossflats (mm)
Tighteningtorque(Nm{kgm})
RangeTarget
Faceseal
NominalNo.threadsperinch, typeofthread Threadroot diameter(mm) (reference) 819 14to16{1.4to1.6}15{1.5} 9/16-18UN14.3 1022 24to27{2.4to2.7}25.5{2.6} 11/16-16UN17.5 12 24{27}43to47{4.4to4.8}45{4.6} 13/16-16UN20.6 15{16}30{32}60to68{6.1to6.8}64{6.5} 1-14UNS25.4 22{20} 36 90to95{9.2to9.7}92.5{9.4} 1 3/16-12UN30.2
Reference:Thefacesealjointofthedimensionin()isalsoused,dependingonthespecification.
Tighteningtorquetableforboltsandnutson102,107and114seriesengines
a Unlessotherwisespecified,tightenthemetricthreadsboltsandnutsusedonthe102,107and114series enginestothetorquesshowninthetablebelow.
Threaddiameter(mm)
Tighteningtorque(Nm{kgm})
Tighteningtorquetablefor102,107,and114seriesengines(jointbolts)
a Unlessotherwisespecified,tightenthemetricjointboltsusedonthe102,107,and114seriesenginesto thetorqueshowninthetablebelow.
Threaddiameter(mm)
Tighteningtorque(Nm{kgm})
Tighteningtorquetablefortaperedscrewson102,107,and114seriesengines(Nationaltaperpipe thread(NPT))
a Unlessotherwisespecified,tightentheNationaltaperpipethreaded(NPT)screwsusedonthe102,107, and114seriesenginestothetorquesshowninthetablebelow.
Materialoffemalescrew Incastironorsteel Inaluminum Nominalthreadsize Tighteningtorque(Nm{kgm})Tighteningtorque(Nm{kgm})
00Indexandforeword
Foreword,safetyandgeneralinformation
Listofabbreviation (ALL-0360-005-A-00-A) (Rev.2015/01)
• Thislistofabbreviationsincludestheabbreviationsusedinthetextoftheshopmanualforparts, components,andfunctionswhosemeaningisnotimmediatelyclear.Thespellingisgiveninfullwithan outlineofthemeaning.
• Abbreviationsthatareusedingeneralsocietymaynotbeincluded.
• Specialabbreviationswhichappearinfrequentlyarenotedinthetext(markedwith a).
• Thislistofabbreviationsconsistsof2parts.Thefirstpartisalistoftheabbreviationsusedinthetextof themanual,andthesecondpartisalistoftheabbreviationsusedinthecircuitdiagrams.
Listofabbreviationsusedintheshopmanual
Abbreviation Actualwordspelled out Purposeofuse(major applicablemachine(*),or equipment/device)
ABS Anti-skidBrake System
Travelandbrake (HD,HM)
AISS AutomaticIdling SettingSystem Engine
AJSS AdvancedJoystick SteeringSystem Steering (WA)
ARAC AutomaticRetarder AcceleratorControl
ARSC AutomaticRetarder SpeedControl
ASR AutomaticSpin Regulator
Travelandbrake (HD,HM)
Travelandbrake (HD,HM)
Travelandbrake (HD,HM)
ATTAttachment Workequipment
BCV Brakecoolingoil controlvalve
Brake (HD)
CAN ControllerArea Network Communicationand electroniccontrol
CDR CrankcaseDepression Regulator Engine
CLSS Closed-centerLoad SensingSystem Hydraulicsystem
CRI CommonRailInjectionEngine
ECM ElectronicControl Module Electroniccontrolsystem
Explanation
Withthisfunction,whenthetiresskid(wheels stoprotating),thebrakesarereleased,and whenthewheelsstarttorotate,thebrakesare appliedagain.
Thisfunctionautomaticallysetstheidle speed.
Aleverisusedtoperformthesteering operationsinsteadofasteeringwheel. Moreover,itshiftsgearandchangesdirection (FORWARDorREVERSE).
Whentheacceleratorpedalisreleasedwhile themachineistravelingdownhill,thisfunction automaticallyappliestheretarderwitha constantbrakingforce.
Whentheacceleratorpedalisreleasedwhile themachineistravelingdownhill,thisfunction automaticallyappliestheretardertoensure thatthemachinespeeddoesnotaccelerate abovethespeedsetbytheoperator.
Whenthetiresspinonsoftgroundsurfaces, thisfunctionautomaticallyusestheoptimum brakingforcetodrivebothwheels.
Adevicethatcanbefixedontoamachinein ordertoenableittododifferentjobs.
Whentheretarderisnotbeingused,this valvebypassespartofthebrakecoolingoilto reducetheloadonthehydraulicpump.
Oneofcommunicationstandardsthatisused inthenetworkonthemachine.
AregulatorvalvewhichisinstalledtoKCCV ventilator.ItiswrittenasCDRvalveanditis notusedindependently.
Thissystemcansimultaneouslyactuate multipleactuatorsregardlessoftheload (providesbettercombinedoperationthanO.L. S.S.).
Enginecontrollerelectronicallycontrols supplypump,commonrail,andinjector.This functionmaintainsoptimumfuelinjection amountandfuelinjectiontiming.
Electroniccontroldeviceusesthesignals fromthesensorsonthemachine.Thissignal indicatestheoptimumactuationtothe actuators.(SameasE.C.U.)
Abbreviation Actualwordspelled out
Purposeofuse(major applicablemachine(*),or equipment/device)
ECMV ElectronicControl ModulationValve Transmission (D,HD,WA,etc.)
ECSS Electronically ControlledSuspension System Travel (WA)
ECUElectronicControlUnit Electroniccontrolsystem
EGR ExhaustGas Recirculation Engine
EMMS Equipment Management MonitoringSystem Machinemonitor
EPC Electromagnetic ProportionalControl Hydraulicsystem
FOPS FallingObject ProtectiveStructure Cabandcanopy
Foreword,safetyandgeneralinformation
Explanation
Proportionalelectromagneticvalvethat graduallyincreasesoilpressuretoengage clutchandreducestransmissionshock.
Thissystemensuressmoothhigh-speed travelbyabsorbingvibrationofmachine duringtravelwithhydraulicspringeffectof accumulator.
Electroniccontroldeviceusesthesignals fromthesensorsonthemachine.Thissignal indicatestheoptimumactuationtothe actuators.(SameasE.C.M.)
Thisfunctionrecirculatespartofexhaustgas tocombustionchamberinordertoreduce combustiontemperature,controlsemissionof NOx.
Thissystemallowsdata(filter,oilreplacement interval,malfunctionsonmachine,failure code,andfailurehistory)fromeachsensoron themachinetobecheckedonthemonitor.
Thismechanismallowsactuatorstobe operatedinproportiontothecurrentsupplied.
Thisstructureprotectstheoperator'shead fromfallingobjects.(FallingObjectProtective Structure)
ThisperformanceisstandardizedasISO 3449.
F-N-R Forward-NeutralReverse Operation Forward-Neutral-Reverse
GNSS GlobalNavigation SatelliteSystem Communication
GPS GlobalPositioning System Communication (KOMTRAX,KOMTRAX Plus)
HSS HydrostaticSteering System Steering (D)
HST HydroStatic Transmission Transmission (D,WA)
ICT Informationand Communication Technology IntelligentMachine Control
IMA InletMeteringActuatorEngine
IMU InertialMeasurement Unit IntelligentMachine Control
IMV InletMeteringValveEngine
KCCV KomatsuClosed CrankcaseVentilation Engine
Ageneraltermforpositioningsystemusing satellitessuchasGPS,GALILEO,etc.
Thissystemusessatellitestodeterminethe currentlocationontheearth.
Thisfunctionusesacombinationofhydraulic motorandbevelshafttocontroldifferencein travelspeedofrightandlefttracks. Accordinglymachinecanturnwithoutusing steeringclutch.
Thisfunctionusesacombinationofhydraulic pumpandhydraulicmotortoshiftthespeed rangesteplesslywithoutusinggears.
Ageneraltermfortheengineeringandits sociallyappliedtechnologyofinformation processingandcommunication.
Thisvalveisinstalledatinletportofpump, anditadjustsfuelintakeamountinorderto controlfueldischargeofsupplypump.Same asI.M.V.
Thisisadevicetodetecttheangularvelocity andaccelerationofthe3axesthatcontrol motions.
Thisvalveisinstalledatinletportofpump, anditadjustsfuelintakeamountinorderto controlfueldischargeofsupplypump.Same asI.M.V.(I.M.A.)
Thismechanismseparatesoilinblowbygas andreturnsittotheintakesidetoafterburnit there.Itprimarilyconsistsoffilters.
00Indexandforeword
Foreword,safetyandgeneralinformation
Abbreviation
Actualwordspelled out
Purposeofuse(major applicablemachine(*),or equipment/device)
KCSF KomatsuCatalyzed SootFilter Engine
KDOC KomatsuDiesel OxidationCatalyst Engine
KDPF KomatsuDiesel ParticulateFilter Engine
KTCS KomatsuTraction ControlSystem Travelandbrake (HMsystem)
VGT KomatsuVariable Geometry Turbocharger Engine
LCD LiquidCrystalDisplay Machinemonitor
LED LightEmittingDiodeElectronicparts
LIN LocalInterconnect Network Communicationand electroniccontrol
LS LoadSensingHydraulicsystem
LVDS LowVoltage DifferentialSignaling Communicationand electroniccontrol
MAFMassAirFlow Engine
MMS MultimediaMessaging Service Communication
NC NormallyClosed
NO NormallyOpen
OLSS Open-centerLoad SensingSystem
PC Pressure Compensation
Electricandhydraulic systems
Electricandhydraulic systems
Hydraulicsystem
Explanation
Thisfiltercapturessootinexhaustgas. ItisbuiltintoKDPF.
Thecatalystusedforpurifyingexhaustgas. ThisisbuiltinKDPForassembledwiththe muffler.
Thiscomponentisusedtopurifytheexhaust gas.KDOC(catalyst)andKCSF(filterto capturesoot)arebuilt-init.
Itisinstalledinplaceoftheconventional muffler.
Thisfunctionrecoversthedriveforceofthe wheelsbybrakingautomaticallywiththe optimumforceandatthesametimeactivates theinter-axledifferentiallockwhenthewheels idlewhilethemachinetravelsonthesoft groundroad.
Theturbochargeronwhichthecross-section areaoftheexhaustpassageismadevariable.
Imagedisplayequipmentsuchasamonitor whichassemblesintheliquidcrystalelement.
Itreferstosemiconductorelementthatemits lightwhenthevoltageisappliedinforward direction.
Oneofcommunicationstandardsthatisused inthenetworkonthemachine
Functionthatdetectsdifferentialpressureof pumpandcontrolsdischargeamount correspondingtoload.
Oneofcommunicationstandardsthatisused inthenetworkonthemachine
Thisindicatesengineintakeairflow.Itisnot usedindependentlybutitisusedascombined withsensor.Massairflowsensorcanbecalled asMAFsensor.
Servicethatallowstransmissionand receptionofshortmessagesconsistingof charactersorvoiceorimagesbetweencell phones.
Deviceactuatedtoopenelectricorhydraulic circuitsthatarenormallyclosedifnot actuated.
Deviceactuatedtocloseelectricorhydraulic circuitsthatarenormallyopenifnotactuated.
Hydraulicsystemthatcanoperatemultiple actuatorsatthesametime,regardlessofthe load.
Hydraulicsystem Afunctionusedtocorrectoilpressure.
PCCS Palmcommandcontrol system Steering (D)
PCV Pre-strokeControl Valve Engine
Systeminwhichacontrollerinstantly analysesdatafromeachlever,pedal,and dial,andperformsoptimumelectroniccontrol oftheengineandtransmission.
Thisvalveisinstalledatinletportofpumpand itadjustsfuelintakeamountinordertocontrol fueldischargeamountofsupplypump.
Abbreviation
Actualwordspelled out
Purposeofuse(major applicablemachine(*),or equipment/device)
PPC ProportionalPressure Control Hydraulicsystem
00Indexandforeword
Foreword,safetyandgeneralinformation
Explanation
Usedforcontrollingproportionalpressure. Thissystemmovesactuatorsinproportionto theoilpressure.
PPM PistonPumpand Motor Hydraulicsystem (D,PC,etc.) Pistonpumpandmotor.
PTOPowerTakeOffPowertransmissionPowertake-offmechanism
PTP PowerTiltandpower Pitchdozer Workequipment (D)
ROPS Roll-OverProtective Structure Cabandcanopy
SI LeSysteme Internationald’ Unites (Internationalunit system) Unit
SOLSolenoid Electricsystem
Thisfunctionperformshydrauliccontrolofthe tiltandpitchofthebulldozerblade.
Ifamachinetipsover,thisstructureprotects theoperatorwiththeseatbeltfastenedfrom beingcrushed.(OperatorProtectiveStructure WhenTipping)
ThisperformanceisstandardizedasISO 3471.
Abbreviationforthe"InternationalSystemof Units".Itistheuniversalunitsystemand"a singleunitforasinglequantity"isthebasic principleapplied.
Itreferstoanactuatorconsistingofasolenoid andanironcorethatismovedbythe magneticforcewhenthesolenoidis energized.
TWV 2-WayValve Hydraulicandelectric systems Solenoidvalvethatswitchesoverdirectionof flow.
*1:Codeforapplicablemachinefamily
D:Bulldozer
HD:Dumptruck
HM:Articulateddumptruck
PC:Hydraulicexcavator
WA:Wheelloader
Listofabbreviationsusedinthecircuitdiagrams
Abbreviation Actualwordspelledout
A/CAirConditioner
A/D Analogue-to-Digital
A/M AirMixDamper
ACC Accessory
ADDAdditional
AUX Auxiliary
BR BatteryRelay
CWClockwise
CCWCounterClockwise
ECUElectronicControlUnit
ECMElectronicControlModule
ENG Engine
EXGNDExternalGround
F.G.FrameGround
GNDGround
IMA InletMeteringActuator
NCNoConnection
S/T Steering
STRG
00Indexandforeword
Foreword,safetyandgeneralinformation
Abbreviation
SIG Signal
SOLSolenoid
STDStandard
OPT Option
OP
PRESSPressure
SPEC Specification
SWSwitch
TEMP Temperature
T/C TorqueConverter
T/MTransmission
Actualwordspelledout
Conversiontable (ALL-2150-931-A-00-A)
Methodofusingtheconversiontable
(Rev.2012/10)
• Theunitconversiontableenablesthesimpleconversioninthefiguresbetweenthedifferentunits.For furtherdetailsofthemethodofuseoftheconversiontable,seetheexamplesgivenbelow.
Example:Methodofusingtheconversiontabletoconvertaunitfrommillimeterstoinches
Conversionof55mmintoinches
1.Locatethenumber50intheverticalcolumnattheleftside,takethisas(A),andthendrawahorizontal linefrom(A).
2.Locatethenumber5intherowacrossthetop,takethisas(B),thendrawaverticallinedownfrom(B).
3.Takethepointwherethe2linescrossas(C).Thispoint(C)givesthevaluewhenconvertingtheunitfrom millimeterstoinches.Therefore,55mm=2.165in.
Conversionof550mmintoinches
1.Thenumber550doesnotappearinthetable,sodivideitby10(movethedecimalpointoneplacetothe left)toget55mm.
2.Thenconvert55mmto2.165inbythesameprocedureasabove.
3.Theoriginalvalue(550mm)wasdividedby10,somultiply2.165inchesby10(movethedecimalpoint oneplacetotheright)togettheoriginalvalue.Thisgives550mm=21.65in.Therefore,550mm=21.65 in.
Millimeterstoinches
1mm=0.03937in 01234 5 6789 000.0390.0790.1180.1570.1970.2360.2760.3150.354
501.9692.0082.0172.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8472.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
Foreword,safetyandgeneralinformation
Millimeterstoinches
1mm=0.03937in 01234 5 6789
000.0390.0790.1180.1570.1970.2360.2760.3150.354 100.3940.4330.4720.5120.5510.5910.6300.6690.7090.748 200.7870.8270.8660.9060.9450.9841.0241.0631.1021.142 301.1811.2201.2601.2991.3391.3781.4171.4571.4961.536 401.5751.6141.6541.6931.7321.7721.8111.8501.8901.929 501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323 602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8472.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898
Kilogramstopounds
1kg=2.2046lb 01234 5 6789
002.204.416.618.8211.0213.2315.4317.6419.84 1022.0524.2526.4628.6630.8633.0735.2737.4839.6841.89 2044.0946.3048.5050.7151.9155.1257.3259.5361.7363.93 3066.1468.3470.5572.7574.9677.1679.3781.5783.7885.98 4088.1890.3992.5994.8097.0099.21101.41103.62105.82108.03 50110.23112.44114.64116.85119.05121.25123.46125.66127.87130.07 60132.28134.48136.69138.89141.10143.30145.51147.71149.91152.12 70154.32156.53158.73160.94163.14165.35167.55169.76171.96174.17 80176.37178.57180.78182.98185.19187.39189.60191.80194.01196.21 90198.42200.62202.83205.03207.24209.44211.64213.85216.05218.26
ll toU.S.Gallons
000.2640.5280.7931.0571.3211.5851.8492.1132.378 102.6422.9063.1703.4343.6983.9634.2274.4914.7555.019 205.2835.5485.8126.0766.3406.6046.8697.1337.3977.661 307.9258.1898.4548.7188.9829.2469.5109.77410.03910.303 4010.56710.83111.09511.35911.62411.88812.15212.41612.68012.944 5013.20913.47313.73714.00114.26514.52914.79515.05815.32215.586 6015.85016.11516.37916.64316.90717.17117.43517.70017.96418.228 7018.49218.75619.02019.28519.54919.81320.07720.34120.60520.870 8021.13421.39821.66221.92622.19022.45522.71922.98323.24723.511 9023.77524.04024.30424.56824.83225.09625.36125.62525.88926.153
ll toU.K.Gallons
1 l =0.21997U.K.Gal
000.2200.4400.6600.8801.1001.3201.5401.7601.980 102.2002.4202.6402.8603.0803.3003.5203.7403.9504.179 204.3994.6194.8395.0595.2795.4995.7195.9396.1596.379 306.5996.8197.0397.2597.4797.6997.9198.1398.3598.579 408.7999.0199.2399.4599.6799.89910.11910.33910.55910.778 5010.99811.28111.43811.65811.87812.09812.31812.52812.75812.978 6013.19813.41813.63813.85814.07814.29814.51814.73814.95815.178 7015.39815.61815.83816.05816.27816.49816.71816.93817.15817.378 8017.59817.81818.03718.25718.47718.69718.91719.13719.35719.577 9019.79720.01720.23720.45720.67720.89721.11721.33721.55721.777 kgmtoft.lb
1kgm=7.233ft.lb 01234 5 6789
007.214.521.728.936.243.450.657.965.1 1072.379.686.894.0101.3108.5115.7123.0130.2137.4 20144.7151.9159.1166.4173.6180.8188.1195.3202.5209.8 30217.0224.2231.5238.7245.9253.2260.4267.6274.9282.1 40289.3296.6303.8311.0318.3325.5332.7340.0347.2354.4 50361.7368.9376.1383.4390.6397.8405.1412.3419.5426.8 60434.0441.2448.5455.7462.9470.2477.4484.6491.8499.1 70506.3513.5520.8528.0535.2542.5549.7556.9564.2571.4 80578.6585.9593.1600.3607.6614.8622.0629.3636.5643.7 90651.0658.2665.4672.7679.9687.1694.4701.6708.8716.1 100723.3730.5737.8745.0752.2759.5766.7773.9781.2788.4 110795.6802.9810.1817.3824.6831.8839.0846.3853.5860.7 120868.0875.2882.4889.7896.9904.1911.4918.6925.8933.1 130940.3947.5954.8962.0969.2976.5983.7990.9998.2 1,005
140 1,0131,0201,0271,0341,0421,0491,0561,0631,0711,078
150 1,0851,0921,0991,1071,1141,1211,1281,1361,1431,150
160 1,1571,1651,1721,1791,1861,1931,2011,2081,2151,222
170 1,1301,2371,2441,2511,2591,2661,2731,2801,2881,295
180 1,3021,3091,3161,3241,3311,3381,3451,3531,3601,367
190 1,3741,3821,3891,3961,4031,4101,4181,4251,4321,439
Foreword,safetyandgeneralinformation
kg/cm2 tolb/in 22 1kg/cm2 =14.2233lb/in22 01234 5 6789
0014.228.442.756.971.185.399.6113.8128.0 10142.2156.5170.7184.9199.1213.4227.6241.8256.0270.2 20284.5298.7312.9327.1341.4355.6369.8384.0398.3412.5 30426.7440.9455.1469.4483.6497.8512.0526.3540.5554.7 40568.9583.2597.4611.6625.8640.1654.3668.5682.7696.9 50711.2725.4739.6753.8768.1782.3796.5810.7825.0839.2 60853.4867.6881.8896.1910.3924.5938.7953.0967.2981.4 70995.6 1,0101,0241,0381,0531,0671,0811,0951,1091,124 80 1,1381,1521,1661,1811,1951,2091,2231,2371,2521,266 90 1,2801,2941,3091,3231,3371,3511,3651,3801,3941,408 100 1,4221,4371,4511,4651,4791,4931,5081,5221,5361,550 110 1,5651,5791,5931,6071,6211,6361,6501,6641,6781,693 120 1,7071,7211,7351,7491,7641,7781,7921,8061,8211,835
130 1,8491,8631,8771,8921,9061,9201,9341,9491,9631,977 140 1,9912,0052,0202,0342,0482,0622,0772,0912,1052,119
150 2,1342,1482,1622,1762,1902,2052,2192,2332,2472,262
160 2,2762,2902,3042,3182,3332,3472,3612,3752,3892,404
170 2,4182,4322,4462,4602,4752,4892,5032,5182,5322,546
180 2,5602,5742,5892,6032,6172,6312,6462,6602,6742,688
190 2,7022,7172,7312,7452,7592,7732,7882,8022,8162,830
200 2,8452,8592,8732,8872,9012,9162,9302,9442,9582,973
210 2,9873,0013,0153,0303,0443,0583,0723,0863,1013,115
220 3,1293,1433,1583,1723,1863,2003,2143,2293,2433,257
230 3,2713,2863,3003,3143,3283,3433,3573,3713,3853,399
240 3,4143,4283,4423,4563,4703,4853,4993,5133,5273,542
Temperature ConversionofFahrenheittoCelsius
• AsimplewaytoconvertaFahrenheittemperaturereadingintoaCelsiustemperaturereadingorvice versaistoseethenumberinthecentercolumnofthefollowingtable.Thefiguresonthefollowingtable showthetemperaturesinbothFahrenheitandCelsius.
• WhenconvertingfromFahrenheittoCelsiusdegrees,considerthecentercolumntobeatableof FahrenheittemperaturesandreadthecorrespondingCelsiustemperatureinthecolumnattheleft.
• WhenconvertingfromCelsiustoFahrenheitdegrees,considerthecentercolumntobeatableofCelsius values,andreadthecorrespondingFahrenheittemperatureontheright.
1°C=33.8°F
-40.4-40-40.0-11.71151.87.846114.827.281177.8 -37.2-35-31.0-11.11253.68.347116.627.882179.6 -34.4-30-22.0-10.61355.48.948118.428.383181.4 -31.7-25-13.0-10.01457.29.449120.228.984183.2 -28.9-20-4.0-9.41559.010.050122.029.485185.0 -28.3-19-2.2-8.91660.810.651123.830.086186.8 -27.8-18-0.4-8.31762.611.152125.630.687188.6 -27.2-171.4-7.81864.411.753127.431.188190.4 -26.7-163.2-7.21966.212.2 54129.231.789192.2 -26.1-155.0-6.72068.012.8 55 131.032.290194.0 -25.6-146.8-6.12169.813.356132.832.891195.8 -25.0-138.6-5.62271.613.9
134.633.392197.6 -24.4-1210.4-5.02373.414.458136.433.993199.4 -23.9-1112.2-4.42475.215.059138.234.494201.2 -23.3-1014.0-3.92577.015.660140.035.095203.0 -22.8-915.8-3.32678.816.161141.835.696204.8 -22.2-817.6-2.82780.616.762143.636.197206.6 -21.7 -719.4-2.22882.417.263145.436.798208.4 -21.1-621.2-1.72984.217.864147.237.299210.2 -20.6 -5 23.0-1.13086.018.365149.037.8100212.0 -20.0-424.8-0.63187.818.966150.840.6105221.0 -19.4-326.603289.619.467152.643.3110230.0 -18.9-228.40.63391.420.068154.446.1115239.0 -18.3-130.21.13493.220.669156.248.9120248.0 -17.8032.01.73595.021.170158.051.7125257.0 -17.2133.82.23696.821.771159.854.4130266.0 -16.7235.62.83798.622.272161.657.2135275.0 -16.1337.43.338100.422.873163.460.0140284.0 -15.6439.23.939102.223.374165.262.7145293.0 -15.0 5 41.04.440104.023.9 75 167.065.6150302.0 -14.4642.85.041105.824.476168.868.3155311.0 -13.9744.65.642107.625.077170.671.1160320.0 -13.3846.46.143109.425.678172.473.9165329.0 -12.8948.26.744111.226.179174.276.7170338.0 -12.21050.07.245113.026.780176.079.4175347.0
00Indexandforeword Foreword,safetyandgeneralinformation
SerialNumber
3001andup
01Specification
201Specification
Tableofcontents (ALL-0310-002-A-00-A)
01Specification.................................................................................................................................01-1
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Specifications (ALL-2111-001-A-00-A)
Specificationdrawing (ALL-2110-001-A-00-A)
HM400-3 (HM400_3-2110-931-A-00-A) Item
Grossmachineweight(machine weight+max.payload+1operator (80kg)) kg
(atenginespeedof2,000min-1 {2,000rpm})
Enginemodel
Engineratedhorsepower
• SAEJ1995(gross)(*1)
• ISO14396
• ISO9249/SAEJ1349(net)(*2)
Enginemax.torque(*2)
kW{HP}/min -1 {rpm}
KomatsuSAA6D140E–6dieselengine
353{473}/2,000{2,000}
353{473}/2,000{2,000}
350{469}/2,000{2,000}
Nm{kgm}/min -1 {rpm} 2,263{231}/1,400{1,400}
A Overalllength mm 11,105
B Overallheightmm 3,735
C Overallheightwhendumpbodyis raised mm 7,171
DOverallwidth mm 3,450
E Min.groundclearance(bottomof rearaxle) mm 615
Min.turningradius(walltowall)mm 8,800
• Reverse
Operatingtemperaturerange °C
*1:Indicatesthevalueofthebasicengine(withoutcoolingfan).
*2:Indicatesthevalueatthelowestcoolingfanspeed.
a Theengineratedhorsepowerisindicatedinthenetvalueandgrossvalue.Thegrossdenotesthe flywheelhorsepowermeasuredonthebasicengineunit,whilethenetdenotesthevaluemeasuredofan engineundertheconditionessentiallythesameasthatwhenitisinstalledonamachine.
a Followingshowstheratedhorsepower(net)atthemaximumcoolingfanspeed.
322kW{432HP}/2,000min -1 {2,000rpm}
Specifications (ALL-2111-001-A-01-A)
HM400-3 (HM400_3-2111-931-A-00-A)
Machinemodel
Grossmachineweight(machineweight +max.payload+1operator(80kg))
Machineweight
Weightdistribution(withmax. payload)
Performance
Gradeability(sin θ) %45
Min.turningradius
Frontwheel(walltowall) mm
Dumpingangle(angletoground)deg. 70
Dimensions
Engine
Machinemodel Unit
HM400-3 SerialNo. 3001andup
Model SAA6D140E –6
Type 4-cycle,water-cooled,in-line,vertical,direct injection,withturbochargerandair-cooled aftercooler
No.ofcylinders-borexstrokemm 6-140x165
Totalpistondisplacement l {cc}15.24{15,240}
Performance
Ratedhorsepower
• SAEJ1995(gross)(*1)
• ISO14396
• ISO9249/SAEJ1349(net)(*2)
Max.torque(*2)
kW{HP}/min -1 {rpm}
Nm{kgm}/min -1 {rpm}
353{473}/2,000{2,000}
353{473}/2,000{2,000}
350{469}/2,000{2,000}
2,263{231}/1,400{1,400}
Fuelconsumptionratioatrated horsepower g/kWh{g/HPh}218{163}
Startingmotor 24V,11kW
Alternator 24V,60A
Battery(*3) 12V,136Ahx2pieces
Radiatormodel CF79-4
Typeofaftercoolercore
Corrugatedaluminum
*1:Indicatesthevalueofthebaseengine(withoutcoolingfan).
*2:Indicatesthevalueatthelowestcoolingfanspeed.
*3:Batterycapacity(Ah)isbasedonthe5-hourrate.
a Theengineratedhorsepowerisindicatedinthenetvalueandgrossvalue.Thegrossdenotesthe flywheelhorsepowermeasuredonthebasicengineunit,whilethenetdenotesthevaluemeasuredofan engineundertheconditionessentiallythesameasthatwhenitisinstalledonamachine.
a Followingshowstheratedhorsepower(net)atthemaximumcoolingfanspeed.
322kW{432HP}/2,000min -1 {2,000rpm}
Powertrain
Torqueconverter
Type
Lockupclutch
Transmission
Type
3-element,1-stage,2-phase
Hydraulicallyactuated,wet-type,singledisc clutch
TORQFLOW,counter-shafttype,fullautomatic, electrically/hydraulicallyactuated,pumpforce lubricationtype
No.ofspeedrangesForward6-speed,reverse2-speed
Reductiongearsystem
Type
Spiralbevelgear,splashlubricationtype
Reductionratio3.727
DifferentialtypeStraightbevelgear,splashlubricationtype
Finalreductiongear
Type
Planetarygear,splashlubricationtype
Reductionratio4.941
Machinemodel Unit
Steering
Steeringmethod
Actuatingmethod
Suspension
Axletype
Frontaxle
Centeraxle
Rearaxle
Suspensionmethod
Frontaxle
Articulationtype
Fullhydraulic
Fullfloatingtype
Fullfloatingtype
Fullfloatingtype
Axlesuspensiontype(DeDiontype)
RearaxleAxlesuspensiontype
Tire
Sizexnumber
Frontwheel
29.5R25x2
Centerwheel29.5R25x2
Rearwheel29.5R25x2
Inflationpressure
Frontwheel
Brake Mainbrake
Frontwheel
Centerwheel
Parkingbrake
Retarder
2}
Independentfrontandcenterwheelbrake, sealed,wet-type,multipledisc, hydraulicallyoperatedtype
Independentfrontandcenterwheelbrake, sealed,wet-type,multipledisc, hydraulicallyoperatedtype
Spring-boostedcaliperdisctype
Independentfrontandcenterwheelbrake, sealed,wet-type,multipledisc, hydraulicallyoperatedtype
Machinemodel Unit
Hydraulicsystem
Steeringandhoistpump
Type
Discharge
Whensteeringisinoperation
(atenginespeedof2,000min -1 {2,000rpm}) l/min
Whenhoistisinoperation
Variabledisplacementswashplatepistontype
(atenginespeedof1,800min -1 {1,800rpm}) 178x2
Radiatorfanpump
Type
Discharge
Variabledisplacementswashplatepistontype
(atenginespeedof2,000min -1{2,000 rpm}) l/min105
Aftercoolerfanpump
Type
Discharge
Gearpump
(atenginespeedof2,000min -1{2,000 rpm}) l/min26.4
Transmissionpump
Type
Discharge
Gearpump
(atenginespeedof2,000min -1{2,000 rpm}) l/min126
Torqueconverterandfrontbrake coolingpump
Type
Discharge
Gearpump
(atenginespeedof2,000min -1{2,000 rpm}) l/min65
Centerbrakecoolingpump
Type
Gearpump
Discharge (atenginespeedof2,000min -1{2,000 rpm}) l/min142.3
Centerbrakecoolingremotemotor drivepump
Type Gearpump
Discharge (atenginespeedof2,000min -1{2,000 rpm}) l/min27.3
Centerbrakecoolingremotepump
Type
Discharge (atenginespeedof2,000min -1{2,000 rpm})
Gearpump
Machinemodel Unit
SerialNo. 3001andup
Brakechargepump
Type
Gearpump
Discharge (atenginespeedof2,000min -1{2,000 rpm}) l/min40.6
Emergencysteeringpump
Type
Gearpump Discharge l/min
Radiatorfanmotor
Type
Fixeddisplacement,swashplate,pistontype
Motorcapacity cc/rev 55
Aftercoolerfanmotor
Type
Fixeddisplacement,swashplate,pistontype
Motorcapacity cc/rev 10
Centerbrakecoolingremotemotor
Type
Fixeddisplacement,swashplate,pistontype
Motorcapacity cc/rev 10
Emergencysteeringmotor Type DCmotor
Hoistcylinder
Steeringcylinder
Hydraulictank
Hydraulicoilfilter
Hydraulicoilcooler
Box-shapedsealedtype
Tankreturnside
Watercooled
Weighttable (ALL-2120-001-A-00-A)
HM400-3 (HM400_3-2120-931-A-00-A)
kk Thisweighttableisaguideforusewhenhandlingortransportingthecomponents.
etc.)
Differential382
• Finaldrive683
Tireandrimassembly(29.5R25AA E-2)(1piece)
• Tireandrimassembly(29.5R25AAE-2)(1piece)
• Rim(25.00-25WTB)(1piece)
Frontsuspensioncylinder(left)93
Frontsuspensioncylinder(right)94
Rearsuspensioncylinder62
Oscillationhitchassembly846 Frontframe2,086 Rearframe2,398
Operator'scab(includinginteriorparts)1,050
Operator'sseat48
Steeringcylinder(1piece)70
Hoistcylinder(1piece)300
Flowamplifiervalve29
Hoistvalve 34
Hydraulictank175
Steeringandhoistpump91
Pumpfordrivingtorqueconverter,transmission,aftercoolerfan, andcenterbrakecoolingmotors 29
Centerbrakecoolingpump,radiatorfanpumpandbrakecharge pump 117
Centerbrakecoolingremotepump
Tableoffuel,coolant,andlubricants
Tableoffuel,coolant,andlubricants (HM400-RA19-05A-K-00-A) a Fordetailsofnotes(Note1,Note2...)inthetable,seeOperationandMaintenanceManual.
Tableoffuel,coolant,andlubricants
HM400-3
SerialNumber
3001andup
10Structureandfunction
310Structureandfunction
10Structureandfunction...................................................................................................................10-1
Tableofcontents........................................................................................................................10-2
Engineandcoolingsystem..........................................................................................................10-4
Enginerelatedparts.............................................................................................................10-4
Outputshaft.........................................................................................................................10-6
VGT .........................10-7
EGRsystempipingdrawing................................................................................................10-13
EGRsystemcircuitdiagram................................................................................................10-15
EGRvalve.........................................................................................................................10-16
EGRcooler........................................................................................................................10-18
KCCVlayoutdrawing.........................................................................................................10-20
KCCVventilator.................................................................................................................10-22
KDPF................................................................................................................................10-24
Coolingsystem..................................................................................................................10-30
Radiatorfanpump..............................................................................................................10-32
Aftercoolerfanmotor..........................................................................................................10-41
Radiatorfanmotor.............................................................................................................10-52
Centerbrakecoolingremotemotor......................................................................................10-61
Centerbrakecoolingremotepump......................................................................................10-65
Oilcoolerbypassvalve.......................................................................................................10-66
Powertrain...............................................................................................................................10-67
Powertrainsystem.............................................................................................................10-67
Driveshaft.........................................................................................................................10-69
Torqueconverterandtransmissionhydraulicpiping..............................................................10-70
Torqueconverter................................................................................................................10-71
Transmission.....................................................................................................................10-77
Transmissioncontrolvalve................................................................................................10-102
ForwardandreverseclutchECMVandgearspeedclutchECMV.........................................10-105
LockupclutchECMV........................................................................................................10-112
DifferentiallockclutchECMV............................................................................................10-116
Mainreliefvalve,torqueconverterreliefvalve,andmainflowselectorvalve..........................10-120
Axle................................................................................................................................10-126
Differential.......................................................................................................................10-129
Finaldrive.......................................................................................................................10-133
Steeringsystem......................................................................................................................10-136
Layoutofsteeringdevices................................................................................................10-136
Steeringcolumn...............................................................................................................10-137
Flowamplifiervalve..........................................................................................................10-138
Steeringvalve..................................................................................................................10-142
Emergencysteeringpump................................................................................................10-147
Brakesystem.........................................................................................................................10-149
Layoutofbrakeparts........................................................................................................10-149
Parkingbrakesolenoidandaccumulatorchargevalve........................................................10-151
Accumulator....................................................................................................................10-157
Shutoffsolenoidvalve......................................................................................................10-158
Brakevalve.....................................................................................................................10-159
Proportionalpressurereducingvalve.................................................................................10-164
Slackadjuster..................................................................................................................10-166
Brake..............................................................................................................................10-170
Brakesystemtank...........................................................................................................10-173
Parkingbrake..................................................................................................................10-174
Undercarriageandframe.........................................................................................................10-177
Suspension.....................................................................................................................10-177
Suspensioncylinder.........................................................................................................10-181
Oscillationhitch...............................................................................................................10-184
Hydraulicsystem....................................................................................................................10-185
Hydrauliccomponentlayout..............................................................................................10-185
Engineandcoolingsystem (ALL-R401-001-K-00-A)
Enginerelatedparts (HM400-A001-041-K-00-A)
1. Air cleaner (*1)
2. KDPF
3. Rear engine mount
4. Engine oil filter
5. Fuel prefilter
6. Fuel main filter
7. KCCV ventilator
8. Front engine mount
9. Auto-tensioner
10.Vibration damper (*1)
11.EGR cooler
12.Drain plug
13.Vacuator valve
14.VGT
*1:Fordetails,seeEngineShopManual.
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Outputshaft (HM400-CB30-041-K-00-A)
1.Rubbercushion(large)
2.Rubbercushion(small)
3.Outerbody
4.Flange
5.Shaft
6.Coupling
7.Innerbody
8.Cover
Function (HM300-CB30-042-K-00-A)
• Theoutputshaftisinstalledtotheengineflywheel,andabsorbsthetorsionalvibrationcausedby fluctuationoftheenginetorque.
VGT: Abbreviation for Variable Geometry Turbocharger and denotes the variable displacement turbocharger. a The shape is subject to machine models.
1. Blower housing
2. VGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10.Blower impeller
11.Turbine impeller
12.Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
1. Air cleaner
2. VGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
• The new exhaust gas regulation not only requires to control emissions at high engine speed but also at low engine speed. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/ intake air flow)
• To obtain a high EGR ratio especially at low engine speed, the turbine inlet pressure (P3) must be higher than the boost pressure (P2). A variable displacement turbocharger (VGT), in which the exhaust gas pressure hitting the turbine impeller (T) can be adjusted, is introduced.
• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to insufficient oxygen at low engine speed.
• The turbine impeller (T) drives the blower impeller (C) via a shaft. In turn the blower impeller (C) sends a large amount of air to the cylinders for combustion. When the air flow from VGT (2) increases, more fuel can be injected, and the engine output increases.
• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be injected, and the engine output increases.
a Adequate amount of clean high quality oil is required to maintain the VGT performance. Be sure to use Komatsugenuinehighqualityoil.FollowtheproceduresintheOperationandMaintenanceManualwhen replacingoiloroilfilter.
• Exhaust gas enters from (C) of turbine housing (4), flows through section (P) and out from (D). Section (P) is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
• The passage area changes when nozzle ring (7) slides right or left.
• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled at the EPC valve installed to the EGR valve, and also controls the right/left slide of push rod (8).
• Exhaust gas hits vane (6), and then turbine impeller (11) drives blower impeller (10) via shaft (9). This works as a compressor and the air entered from (A) is compressed and sent out from (B).
• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speed), push rod (8) slides to the right to narrow section (P).
• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases, and more air (oxygen) is inhaled.
• The turbocharger speed is sensed by VGT speed sensor (2).
Whennozzleringisclosed
• Atlowenginespeed,exhaustgasinletpassage(P)isnarrowed(L1).(Notcompletelyclosed.)
• Whentheturbineinletpressureincreaseswhilethenozzleringisclosed,theflowspeedtotheturbine increasesandtheturbochargerspeedincreases.
Whennozzleringisopen
• Athighenginespeed,exhaustgasinletpassage(P)iswidened(L2).
• Astheenginespeedandtheturbineinletpressure(exhaustgaspressure)increases,exhaustgasinlet passage(P)widens(L2)toeffectivelyapplytheexhaustgaspressuretoturbineimpeller(11).
a Nozzle ring (7), vane (6) and push rod (8) are integrated and slide together but do not rotate.
a VGT position sensor is installed to hydraulic actuator (3). The VGT position sensor is calibrated together with the variable mechanism in the VGT, and values are stored in the memory inside the VGT position sensor. If any of the hydraulic actuator (3), VGT position sensor, or VGT body fails, replace the whole VGT.
Hydraulicactuatoroperation
• Hydraulicactuator(6)ismovedbytheoilpressurecontrolledbyEPCvalve(8)installedtoEGRvalve (10).
• Theforceforthemovementistheoilpressuresuppliedfromboostpump(12).
a Theshapeissubjecttomachinemodels.
• Position of hydraulic actuator (6) is sensed by VGT position sensor (5) and the signals are fed back to engine controller (7).
1.Aircleaner
2.Massairflowandtemperaturesensor
3. VGT
4. VGT speed sensor
5. VGT position sensor
6. Hydraulic actuator
7. Engine controller
8. EPC valve (for VGT)
9. KDPF
10. EGR system (EGR cooler and EGR valve)
C: Blower impeller
T: Turbine impeller
VGT control system
• Based on information from VGT position sensor (5), mass air flow and temperature sensor (2), and VGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil pressure controlled by EPC valve (8), to move the piston.
• A good response at high altitudes is maintained by sensing high elevations with the ambient pressure sensor, and automatically controlling the fuel injection and the VGT
Lubrication
• Cooled oil from the engine oil cooler is sent through the supply pipe to the VGT for lubrication.
• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil pan.
Cooling
• Coolant from the cylinder block enters the center housing to cool the VGT.
• Coolant return flows from the center housing and joins the flow at the EGR cooler air bent piping.
EGR: Abbreviation for Exhaust Gas Recirculation a The shape is subject to machine models.
7.Exhaustmanifold
Function (ENG140-A9J0-042-K-00-A)
• EGRvalve(drivenhydraulically)
Controlsthegasflowfromtheexhaustsystemtotheairintakesystem.Sincetheexhaustpressureis higherthantheboostpressure,theexhaustgasflowstotheairintakeside.
• EGRcooler
Coolstheexhaustgas. Enginecoolantisusedforcooling.
• Mixingconnector
Mixestheairfromtheair-cooledaftercoolerandexhaustgasfromtheEGRvalve.
• ControlseachpartoftheEGRcircuitandcontrolstheEGRrateaccordingtotheoperatingconditionto ensurecleanexhaustatalltimes.
• SincetheEGRcircuitismonitoredandtroubleshooted,aserioustroubleisprevented.
EGRsystemcircuitdiagram (ENG125-A9J0-052-K-00-A)
EGR:AbbreviationforExhaustGasRecirculation
1.Aircleaner
2.KDPF
3.Ambientpressuresensor
4.Aftercooler
5.EGRcooler
6.EGRvalve
7.Hydraulicactuator(powerpiston)
8.EPCvalve(forEGRvalve)
9.EGRvalveliftsensor
10.Exhaustmanifold
11.Boostpump
12.Intakemanifold
13.Charge(boost)pressureandtemperaturesensors
14.Enginecontroller
15.Mixingconnector
C:Blowerimpeller
T:Turbineimpeller
Operation (ENG125-A9J0-044-K-00-A)
• TheenginecontrolleroutputssignalsforopeningEGRvalve(6)mostproperlyaccordingtotheloadon theenginetoattainbothcleanexhaustgasandlowfuelconsumption.
• WhenEGRvalve(6)opens,apartoftheexhaustgas(EGRgas)flowsfromexhaustmanifold(10) throughEGRpipingtoEGRcooler(5).
• TheexhaustgascooledbyEGRcooler(5)flowsthroughEGRvalve(6)andmixeswiththeintakeairin mixingconnector(15),andthenflowsintointakemanifold(12).
EGRvalve (ENG107-A9K1-041-K-00-A)
a Theshapeissubjecttomachinemodels.
1.Valve
2.Spring
3.Powerpiston
4.Spool
5.Spring
6.EGRvalveliftsensor
7.EPCvalve(forEGRvalve)
8.EPCvalve(forVGT)
A:EGRgasinlet(fromEGRcooler)
B:EGRgasoutlet(tointakemanifold)
C:Servodriveoilinlet
D:Servodriveoiloutlet
E:VGTcontroloilpressureoutlet
F:VGTdriveoilpressureoutlet
Structure
• TheEGRvalveconsistsoftheEGRgasflowcontrolmechanismandtheEPCvalves
• TherearetwoEPCvalves,onefortheEGRvalvescontrolandonefortheVGTcontrol.
Operation (ENG107-A9K1-044-K-00-A)
• OilfromtheboostoilpumpflowsintotheEGRvalvefromport(C).ControlpressurefromtheEPCvalve flowsintoport(E).
• Spool(4)ispressedtotherightbythereactionforceofspring(5),andEGRvalve(1)isclosedbythe reactionforceofspring(2)Therefore,exhaustgasfromtheEGRcoolerdoesnotflowtotheintakeside.
• ToopenEGRvalve(1),firstthecontrolpressurefromtheEPCvalveentersport(E).Spool(4)movestoa positionwhereatthiscontrolpressureandtheforceofspring(5)arebalanced.
• Thehydrauliccircuitinpowerpiston(3)opens,andthentheoilfromtheboostoilpumpenteringfromport (C)pushespowerpiston(3)totheleft.
• Oilfromtheboostoilpumpactsonpowerpiston(3)andgeneratesforce(Fp).
• Whenforce(Fp)becomeslargerthanreactionforce(Fs)ofspring(2),EGRvalve(1)opensandthen exhaustgaswillflowtotheintakeside.
• Sincethehydrauliccircuittospool(4)isclosedbymovementofpowerpiston(3),powerpiston(3)stopsat apositiondeterminedbyspool(4).
• Thevalvepositioniscontrolledbytheenginecontrollerbycontrollingthespoolpositionwiththecontrol pressureoftheEPCvalve.
• Aservomechanismpreventsexternalforceappliedtovalve(1)fromactingonspool(4),whichisin contactwithpowerpiston(3).
• Positionofspool(4)issensedbytheEGRvalveliftsensor.
EGRcooler (ENG125-A9L0-041-K-00-A)
a Theshapeissubjecttomachinemodels.
1.Headerplate
4.Shell
A:EGRgasinlet
B:EGRgasoutlet(toEGRvalve)
C:Coolantinlet
D:Coolantoutlet
E:Airvent
F:Airvent
2.Flattube
3.Innerfin
Operation (ENG125-A9L0-044-K-00-A)
• TheEGRgasentersfrom(A)andflowsthrough9flattubes(2).
• Coolantentersfrom(C)andflowsaroundflattube(2)inshell(4)andthengoesoutfrom(D).
• TheEGRgasiseffectivelycooledbyflattubes(2)withinnerfins(3)andflowsoutfromEGRgasoutlet (B).
KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation
a The shape is subject to machine models.
1. KCCV ventilator
2. VGT
3. Check valve
4. CDR valve
A: Blowby gas
B: Engine oil-free blowby gas (to VGT intake side)
C: Engine oil mist separated from the blowby gas by the ventilator KCCV (to oil pan)
• Formerly blowby gas (A) was discharged to the atmosphere as is. However, the tightened exhaust gas regulation no longer permits releasing blowby gas to the atmosphere.
• Since blowby gas (A) contains engine oil components, which may cause the following problems when recirculated to VGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1.Degradedperformanceofturbochargerandaftercoolerduetoadherenceofengineoil
2.Abnormalenginecombustion
3.Malfunctionofsensorsduetoadherenceofengineoil
a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere. ThefigureontherightshowstheflowofblowbygasrecirculatedtotheintakesystembytheKCCV ventilator.
1. Air cleaner 2. VGT 3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and then the cleaned gas (B) is recirculated to the intake side of the VGT.
• Separated engine oil (C) flows through a check valve and falls to the oil pan.
a The shape is subject to machine models.
1. Heater tube
2. Crankcase pressure sensor
3. Case
4. CDR valve
5. Filter
6. Relief valve
7. Impactor
A: Blowby gas inlet (from engine breather)
B: Blowby gas outlet (to VGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlet
Function
• When blowby gas is recirculated to the intake side of the VGT, the pressure inside the crankcase becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve (regulator valve) controls the pressure inside the crankcase.
• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog of filter is detected by crankcase pressure sensor.
• There are two types of filters that differ by the filter replacement method; the top load type (removed upward) and the bottom load type (removed downward).
• Warmed engine coolant is conducted to the locations that pose potential problem of freezing to prevent it from happening.
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Operation (ENG140-A18H-044-K-00-A)
• Blowbygasentersfrom(A).Thelargerdropsofoilmistareremovedfromtheblowbygaswhenitflows throughtheimpactor(7)holesinfilter(5).
• Smallerdropsofoilmistareremovedbyfilter(5).
• Removedoilflowsdownalonginthefiltertooildrainport(C)andthenflowstotheoilpan.
• TheCDRvalveisoperatedbythenegativeintakepressureoftheKGVTtopreventexcessivenegative pressureinthecrankcase.
• Crankcasepressuresensor(2)sensestheblowbygaspressure(crankcasepressure).
• Whentheenginecontrollerdeterminesthatthefilteriscloggedfromcrankcasepressuresensor(2) signals,failurecodeCA555isissued.Ifthepressureincreasesfurther,failurecodeCA556isissued.
• Reliefvalve(6)isinstalledincase(3).ItoperatestoprotecttheKCCVventilatorandenginewhenfilter(5) isblocked.
CDRvalve (ENG107-A18A-041-K-00-A)
CDR:AbbreviationforCrankcaseDepressionRegulator
1.Diaphragm
2.Spring
A:Crankcaseside
B:VGTside(intakeside)
• TheCDRvalveisaregulatorvalvewhichpreventsexcessivenegativecrankcasepressure(P1).
• Normally,diaphragm(1)ispushedupbyspring(2)andblowbygasflowsfromcrankcaseside(A)toVGT side(intakeside)(B).
• WhenintakeairflowatVGTside(intakeside)(B)increasesandcrankcasepressure(P1)decreases,the reactionforceofspring(2)yieldstoambientpressure(P2).Thediaphragmshutsthepassageand temporarilyblockstheflow.
• Then,whenblowbygasaccumulatesinthecrankcaseandpressure(P1)recovers,thediaphragmis pushedupagainandblowbygasstartstoflowagain.
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter
a The shape is subject to machine models.
1. KCSF unit
2. Aggregate connector box
3. Inlet unit
4. KDOC inlet temperature sensor
5. KDOC unit
6. KDPF differencial pressure sensor port
7. KDOC outlet temperature sensor
8. KDPF differencial pressure sensor
9. KDPF differencial pressure sensor port
10. Outlet unit
11. KDPF outlet temperature sensor
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From VGT
B: Exhaust
C: Water drain
• TheKDPFconsistsofthefollowingcomponents:inletunit(3)tointroduceexhaustgas,KDOCunit(5)that housesanoxidationcatalyst,KCSFunit(1)thathousesasootcollectingfilterwithacatalyzer,andoutlet unit(10)thatsendsoutexhaustgasandhasa"dam"topreventrainwaterfromenteringKCSFunit(1).
• KDOCunit(5)consistsofaceramichoneycombcoatedwithoxidationcatalystmaterial.Byusingthis ceramichoneycomb,itperformstwofunctionsproperly;OneistooxidizeNO(nitrogenmonoxide)inthe
exhaustgasintoNO2 (nitrogendioxide)andtheotheristoburnthefuelinjectedduringautomatic regenerationandmanualstationaryregeneration(*1).
• Theceramichoneycombisguardedbyamatmadeofspecialfibertopreventdamagecausedbyengine andmachinevibrations.
• ThematalsopreventsoverheatingoftheKDPFouterperipherybyinsulatingtheheatgeneratedatthe ceramichoneycombduringoperation.
• TheKCSFunit(1)alsoconsistsofaceramichoneycombcoatedwithoxidationcatalystmaterial,likethe KDOCunit(5).Thisceramichoneycombcollectssoot.
• Threetemperaturesensorsandonedifferentialpressuresensor(anintegratedKDPFdifferentialpressure andKDPFoutletpressuresensor)areinstalledtotheKDPF.
• TemperaturesignalsfromthesethreetemperaturesensorsareusedincombinationtomonitortheKDOC andKCSFoperationsandtoperformvarioustroubleshootings.
• ThedifferentialpressuresensordetectstheamountofsootdepositedintheKCSFbysensingthe pressuredifferenceacrosstheKCSF.Likethetemperaturesensors,thissensorisalsousedforvarious troubleshootings.
*1:Denotestopurification(oxidation)processingofsoot.
kk Whileengineisrunningandforsometimeafterengineisstopped,thesurfaceofKDPFand nearbypipingareextremelyhot.BecarefulnottogetburnedwhenworkingneartheKDPF.
A:Flowofexhaustgas
1.KDOC(oxidationcatalyzer)
2.KCSF
3.Sealing(madeofceramics)
4.Cell
5.Ceramicshoneycomb
• The KDPF purifies the exhaust gas by catching most of the granulous or chain-like soot formed by the PM (particulates in air such as soot) included in the exhaust from the engine.
• KCSF (2) is made of ceramic.
• Inside the KCSF (2), there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and cells plugged at the outlet side are alternately arranged.
• The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1) (oxidation catalyzer), in operating conditions with relatively high exhaust gas temperatures. (This is referred to as "passive regeneration".)
• On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low load operations, the deposit of soot in KCSF (2) increases.
• The engine controller continuously monitors the amount of deposited soot by estimating from the operating conditions and calculating based on the KCSF (2) differential pressure sensor signals.
• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn (oxidize) the soot.
• During automatic regeneration, the engine controller automatically controls the fuel injection timing and the VGT to raise the exhaust temperature. (This operation is called "exhaust temperature-raising control")
• As the exhaust temperature increases, the engine controller automatically performs calculations based on the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently burn (oxidize) the soot.
• Fuel is injected from (fuel doser) installed to the outlet portion of turbocharger. (Fuel dosing) Fuel that is injected into this piping mixes with exhaust gas and combusts (oxidizes) soot by the action of KDOC (1).
• Automaticregenerationisnotperformedwhenregenerationisexecutedfromthemachinemonitor,or whentheoutsideairtemperatureisextremelylow,andwhentheexhaustgastemperatureisnothigh enoughtoburnsootbecausetheenginehasbeenoperatedatlowloadsforawhile.Thus,sootdepositin theKCSF(2)willincrease.
• IfthesootdepositintheKCSF(2)exceedsacertainlevel,itwillbenecessarytoperform"manual stationaryregeneration"toburnaway(oxidize)thesootintheKCSF(2).
• Ifthesootdepositexceedstheacceptablelevel,theexhaustgasflowwillberestricted.Thiscanincrease fuelconsumption,degradeenginecombustion,orcauseotherproblems.
• Ifthesootdepositexceedsthelimittosafelyperform"manualstationaryregeneration",theKDPFfailsand replacementbecomesunavoidable.MakesuretofollowtheproceduresintheOperationand MaintenanceManualwhenperforming"manualstationaryregeneration"
a Regeneration refers to a new function used for purifying (oxidizing) soot accumulated in the soot collection filter(KCSF)insidetheKDPF.
1. Passive regeneration
When the engine exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will be stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration (increase of engine exhaust temperature + fuel dosing)
1) Automatic regeneration
This is the regeneration process started automatically when the soot deposit exceeds a certain level. At this time, the engine controller performs the exhaust temperature-raising control mode (*1) and fuel dosing (*2). Another type of automatic regeneration is performed by the engine controller at certain intervals, regardless of the amount of soot deposited in the KCSF
*1: The fuel injection timing and the VGT are controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process.
2) Manual stationary regeneration
When the exhaust temperature does not reach a certain level due to the machine operating condition, or when regeneration is disabled by the operator, automatic regeneration will not be performed and the soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual stationary regeneration request, on the screen. The operator must perform regeneration by operating the machine monitor on its screen. A regeneration feature is also provided for the technician who should use this feature from the machine monitor menu after engine controller replacement, KDPF replacement, and KCSF ash cleaning. ("Regeneration for Service")
• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF when the machine is operated for a long time with low exhaust temperature.
• When certain conditions are met, the engine controller automatically switches control to increase the exhaust temperature to dry the KDOC. If some of the conditions for automatic drying are not met, manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping KDPF regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the KDPF, leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is low. Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the VGT automatically operatesandtheenginesoundchanges.TheflowofexhaustgasthroughtheKDPFchangesand theexhaustsoundchanges,butthisisnormal.
a Duringautomaticregenerationandmanualstationaryregeneration,especiallyatlowtemperatures, whitesmokemaycomeoutfromtheexhaustpipeforashorttime,butthisisnormal.Besureto performregenerationatawellventilatedplacesincecarbonmonoxidecanbeproduced.
a Duringautomaticregenerationandmanualstationaryregeneration,astrangeodormaybesmelled fromtheexhaustpipe,butthisisnormal.
a Duringautomaticregenerationandmanualstationaryregeneration,theexhausttemperatureatthe exhaustpipecanexceed650°C.Makesurethatthereisnoflammablematerialneartheexhaust systemtopreventfire.Makesurethatnobodyisstandinginfrontoftheexhaustpipe,andpay sufficientattentiontosafetyoftheenvironment.
a KDPFtemperaturevaluesareshownbelowforreference.
KDOC_In (KDOCinlettemperature sensor)
KDOC_Out (KDOCoutlet temperaturesensor)
Notregenerating(idling) 100to250°C
KDPF_Out (KDPFoutlet temperaturesensor)
Regenerating(under exhausttemperature-raising control:1,000rpm) 100to250°C400to550°C
10Structureandfunction
Coolingsystem
Coolingsystem (HM400-B000-041-K-00-A)
1.Aftercooler
2.Aftercooleroutlethose
3.Aftercoolerinlethose
4.Reservoirtank
5.Waterfillerport
6.Sub-tank
7.Torqueconverterandsteeringoilcooler
8.Radiatoroutlethose
9.Radiator
10.Radiatorinlethose
11.Aftercoolerfanmotor
12.Radiatorfanmotor
13.Oilcoolerbypassvalve
Specifications (HM400-B000-030-K-00-A)
Radiatorfanpump (HM400-B450-041-K-00-A)
P1:Pumpdischargeport
PAEPC:EPCoutputpressurepickupplug
PEPC:EPCvalvesourcepressureinputport
PS:Pumpsuctionport
TO:Drainport
1.Servovalve
2.Airbleeder
3.EPCvalve
Serialnumber:3001 – 3258
1.Shaft
2.Servopiston
3.Spring
4.Rockercam
5.Shoe
6.Piston
7.Cylinderblock
8.Valveplate
9.Case
10.Oilseal(Single)
11.Ballretainer
a Theonlydifferencefromserialnumber:3259andupinstructureisthenumberofoilseal(10).
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Serialnumber:3259andup
1.Shaft
2.Servopiston
3.Spring
4.Rockercam
5.Shoe
6.Piston
7.Cylinderblock
8.Valveplate
9.Case
10.Oilseal(Double)
11.Ballretainer
a Theonlydifferencefromserialnumber:3001to3258instructureisthenumberofoilsseal(10). Hereinafterexplanationwillbeprovidedbyreferencetothedrawingsofserialnumber:3001to3258.
Structure
• Cylinderblock(7)issupportedtoshaft(1)byspline(11).
• Shaft(1)issupportedbyeachbearing(12)atthefrontandrear.
• Thetipofpiston(6)isaconcaveballandintegrateswithshoe(5)bygrippingit.
• Piston(6)andshoe(5)formasphericalbearing.
• Rockercam(4)hasflatsurface(A),andshoe(5)isalwayspressedagainstthissurfacewhileslidingina circularpattern.
• Rockercam(4)pivotsonballretainer(13).
• Piston(6)movesrelativelyintheaxialdirectionineachcylinderchamberofcylinderblock(7).
• Cylinderblock(7)rotatesrelativelytovalveplate(8)whilesealingthepressurizedoil.
• Thissurfaceisdesignedsothattheoilpressurebalanceismaintainedatasuitablelevel.
• Thepressurizedoilissuckedinanddischargedfromeachcylinderchamberincylinderblock(7)through valveplate(8).
Specifications (HM400-B450-030-K-00-A)
Model LPV45
TypeVariabledisplacementswashplatetypepistonpump
Theoreticaldelivery(cm3/rev) 45
Fandrivepressure(MPa{kg/cm 2}) 15.6{159}
Ratedspeed(rpm) 2,374
Function (HM300-B450-042-K-00-A)
• Thispumpconvertstherotationandtorqueoftheenginetransmittedtoitsshaftintohydraulicenergyand dischargeshydraulicoilaccordingtotheload.
• Thedischargecanbechangedbychangingtheswashplateangle.
Operation (HM400-B450-044-K-00-A)
• Cylinderblock(7)rotatestogetherwithshaft(1)andshoe(5)slidesonplane(A).
• Rockercam(4)pivotsonballretainer(13),andaccordinglyangle(a)betweencenterline(X)ofrocker cam(4)andtheaxialdirectionofcylinderblock(7)changes.
• Angle(a)iscalledtheswashplateangle.
• Whileangle(a)ismadebetweencenterline(X)ofrockercam(4)andtheaxisofcylinderblock(7),plane (A)worksasacamforshoe(5).
• Piston(6)slidesinsidecylinderblock(7)andadifferenceismadebetweenvolumes(E)and(F)incylinder block(7).
• Oilinamountof(F)minus(E)goesinandoutofeachcylinder.
• Oilisdischargedwhilecylinderblock(7)rotatesandthevolumeofchamber(E)decreases.
• Oilissuckedinwhilethevolumeofchamber(F)increases.
• Whencenterline(X)ofrockercam(4)matchestheaxisofcylinderblock(7)(theswashplateangleis zero),thedifferencebetweenvolumes(E)and(F)insidecylinderblock(7)iszero.
• Pressurizedoilisnotsuckedordischarged,namelypumpingactionisnotperformed.(Actually,however, theswashplateangleisnotsetto0deg.)
• Thepumpdeliveryisinproportiontoswashplateangle(a).
• Whenswashplateangle(a)isincreased,thedifferencebetweenvolumes(E)and(F)isincreased,then delivery(Q)isincreased.
• Swashplateangle(a)ischangedbyservopiston(10).
• Servopiston(10)reciprocateslinearlyaccordingtothesignalpressureoftheservovalve.
• Thisstraightlinemovementistransmittedtorockercam(4).
• Rockercam(4)supportedwithballretainer(13)pivotsonballretainer(13).
Servovalve (HM400-B4H0-041-K-00-A)
P:EPCvalvesourcepressureport
PE:Controlpistonpressureport
PH:Pumpdeliverypressureport
T:Drainport
1.Plug
2.Lever
3.Retainer
4.Seat
5.Spool
6.Piston
7.Sleeve
8.Spring
9.EPCvalve
Function (PC400-B4H0-042-K-00-A)
• Theservovalvecontrolsthepumpsothattheinputcurrent(i)totheEPCvalverelatestopumpdischarge (Q)asshowninthefigurebelow.
Operation (PC400-B4H0-044-K-00-A)
• TheoutputpressureoftheEPCvalveenterspistonchamber(C)andpushespiston(6).
• Piston(6)pushesspool(5)andmovestoapositionwhereitisbalancedwiththespring.
• Land(PE)oftheservopistonpressurepassageisconnectedtopumpdeliverypressurepassage(PH) throughthenotchofspool(5),sothepumpdeliverypressureistransmittedtoservopiston(10).
• Rockercam(9)ispushedupbyservopiston(10),andthenitspositionisfedbackandlever(2)movesto compressspring(8).
• Ifspool(5)ispushedback,thepumpdeliverycircuitandservopistoncircuitaredisconnected.
• Thepressureintheservopistonchamberdecreasesandrockercam(9)movestowardthemaximum swashplateangle.
• TheseprocessesarerepeateduntiltheswashplatestabilizesatananglewheretheEPCoutputpressure isbalancedwiththeforceofspring(8).
• AstheEPCoutputpressureincreases,theswashplateangledecreases.AstheEPCoutputpressure decreases,theswashplateangleincreases.
Aftercoolerfanmotor (HM400-B5L0-041-K-00-A)
P:Frompumpthroughchargevalve
T:Tohydraulictankthroughreturnfilter
TC:Tohydraulictank
1.TerminalER
2.TerminalEF
3.TerminalEN
4.EPCvalve
5.Aftercoolerfanreversesolenoidvalve
1.Outputshaft
2.Case
3.thrustplate
4.Pistonassembly
5.Cylinderblock
6.Valveplate
7.Endcover
8.Bearing
9.Spring
10.Retainershoe
11.Retainerguide
12.Bearing
13.Oilseal
14.Flowcontrolspool
15.Suctionsafetyvalve
16.Reversiblespool
17.Speedsensor
Structure
• Thisfanmotorisinstalledwithinthebladewidthasshowninthefigure.
Specifications (HM300-B5L0-030-K-00-A)
Model LMF10
TypeSwashplatetypepistonmotor
Hydraulicmotor (HM300-B5N0-042-K-00-A)
Function
• Thishydraulicmotoriscalledaswashplateaxialpistonmotor.Itconvertstheenergyofthepressurizedoil sentfromthehydraulicpumpintorotarymotion.
Principleofoperation (HM300-B5N0-04B-K-01-A)
• Thepressurizedoilsentfromthepumpflowsthroughvalveplate(6)intocylinderblock(5).
• Thisoilcanflowtoonlyonesideofthe(Y-Y)lineconnectingthetopdeadcenterandbottomdeadcenter ofthestrokeofpiston(4).
• Thepressurizedoilsenttoonesideofcylinderblock(5)pusheseachpiston(4)(2or3pistons).
• Eachpiston(4)generatesforce(F1)[F1(kg)=P(kg/cm 2)x x D2 /4(cm2)].
• Thisforceactsonthrustplate(2).
• Sincethrustplate(2)isfixedatspecificangle(a)tooutputshaft(1),theforceisdividedintocomponents (F2)and(F3).
• Radialcomponent(F3)generateseachtorque[T=F3xri]againstthe(Y-Y)lineconnectingthetopdead centerandbottomdeadcenter.
• Thetotalofthesetorque[T= Σ(F3xri)]rotatescylinderblock(5)throughpiston(4).
• Cylinderblock(5)isconnectedtooutputshaft(1)withspline.
• Outputshaft(1)rotatestotransmitthetorque.
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Suctionsafetyvalve (HM300-B6D6-001-K-00-A)
Functionassuctionvalve (HM300-B6D6-042-K-00-A)
• Whenthepumpstops,thepressurizedoildoesnotflowintothemotoranymore.
• Sincethemotorcontinuestorotatewiththeforceofinertia,thepressureontheoutletsideofthemotor increases.
• Whentheoilstopsflowinginfrominletport(P),suctionsafetyvalve(1)sucksintheoilontheoutletside andsuppliesittoport(MA),compensatingforthelackofoilonthatsidetopreventcavitation.
Operation (HM400-B6D6-044-K-00-A)
Whenstarted
• Thepressurizedoilfromthepumpissuppliedtoport(P),increasingthe(MA)sidepressure.
• Thestartingtorqueisgeneratedinthemotor,andthemotorstartsrotating.
• Thepressurizedoilonthemotoroutlet(MB)sidereturnstothetankthroughport(T).
Whenstopped
• Whentheenginestops,thepumpinputspeedbecomes0rpm.
• Thepressurizedoilfromthepumpisnotsuppliedtoport(P).
• Asthepressurizedoilisnotsuppliedto(MA)sideofthemotor,themotorspeeddecreasesgraduallyto stop.
• Whenthemotorshaftisrotatedbytheforceofinertiawhiletheoilflowintheport(P)isdecreasing,theoil inport(T)ontheoutletsideissentbysuctionsafetyvalve(1)tothe(MA)sidetopreventcavitation.
Functionassafetyvalve (HM300-B6D6-042-K-01-A)
• Thepressureinport(P)ofthemotorisincreasedwhentheengineisstartedetc.
• Suctionsafetyvalve(1)isinstalledtoprotectthefansystemcircuitinsuchacase.
Operation (HM400-B6D6-044-K-01-A)
• Ifthepressureinport(P)risesabovethecrackingpressureofsuctionsafetyvalve(1),valve(2)ofsuction safetyvalve(1)openstoreleasethepressurizedoilintoport(T).
• Thisoperationpreventsgenerationoftheabnormallyhighpressureinport(P).
Reversiblevalve (HM400-B6E0-041-K-00-A)
Operation
Whenaftercoolerfanreversesolenoidis"de-energized"
• Whencoil(1)is"de-energized",thepressurizedoilfromthepumpisblockedbyvalve(2),andport(C)is connectedtothetankcircuit.
• Spool(3)ispushedtotherightbyspring(4)toopenmotorport(MA),andthenthepressurizedoilflowsin torotatethemotorforward(clockwise).
Whenaftercoolerfanreversesolenoidis"energized"
• Whencoil(1)is"energized",valve(2)switchestoallowthepressurizedoilfromthepumptoflowthrough port(C)tospoolchamber(D).
• Thepressurizedoilinchamber(D)pushesspool(3)totheleftagainstspring(4).
• Motorport(MB)opensandthepressurizedoilflowsintorotatethemotorinreverse(counterclockwise).
Flowcontrolvalve(steplessly-variabletype) (HM300-B6D5-001-K-00-A)
Function (HM300-B6D5-042-K-00-A)
Thisvalvesuppliesthepumpdischargetothemotorbythenecessaryquantity,andreturnstheexcessoilto thehydraulictank.
• Themotorspeedincreasesinproportiontomotorflow(Q)asshowninFig1.
• Whenthemotorflowis(Q1),motorspeedis(B)rpm.
• Inordertoreducenoiseandperformancelossofthemotor,thisvalvekeepsthefanspeedconstantat necessarylevelregardlessofthemotorflow.
• Evenifthemotorflowisincreasedfrom(Q0)to(Q1),thisvalvemaintainsthemotorspeedconstantat(A) rpmand(C)rpm.
Operation (HM400-B6D5-044-K-00-A)
• Intheflowcontrolvalve,theupstreampressureoftheorificeisappliedtotherightsideofspool(1)and thedownstreampressureisappliedtotheleftside.
• Thedifferentialpressurecausedbythemotorflowoverorifice(E)actsonspring(2).
• InFig.1,ifthemotorflowexceeds(Q0),thedifferentialpressureacrossspool(1)exceedstheloadat installedlengthofspring(2).
• Spool(1)movestotheleftandport(P)andport(T)areinterconnected.
• Theexcessiveoilof(Z)portioninFig.1flowstothehydraulictankthroughtheflowcontrolvalve,andthe motorspeediskeptconstantintherangefrom(A)to(C).
• Thisflowcontrolvalvecanbeadjustedsteplessly.
• AsshowninFig.2,theflowcontrolvalvecanbeadjustedsteplesslywhilemaintainingthemotorspeed constantbetween(A')to(C')bychangingthecommandcurrentbetweenthemotorspeed(A)and(C).
Radiatorfanmotor (HM400-B5L0-041-K-01-A)
P:Fromfanpump
T:Tohydraulictankviacooler
TC:Tohydraulictank
1.Outputshaft
2.Case
3.thrustplate
4.Pistonassembly
5.Cylinderblock
6.Valveplate
7.Endcover
8.Centerspring
9.Checkvalve
10.Pilotvalve
11.Reversiblevalvespool
12.Safetyvalve
13.Speedsensor
Structure
• Thisfanmotorisinstalledwithinthebladewidthasshowninthefigure.
Specifications (HM400-B5L0-030-K-00-A)
Model LMF55
TypeSwashplatetypepistonmotor
Ratedspeed(rpm)
Ratedflowrate(
Hydraulicmotor (HM300-B5N0-042-K-00-A)
Function
• Thishydraulicmotoriscalledaswashplateaxialpistonmotor.Itconvertstheenergyofthepressurizedoil sentfromthehydraulicpumpintorotarymotion.
Principleofoperation (HM300-B5N0-04B-K-01-A)
• Thepressurizedoilsentfromthepumpflowsthroughvalveplate(6)intocylinderblock(5).
• Thisoilcanflowtoonlyonesideofthe(Y-Y)lineconnectingthetopdeadcenterandbottomdeadcenter ofthestrokeofpiston(4).
• Thepressurizedoilsenttoonesideofcylinderblock(5)pusheseachpiston(4)(2or3pistons).
• Eachpiston(4)generatesforce(F1)[F1(kg)=P(kg/cm 2)x x D2 /4(cm2)].
• Thisforceactsonthrustplate(2).
• Sincethrustplate(2)isfixedatspecificangle(a)tooutputshaft(1),theforceisdividedintocomponents (F2)and(F3).
• Radialcomponent(F3)generateseachtorque[T=F3xri]againstthe(Y-Y)lineconnectingthetopdead centerandbottomdeadcenter.
• Thetotalofthesetorque[T= Σ(F3xri)]rotatescylinderblock(5)throughpiston(4).
• Cylinderblock(5)isconnectedtooutputshaft(1)withspline.
• Outputshaft(1)rotatestotransmitthetorque.
Suctionvalve (HM300-B6D0-001-K-00-A)
Function (HM300-B6D0-042-K-00-A)
• Whenthepumpstops,thepressurizedoildoesnotflowintothemotoranymore.
• Sincethemotorcontinuestorotatewiththeforceofinertia,thepressureontheoutletsideofthemotor increases.
• Whentheoilstopsflowinginfrominletport(P),suctionvalve(1)sucksintheoilontheoutletsideand suppliesittoport(MA),compensatingforthelackofoilonthatsidetopreventcavitation.
Operation (HM400-B6D0-044-K-00-A)
Whenstarted
• Thepressurizedoilfromthepumpissuppliedtoport(P),increasingthe(MA)sidepressure.
• Thestartingtorqueisgeneratedinthemotor,andthemotorstartsrotating.
• Thepressurizedoilonthemotoroutlet(MB)sidereturnstothetankthroughport(T).
Whenstopped
• Whentheenginestops,thepumpinputspeedbecomes0rpm.
• Thepressurizedoilfromthepumpisnotsuppliedtoport(P).
• Asthepressurizedoilisnotsuppliedto(MA)sideofthemotor,themotorspeeddecreasesgraduallyto stop.
• Whenthemotorshaftisrotatedbytheforceofinertiawhiletheoilflowinport(P)isdecreasing,theoilin port(T)ontheoutletsideissentbysuctionsafetyvalve(1)tothe(MA)sidetopreventcavitation.
Reversiblevalve (HM400-B6E0-041-K-01-A)
Operation
Whenradiatorfanreversesolenoidis"de-energized"
• Whencoil(1)is"de-energized",thepressurizedoilfromthepumpisblockedbyspool(2).
• Port(C)connectstothetankcircuit.
• Spool(3)ispushedtotherightbyspring(4).
• Port(MA)opensandthepressurizedoilflowsintorotatethemotorinnormaldirection(clockwise).
• Whencoil(1)is"energized",spool(2)switches.
• Thepressurizedoilfromthepumpentersport(C)andflowsintospoolchamber(D).
• Thepressurizedoilinchamber(D)compressesspring(4).
• Spool(3)movestotheleft.
• Port(MB)opensandthepressurizedoilflowsintorotatethemotorinreverse(counterclockwise).
Safetyvalve (ALL-B6G0-001-K-00-A)
Function (PC400-B6G0-042-K-00-A)
• Whentheengineisstarted,thepressureinport(P)ofthefanmotorisincreasedinsomecases.
• Safetyvalve(1)isprovidedinordertoprotectthefansystemcircuit.
Operation (HM400-B6G0-044-K-00-A)
• Whenthepressureinport(P)risesabovethecrackingpressureofsafetyvalve(1),valve(2)ofsafety valve(1)openstoreleasethepressurizedoilintoport(T).
• Thisoperationpreventsgenerationoftheabnormallyhighpressureinport(P).
Centerbrakecoolingremotemotor (HM400-GD7C-034-K-00-A)
Generalview
1.EFterminal
2.EPCvalve
3.TerminalEN
P:Frompump
PEPC:Fromself-pressurereducingvalve
T:Tohydraulictankthroughreturnfilter
TC:Tohydraulictank
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