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00 Index and Foreword
E-3 Automatic Preheating System Does Not Work (For Machines Without Pre-lubrication
E-4
E-5 While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On
E-6 LCD Unit,
E-8
E-9
Machine Monitor is Abnormal 40-2677
E-13 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly 40-2682
E-14 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate ..............40-2687
E-15
E-21
E-22
E-23 Parking Brake Indicator Lamp Does Not Come On When Parking Brake is ON (Parking) Position
E-24 Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low..............................................................................................................................40-2734
E-25 Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is
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00 Index and Foreword
Foreword, Safety, Basic Information
How to Read the Shop Manual
How to Read the Shop Manual
•Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
•The materials and specifications are subject to change without notice.
•Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
•Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
•The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in accordance with the machine.
•For details of the symbols shown on the machine monitor, see STRUCTURE AND OPERATION, “Caution Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
•For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine Monitor”.
•For details of the switches, see the “Operation and Maintenance Manual”.
•All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.
Symbol Item Remark
Danger
Warning
Caution
Weight
Tightening torque
Coat
This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.
This symbol shows the weight of parts and components. Refer to this symbol when you handle heavy object for selection of the required equipment such as crane and lifting tools, and for what kind of working posture to take.
This signal indicates the tightening torque for portions which requires special care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.
Oil and coolantThis signal indicates a place to supply oil, coolant, etc. and the quantity.
DrainingThis signal indicates a place to drain oil, coolant, etc. and the quantity.
Safety
Signal Word
This symbol indicates the works which require special caution for the machine safety when assembling.
Signal word for notice and remark describes the following.
Symbol Item Remark
NOTICE Notice If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur
REMARK RemarkThis signal word contains useful information to know.
Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.
Safety Notice for Operation
•Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purposes.
•The symbol mark is indicated for such matters that require special precautions. The work indicated with this warning mark should be performed according to the instructions with special attention. Should a hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary measures.
Safety Considerations
•Well organized work place
•Correct work clothes
•Observance of work standard
•Enforcement of hand signals
•Prohibition against unlicensed persons operating and handling the machine
•Safety check before starting work
•Wear of dust glasses (for cleaning or grinding work)
•Wear of welding goggles and protectors (for welding work)
•Being in good physical condition, and good preparation
•Always be alert and careful.
General Precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the operation and maintenance manual before operation. Read and understand what is described in this manual before operation.
•Read and understand the meaning of all the safety labels stuck to the machine before performing any greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation and Maintenance Manual.
•Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on the floor. Smoke only in the designated areas. Never smoke while working.
•Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
•Always wear safety shoes and helmet when performing any operation. Do not wear loose clothes, or clothes with buttons missing.
•Always wear the protective eyeglasses when hitting parts with a hammer.
•Always wear the protective eyeglasses when grinding parts with a grinder, etc.
•When performing any operation with multiple workers, always agree on the operating procedure before starting. Be clear in verbal communication, and observe hand signals. Hang “UNDER REPAIR” warning tag in the operator's compartment Before starting work.
•Only the approved personnel can do the work in a closed environment or in a prohibited area.
•Work and operation which require license or qualification should be performed by qualified workers.
•Welding repairs should be performed by trained and experienced welders. When performing welding work, always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
•Warm up before starting the work with exercise which increases alertness and the range of motion in order to prevent injury.
•Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe area.
•When you work in high places, use a platform.
•Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
•Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
•Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
•When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).
•If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the machine has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.
Precautions for Preparatory Work
•Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving before adding oil or making any repairs.
•Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang “UNDER REPAIR” warning tag on them.
•When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
•Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.
Precautions During Work
•For the machine with the battery disconnect switch, check before starting the work that the system operating lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type. For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.
•For the machine with the quick release battery terminal (-), check before starting the work that the system operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-).
•Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.
•When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.
•The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
•Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.
•When raising a heavy component (heavier than 20kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
•When removing a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.
•When removing components, do not break or damage the electrical wiring. Damaged wiring may cause a fire.
•When removing piping, do not spill the fuel or oil. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
•Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in particular.
•Install the disassembled parts again to the original position. Replace the damaged parts or the parts that cannot be used again with new ones. Before you connect the hoses or wiring harnesses, make sure that they do not touch and give damage to other parts when you operate the machine.
REMARK
When you replace the removed or disassembled parts with new ones, refer the parts book to find out the part number.
•When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed.
•When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.
•Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
•Check that the measuring tools are correctly installed when measuring hydraulic pressure.
•Take care when removing or installing the tracks of track-type machines. Since the track shoe may separate suddenly when you remove it, never let anyone stand at either end of the track shoe.
•If the engine is operated for a long time in a closed place with poor ventilation, it may cause gas poisoning. Open the windows and doors to ventilate the place well.
Precautions for Slinging Work and When You Make Signals
•Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely.
k Do not do the work while the lifted load is in the range where it possibly falls. It is not allowed to go in the range where the lifted load possibly falls.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly.
•When you lift or fix the machine, see “Operation and Maintenance Manual” or “Field Assembly Instruction”.
k Do not lift or fix the machine by the positions where the name plate is not attached.
•When you lift the machine for the disassembly and assembly, follow the instructions on the Disassembly and Assembly.
•Check the slings before starting sling work.
•Keep putting on gloves during sling work. (Put on leather gloves, if available.)
•Measure the weight of the load by the eye and check its center of gravity.
•Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.
•Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident.
•Hanging angle must be 60 ° or smaller as a rule.
•When slinging a heavy load (20kg or heavier), the hanging angle of the rope must be narrower than that of the hook.
REMARK
When slinging a load with 2 or more ropes, the force subjected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kgf} vertically, at various hanging angles. When the 2 ropes sling a load vertically, they can sling up to 2000 kg of total weight. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 2000 kg load at a hanging angle of 150 °, each rope is subjected to a force as large as 39.2 kN {4000kgf} .
•When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.
•Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
•Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch system.
k Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.
•Never use a wire rope which has breaks in strands (A), reduced diameter (B), or kinks (C). There is a danger that the rope may break during the towing operation.
Precautions for slinging up
•Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.
•After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
•If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
•Do not lift up the load at an angle.
Precautions for slinging down
•When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
•Check that the load is stable, and then remove the sling.
•Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
Precautions When You Use Mobile Crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely
Precautions When You Use Overhead Traveling Crane
k When raising a heavy component (heavier than 20kg), use a hoist or crane.
Weight of component whose weight is heavier than 20kg is shown with symbol in “Disassembly and Assembly”.
REMARK
The symbol shows the weight of the parts with weight of 20kg or more for convenience of workers. But the weight can possibly be shown even if it is less than 20kg in accordance with the work environment. Do the work safely in response to the work environment and the physical build, preexisting condition, and physical condition of the operator. And obey the laws and regulations of each country.
•Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing caution lamp, and check the following safety items.
•Be sure not to touch the lifting tool and lifted load directly. Use push-pull sticks or tagline ropes.
•Observe the signals for sling work.
•Operate the hoist at a safe place.
•Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button.
•Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
•Do not raise or lower a load while the crane is moving longitudinally or laterally.
•Do not drag a sling.
•When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
•Consider the travel route in advance and lift up a load to a safe height.
•Place the control switch in a position where it is not an obstacle to work and passage.
•After operating the hoist, do not swing the control switch.
•Remember the position of the main switch so that you can turn off the power immediately in an emergency.
•If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition.
•If you find an obstacle around the hoist, stop the operation.
•After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
Select Wire Ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.
Wire Rope (JIS G3525 6x37-A Type) (Standard Z Twist Wire Ropes Without Galvanizing)
Nominal diameter of rope (mm) Allowable load (kN {t} )
Precautions When You Disconnect Air Conditioner Piping
NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.
REMARK
•Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a).
•Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are collecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite.
•When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut.
Precautions for Air Conditioner Piping
•When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
•Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
•Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
•When removing the O-rings, use a soft tool so that the piping is not damaged.
•Check that the O-ring is not damaged or deteriorated.
•Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
REMARK
• The figure shows an example of fitting of O-ring.
•An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see Others, “Precautions for Disconnection and Connection of Air Conditioner Piping”.
Precautions to Prevent Fire
Fire Caused by Fuel, Oil, Coolant or Window Washer Fluid
Do not bring any open flame close to fuel, oil, coolant or window washer fluid. Always observe the following.
•Do not smoke or use any open flame near fuel or other flammable substances.
•Shut down the engine before adding fuel.
•Do not leave the machine when adding fuel or oil.
•Tighten all the fuel and oil caps securely.
•Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.
•After adding fuel or oil, wipe up any spilled fuel or oil.
•Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace.
•When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire.
•Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
•Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
•When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.
Fire Caused by Accumulated or Attached Flammable Objects
•Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
•To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.
Fire Caused by Electrical System
Short circuits in the electrical system can cause fire. Always observe the following.
•Keep all the electric wiring connections clean and securely tightened.
•Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.
Fire from Pipings
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.
Fire Caused by High Temperature Exhaust Gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (regeneration), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not bring any flammable materials close to exhaust pipe outlet.
•When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion Caused by Light
•When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.
•When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual.
Procedures If Fire Occurs
• Turn the starting switch to OFF position to stop the engine.
•Use the handrails and steps to get off the machine.
•Do not jump off the machine. You may fall and suffer serious injury.
•The fumes generated by a fire contain harmful materials which have a bad influence on your body when they are inhaled.
Do not breathe the fumes.
•After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.
Precautions When You Dispose of Waste Materials 00 Index and Foreword
Precautions When You Dispose of Waste Materials
To prevent environmental pollution, be very careful about the disposal of waste materials.
•Always drain the waste into containers such as cans, tanks. Never pour the waste into the ground, or to the river, sewage, sea or lake.
•When disposing of harmful substances such as oil, fuel, cooling water, solvents, filters, batteries, obey the applicable laws and regulations.
Some of the rubber and plastics generate harmful gases that can cause adverse effects on the human body when burned.
•Disposal of rubber, plastic, and other components (hoses, cables, harnesses, etc.) which contains rubber and plastics shall be entrusted to the processing contractor in accordance with applicable laws and regulations.
Engine Technology to Conform Exhaust Gas Emission
This machine complies with regulation Tier4 Final (North America) or StageⅣ (EU) (until 2018), StageV (EU) (after 2019).
The exhaust gas aftertreatment devices that consists of the following systems are installed.
Komatsu Diesel Particulate Filter (hereafter KDPF): Captures and purifies the soot in exhaust gas. To purify the captured soot, the system preforms the soot burning process called "regeneration".
Precautions When You Handle Hydraulic Equipment
Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.
Select an Applicable Workplace
•In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the machine.
Disassembly and Maintenance Work in the Field
k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit and it may result in serious personal injury or death when removing and disassembling of the hydraulic equipment is performed.
k Release the remaining pressure from the hydraulic circuit always before performing the work.
•In the field, there is a risk of dust entering the component during disassembling or maintenance work, and performance check is hardly performed. Replacement of the assembly is recommended.
•Perform disassembling and maintenance work in the dust proof area.
Seal Openings (Prevention of Flowing Out of Oil)
Plug the openings of the piping and the device which have been removed to prevent foreign material from entering and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs.
Preventing Intrusion of Foreign Materials While You Refill
•During refilling with the hydraulic oil, do not let water enter the electrical components.
•Clean the oil filler port and its around, refilling pump, oil jug, or etc.
•Refilling by using an oil cleaning device is better method since it can filtrate the contaminants accumulated in the oil during storage.
Replace Hydraulic Oil While Its Temperature is High
•The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high.
•Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludges, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the circuit.
Do Not Use the Hydraulic Oil and Lubricating Oil Again
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine. If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing Operation
•Flushing is required to completely dislodge the contaminants and sludges, and existing oil containing those inside the hydraulic circuit after disassembling and assembling, and when replacing the oil with the new one.
•Normally, flushing is performed twice. Primary flushing is performed by using the flushing oil (1) and the secondary flushing is performed by using the specified hydraulic oil.
Cleaning Operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine. 00 Index and Foreword
REMARK
The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment cannot remove. So, it is very effective device. Precautions When You Handle Hydraulic Equipment
Index and Foreword
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Precautions When You Disconnect and Connect Pipings
When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and assembly" of the components, observe the following precautions.
Precautions for Removal and Disassembly Work
•If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly.
•After disconnecting the hoses or tubes, plug them to prevent dust from entering.
•When draining oil, prepare a container with sufficient capacity.
•Check the matchmarks which indicate the installing position, and put matchmarks on the places where they seem necessary before removal of the components to prevent any mistake when assembling.
•Hold the wiring connectors when disconnecting the connectors, and do not apply excessive force to the wiring.
•Place tags to the wirings and hoses in order not to install them to wrong positions.
•Check the quantity and thickness of shims when storing shims.
•Prepare the slings with sufficient strength for hoisting the components.
•When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
•Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal.
•To disconnect the face seal type hose from the cylinder tube connected to the cylinder with the face joint seal, loosen it by gripping the two wrenches together, one is the wrench (1) on the hose side, and the other is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only. Check after the hose is disconnected that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.
•After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine.
Introduction of Parts for the Disassembly of the Face Seal Type Hoses and Tubes
Introduction of Parts for the Disconnection of the Taper Seal Type Hoses and Tubes
Introduction of Parts for the Disconnection of the Split Flange Type Hoses and Tubes
Introduction of Parts for the Removal of O-Ring Boss Type Joint
Introduction of Parts for the Removal of Taper Pipe Thread Type Joint
Precautions for Installation and Assembly Work
•Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones. Precautions When You Disconnect and Connect Pipings
• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
•Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.
•Bend the cotter pins and lock plates securely.
•When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to the threaded portion.
•When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dust or damage.
•Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
•Apply engine oil to the rotating parts and sliding surface.
•Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
•After installing the snap ring, check that the snap ring is settled in the ring groove completely.
•When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then connect them securely.
•Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook.
•When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
•As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure.
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape. When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come off. If the sealed tip is pushed outside, it may cause oil leakage.
•To connect the face seal type hose to the cylinder tube connected to the cylinder with the face joint seal, tighten it by gripping the two wrenches together, one is the wrench (1) on the hose side, and the other is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only. Check after the hose is connected that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed, be sure to bleed air from the hydraulic circuit before operating it for the first time according to the following procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximately 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke end for 3 or 4times.
NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air from the hydraulic circuit according to the same procedure.
Precautions When You Disconnect and Connect Pipings 00 Index and Foreword
Precautions at the End Time of Work
Refilling of coolant, oil, and grease
• Supply the specified amount of grease to the work equipment parts.
•When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
•When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.
•If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system. See "TESTING AND ADJUSTING".
Testing installed condition of cylinder heads and manifolds
•Check the cylinder head and intake and exhaust manifold mountings for looseness.
•If there is any looseness, perform re-tightening.
REMARK
For the tightening torques, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the following. (The applications or components of equipment are different depending on its models or specifications.)
•Muffler
•Exhaust pipe
•Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there is any damage, replace the part.
Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the installation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the following. (The applications or components of equipment are different depending on its models or specifications.)
•Muffler
•Exhaust pipe
•Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new If there is any unusual noise, repair muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY". 00 Index and Foreword
Precautions When You Handle Electrical Equipment
To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical equipment".
Handle Wiring Harnesses and Connectors
•Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires.
•Compared with other electrical components fitted in boxes or cases, wiring harnesses are likely to be directly affected by rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling and maintenance of the wiring harnesses.
Main Causes of Failure in Wiring Harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.
Defective crimping or soldering of connectors
The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage.
Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the soldering, or break the wiring harness.
Water entering the connector by high-pressure jetting
The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained. If water enters into the connector, water goes through pins to cause short-circuit. Drying the drenched connector or take appropriate actions before providing electricity.
Water, sand, soil, dust entering the connector when the connector is disconnected
If any water, mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a piece of dry cloth or blow it with compressed air.
Oil, grease, sand, soil, sand attaching to the connector
If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through, resulting in defective contact. If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air and spray it with electrical contact restorer.
NOTICE
•When wiping the jointed portion of the connector, do not apply excessive force or deform the pins.
•If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from.
Precautions When You Handle Fuel System Equipment
The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an Applicable Workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Seal the Opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.
How to Clean Parts When Dirt is Stuck
If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions When You Replace Fuel Filter Cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter other than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
Precautions When You Handle Intake System Equipment
The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an Applicable Workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Seal the Opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.
Practical Use of KOMTRAX
Various information which KOMTRAX system transmits by using the radio communication is useful for KOMTRAX operator to provide various services for the customers.
When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.
Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.
REMARK
(KOMTRAX may not be installed to the machine in some countries or areas.)
Advantage to Use KOMTRAX
•The location where the machine is working at can be checked on the map in a personal computer.
•Operation information such as service meter, operating hours, fuel consumption, and occurred caution as well as failure code can be checked.
•The operator can check the hours used and replacement interval of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
•Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be checked, and it is used to presume the machine operating condition.
•Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is utilized as an advice tool for the user and operator.
•KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the soundness of machine, in addition to KOMTRAX function described above. These data can be used on personal computer screens.
How to Make a Full Use of KOMTRAX
Making use of KOMTRAX enables the following activities.
•Quick response to a request for immediate repair
1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair request from a user.
2. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
3. To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
• Proactive maintenance
1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure code indicated by a red or yellow flag.
2. To check the condition of the machine with the customer and to make a plan to visit.
3. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
• Practice of periodic maintenance and periodic inspection service
1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits for the consumable parts indicated by red flags are over.
2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer
3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to Operate KOMTRAX
For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.
00 Index and Foreword
Disconnect and Connect Push-Pull Type Coupler
Disconnect and Connect Push-Pull Type Coupler
REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
•Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.
How to Disconnect and Connect Type 1 Push-Pull Type Coupler
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating adapter (3).
REMARK
• Push it in approximately 3.5 mm.
•Do not hold rubber cap portion (4).
2. While having adapter (3) inserted into hose side joint (2), insert rubber cap (4) to adapter (3) side until it clicks.
3. Hold hose adapter (1) or hose (5), and pull it out.
REMARK
Provide an oil container to receive a quantity of hydraulic oil which may flow out.
Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).
Disconnect and Connect Push-Pull Type Coupler
2. After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a problem.
How to Disconnect and
Disconnection
00 Index and Foreword
Connect
Type 2 Push-Pull Type Coupler
1. Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
2. While keeping the condition of step 1, turn lever (3) to the right (clockwise).
3. While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil which may flow out.
Connection
Hold the tightening adapter part, and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
and Connect Push-Pull Type Coupler
How to Disconnect and Connect Type 3 Push-Pull Type Coupler
Disconnection
1. Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
2. While keeping the condition of step 1, push cover (3) straight until it contacts contact surface (a) of the hexagonal portion on the male side.
3. While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil which may flow out. 00 Index and Foreword
Disconnect and Connect Push-Pull Type Coupler
Connection
Hold the tightening adapter part, and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
00 Index and Foreword
Precautions for Disconnection and Connection of Connectors
Disconnect Connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the connecting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing the stopper (1) with your thumb.
2. When removing a connector from a clip
•Both of the connector and clip have stoppers (2), which are engaged with each other when the connector is connected.
•When removing a connector from a clip, pull the connector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the right or left, it may break the housing.
3. Action to be taken after removing connectors
After removing the connector, cover it with plastic bags to prevent entry of dust, dirt, oil, or water in the contact portion.
NOTICE
Be sure to cover the connector with plastic bags when leaving the machine disassembled for a long time, otherwise defective contact may occur.
Connect Connectors
1. Check the connector visually.
• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
•Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
•If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is any water intrusion into the connector, warm the inside of the connector and harness with a dryer. Do not overheat the connector, otherwise short circuit may occur.
•If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the wiring harness.
•If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the wiring harness cannot be fixed, remove the clamp to adjust them.
•If the connector clamp is removed, be sure to return it to its original position. Check that there is no looseness.
Dry Wiring Harness
REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.
1. Disconnect the connector and wipe off the water with a dry cloth.
NOTICE
If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow.
2. Dry the inside of the connector with a dryer. If water enters inside the connector, use a dryer to dry the connector.
NOTICE
Hot air from a dryer can be used, but limit the time of using a dryer to prevent the connector or related parts from becoming too hot, as this will cause deformation or damage to the connector.
3. Perform a continuity test on the connector.
After drying, leave the wiring harness disconnected, connect T-adapter(1), and perform a continuity test to check for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact restorer, and reassemble them.
Handle Controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
NOTICE
•Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine.
•Do not leave things on the controller.
•Cover the connector portion of the controller with a tape and a plastic bag. Do not touch the connecting portion of connector.
•Do not leave the controller in a place where it is exposed to rain.
•Do not place the controller on oil, water, soil or any places where the temperature is likely to be high even for a short period of time (Place it on a suitable dry stand).
Precautions for Troubleshooting Electrical Circuits
•Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
•Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
•Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated failure beside the actual failed part may be displayed.
•When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.
How to Disconnect and Connect Deutsch Connector
Disconnect DEUTSCH Connector
While pressing locks (a) and (b) from each side respectively, pull out female connector (2).
Connect DEUTSCH Connector
1. Push in female connector (2) horizontally, and insert it straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely. 00 Index and Foreword
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward you, push up portion A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.
How to Connect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2)
Insert it straight until it clicks.
How to Disconnect Slide Lock Type Connector (FRAMATOME-24)
1. Slide down lock (red) (L1).
2. While pressing lock (L2), pull out connector (1).
REMARK
Lock (L2) is located behind connector (1) in the figure.
How to Connect Slide Lock Type Connector (FRAMATOME-24)
Insert it straight until it clicks. 00 Index and Foreword
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect Connector with Lock to Pull
Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
How to Connect Connector with Lock to Pull
Insert the connector securely until it “clicks”.
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect Connector with Lock to Push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow •114 series
REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
How to Connect Connector with Lock to Push (BOSCH-3)
Insert it straight until it clicks.
How to Disconnect Connector with Lock to Push (AMP-3)
While pressing lock (E), pull out connector (5) in the direction of the arrow.
How to Connect Connector with Lock to Push (AMP-3)
Insert it straight until it clicks.
How to Disconnect Connector with Lock to Push (SUMITOMO-3)
While pressing lock (E), pull out connector (5) in the direction of the arrow.
REMARK
Pull up the connector straight.
How to Connect Connector with Lock to Push (SUMITOMO-3)
Insert it straight until it clicks.
How to Disconnect Connector with Lock to Push (SUMITOMO-4)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
How to Connect Connector with Lock to Push (SUMITOMO-4)
Insert it straight until it clicks.
How to Disconnect and Connect Connector with Housing to Rotate
How to Disconnect Connector with Housing to Rotate
Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.
Connect Connector with Housing to Rotate
1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.
Standard Tightening Torque Table
Table of Tightening Torque for Bolts and Nuts
REMARK
Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.
Thread diameter (mm)
6
12
*1: Split flange bolt
*2: Flanged bolt
REMARK
Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in the table below. Standard Tightening Torque Table
{23.5 to 29.5} (*1) 22
{33 to 41}
to 58}
to 78}
Thread diameter (mm)
Width across flats (mm) Tightening torque (Nm {kgfm} ) 6 10 5.9 to 9.8 {0.6 to 1.0} 8 12 13.7 to 23.5 {1.4 to 2.4}
14 34.3 to 46.1 {3.5 to 4.7} 12 17 74.5 to 90.2 {7.6 to 9.2}
REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
Type of bolt
1/4-20UNC 9.8 to 14.7 {1 to 1.5}12.7 {1.3}2.9 to 3.9 {0.3 to 0.4}3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5}29.4 {3}6.9 to 8.8 {0.7 to 0.9}7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6}52.0 {5.3}9.8 to 14.7 {1 to 1.5}11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10}86.3 {8.8}19.6 to 24.5 {2 to 2.5}21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15}127 {13}29.4 to 39.2 {3 to 4}34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22}186 {19}44.1 to 58.8 {4.5 to 6}51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30}265 {27}63.7 to 83.4 {6.5 to 8.5}68.6 {7}
3/4-10UNC 392 to 530 {40 to 54}461 {47}108 to 147 {11 to 15}127 {13}
7/8-9UNC 637 to 853 {65 to 87}745 {76}177 to 235 {18 to 24}206 {21}
Type of bolt
Nominal sizethreads per inch Tightening torque (Nm {kgfm} )
torque (Nm {kgfm} )
1-8UNC 883 to 1196 {90 to 122}1040 {106}245 to 333 {25 to 34}284 {29}
11/8-7UNC 1187 to 1608 {121 to 164}1393 {142}333 to 451 {34 to 46}392 {40}
11/4-7UNC 1598 to 2157 {163 to 220}1873 {191}451 to 608 {46 to 62}530 {54}
11/2-6UNC 2354 to 3177 {240 to 324}2765 {282}657 to 892 {67 to 91}775 {79}
REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
Type of bolt
1/4-28UNF 14.7 to 19.6 {1.5 to 2}17.7 {1.8}3.9 to 4.9 {0.4 to 0.5}4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4}34.3 {3.5}7.8 to 9.8 {0.8 to 1}8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7}61.8 {6.3}14.7 to 19.6 {1.5 to 2}16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11}96.1 {9.8}24.5 to 29.4 {2.5 to 3}26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17}147 {15}34.3 to 49.0 {3.5 to 5}41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25}216 {22}49.0 to 68.6 {5 to 7}58.8 {6}
5/8-18UNF 255 to 343 {26 to 35}294 {30}73.5 to 98.1 {7.5 to 10}83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61}520 {53}127 to 167 {13 to 17}147 {15}
7/8-14UNF 716 to 961 {73 to 98}843 {86}196 to 265 {20 to 27}226 {23}
1-14UNF1020 to 1373 {104 to 140}1196 {122}284 to 382 {29 to 39}333 {34}
11/8-12UNF 1353 to 1844 {138 to 188}1598 {163}382 to 520 {39 to 53}451 {46}
11/4-12UNF 1804 to 2432 {184 to 248}2118 {216}510 to 686 {52 to 70}598 {61}
11/2-12UNF 2707 to 3658 {276 to 373}3177 {324}765 to 1030 {78 to 105}892 {91}
Table of Tightening Torque for O-Ring Boss Piping Joints
REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.
0420
0624
1233
depending on type of connector
Table of Tightening Torque for O-Ring Boss Plugs
REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.
Standard Tightening Torque Table 00 Index and Foreword
Table of Tightening Torque for Hose (Taper Seal Type and Face Seal Type)
REMARK
•Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table unless otherwise specified.
•The table is applied to the threaded portion coated with engine oil (wet threaded portion).
(10)41 177 to 245 {18.0 to 25.0}216 {22.0}33
(12)46197 to 294 {20.0 to 30.0}245 {25.0}36
(14)55246 to 343 {25.0 to 35.0}294 {30.0}42
Table of Tightening Torque for Face Seal Joints
REMARK
•The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated low pressure piping which is used for engine.
•The table is applied to the threaded portion coated with engine oil (wet threaded portion).
•Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.
ameter of adequate pipe (mm)
Tightening Torque Table for Bolts and Nuts on 102, 107 and 114 Series Engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table unless otherwise specified. Thread
Tightening Torque Table for 102, 107, and 114 Series Engines (Joint Bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following table unless otherwise specified.
Tightening Torque Table for Tapered Screws on 102, 107, and 114 Series Engines (National Taper Pipe Thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
{4.59±0.51} Standard Tightening Torque Table 00 Index and Foreword
{1.53±0.20}
{0.51±0.10} 1/8
/4
3/8
{2.04±0.20}
{2.55±0.31}
{3.57±0.41}
{1.53±0.20}
{2.04±0.20}
{2.55±0.31}
1/2 55±6 {5.61±0.61} 35±4 {3.57±0.41}
3/4
{7.65±0.82}
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Conversion Table
How to Use the Conversion Table
The conversion table is provided to enable simple conversion of the numerical numbers between the different units. For further details of the method of using the conversion table, see the examples given below
Examples to Use the Conversion Table to Change a Unit from mm to
in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left) to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point one place to the right) to restore the target value. This gives 550 mm = 21.65 in mm to in
•A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures in the center of the following table show the temperatures in both Fahrenheit and Celsius.
•When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
•When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.
•This list of abbreviations includes the abbreviations for functions, devices, and parts which are used in the shop manual.
•Commonly used abbreviations are not included.
•Special abbreviations which are not shown frequently are included in the text as additional information.
List of Abbreviations Used in the Text
AbbreviationActual word spelled out
AJSS Advanced Joystick Steering System
Explanation
AJSS is a function that allows operators to drive the machine forward and reverse, operate steering, and shift the gear by use of the joystick. The right or left tilt of the joystick links the steering angle of the machine body.
APIAmerican Petroleum InstituteAPI is the abbreviation for American Petroleum Institute.
BOCBolt-On Cutting edge
CANController Area Network
CDR valve Crankcase Depression Regulator valve
CLSS Closed-center Load Sensing System
CRICommon Rail Injection
DEFDiesel Exhaust Fluid
ECMElectronic Control Module
ECMV Electronic Control Modulation Valve
ECSS Electronically Controlled Suspension System
ECUElectronic Control Unit
EGRExhaust Gas Recirculation
EPC Electromagnetic Proportional Control
EPCElectrical Pressure Control
FOPS Falling Object Protective Structure
GNSS Global Navigation Satellite System
BOC is a cutting edge that is attached with bolts to the bucket.
CAN is one of networks that communicate between the machine monitor and controllers.
CDR valve is a valve that is attached to the KCCV ventilator.
CLSS is a hydraulic system that provides total control over the pumps, valves, and actuators. When actuators are in neutral, pump circuits are closed.
CRI is a function that is composed of the supply pump, common rail, and injector, and that controls the fuel injection rate and injection timing.
DEF is a urea solution that is used for the SCR system.
ECM is an electronic device that controls actuators adequately with signals from sensors.
ECMV is a device that controls the connection and disconnection of clutches of the transmission and brake.
ECSS is a function that decreases bucket vibration during travel to reduce load spillage and operator's fatigue.
ECU is an electronic device that controls actuators adequately with signals from sensors.
EGR is a function that recirculates part of exhaust gas to the intake side to control NOx emissions.
HST is a device that is composed of the hydraulic pump and motor, and that controls the forward and reverse travel of the machine and the shift of speed range without gears. Abbreviation List
EPC is a function that controls the pressure of the hydraulic circuit in proportion to the electric current.
EPC is a function that controls the pressure of the hydraulic circuit in proportion to the electric current.
FOPS is a structure that protects operators from falling objects.
GNSS is a general term for satellite positioning systems.
GPSGlobal Positioning SystemGPS is one of satellite positioning systems.
HSTHydroStatic Transmission
AbbreviationActual word spelled out
IMAInlet Metering Actuator
IMVInlet Metering Valve
KCCV KOMATSU Closed Crankcase Ventilation
Explanation
IMA is a device that controls fuel intake volume at the inlet of the supply pump.
IMV is a device that controls fuel intake volume at the inlet of the supply pump.
KCCV is a function that isolates oil from blowby gas in the engine and returns the blowby gas to the intake side.
KCSFKOMATSU Catalyzed Soot FilterKCSF is a filter that catches soot in exhaust gas.
KDOC KOMATSU Diesel Oxidation Catalyst KDOC is a device that purifies exhaust gas.
KDPF KOMATSU Diesel Particulate Filter
KOWAKomatsu Oil and Wear Analysis
KTCS KOMATSU Traction Control System
LINLocal Interconnect Network
LSLoad Sensing
MAF sensorMass Air Flow sensor
NCNormally Closed
NONormally Open
PCPressure Compensation
KDPF is a device that is composed of the KCSF and KDOC, and catches soot (Particulate Matter, PM) in exhaust gas.
KOWA is a preventive maintenance service that collects and analyzes oil in the machine at the specified interval so that wear of the machine and other problems can be found at short time.
KTCS is a function that prevents tire slip to keep the driving force.
LIN is one of networks that communicate between controllers and sensors or actuators.
LS is a function that senses the load pressure of actuators and controls hydraulic pumps.
MAF sensor is a device that measures the engine intake air flow.
NC is an electrical circuit where contact pair is closed while the device is not in operation.
NO is an electrical circuit where contact pair is open while the device is not in operation.
PC is a function that controls discharged volume of the hydraulic pump by use of the discharged pressure.
PCSProportional Control SwitchPCS is a device that provides fine control of the work equipment.
PCVPressure control valve
PPCProportional Pressure Control
PTOPower Take Off
ROPSRoll-Over Protective Structure
SCRSelective Catalytic Reduction
PCV is a device that controls fuel discharged volume at the outlet of the supply pump.
PPC is a function that controls the pressure of the hydraulic circuit in proportion to the degree of the lever operation.
PTO is a mechanism that takes out the engine power.
ROPS is a structure that protects operators from falling objects or in the event of a machine roll-over
SCR is a device that purifies nitrogen oxides (NOx) in exhaust gas from the engine.
VGTVariable Geometry TurbochargerVGT is a variable type turbocharger.
List of Abbreviations Used in the Circuit Diagrams
Abbreviation Actual word spelled out
A/CAir Conditioner
A/DAnalogue-to-Digital
A/MAir Mix damper
ACCAccessory
Abbreviation List
Abbreviation Actual word spelled out
ADDAdditional
AUXAuxiliary
BRBattery Relay
CWClockwise
CCWCounter Clockwise
ECUElectronic Control Unit
ECMElectronic Control Module
ENGEngine
EXGNDExternal Ground
F.G.Frame Ground
GNDGround
IMAInlet Metering Actuator
NCNo Connection
S/T Steering STRG
SIGSignal
SOLSolenoid
STDStandard
OPT Option
OP
PRESSPressure
SPECSpecification
SWSwitch
TEMPTemperature
T/CTorque Converter
T/MTransmission
01 Specifications
Specifications
Specification Drawing
Specification Drawing WA800-8E0
(heaped, with tooth)
Engine model -Komatsu SAA12V140E-7 diesel engine
Engine rated horsepower kW {HP}/ min-1{rpm}
• SAE J1995 (gross) (*1)
• ISO 14396
• ISO 9249/SAE J1349 (net) (*2)
638.4{856.1}/2025{2025}
638.4{856.1}/2025{2025}
637.2{854.5}/2025{2025}
AOverall length (with tooth) mm 15205
BOverall height (top of ROPS) mm 5600
C Overall height when bucket is raised maximum mm 9495 DOverall width
G Dumping clearance (*3) Bucket end/tooth endmm 5145/4715
I Bucket angle in forward tilt (maximum position) Degree 49
Minimum turning radius (*4)
Allowable towing load
Travel speed (P mode)
Tooth end mm 11610 Center of outside tiremm 9880
{67800}
1st (forward/reverse)
2nd (forward/ reverse)
3rd (forward/reverse)
*1: Shows the value of the bare engine (without cooling fan).
*2: Shows the value at the minimum cooling fan speed.
REMARK
•The engine rated horsepower is shown in the net value and gross value. Gross is the rated horsepower measured on the basic engine unit while net is the value measured of an engine in the condition nearly the same as that when it is installed on a machine.
•The rated horsepower (net) at the maximum cooling fan speed is the value that follows. 594 kW{796.5 HP}/2025 min-1{2025 rpm}
*3: Shows the value when the bucket angle is 45 ° tilted forward.
*4: At 38 deg. of a maximum steering angle limit (It is set by STEERING STOPPER BOLT).
Specification Drawing WA900-8E0
Bucket capacity (heaped, with tooth) m3 13
Engine model -Komatsu SAA12V140E-7 diesel engine
Engine rated horsepower kW {HP}/ min-1{rpm}
• SAE J1995 (gross) (*1)
• ISO 14396
• ISO 9249/SAE J1349 (net) (*2)
672{901}/2050{2050}
672{901}/2050{2050}
671{899}/2050{2050}
AOverall length (with tooth) mm 15355
BOverall height (top of ROPS) mm 5600
C Overall height when bucket is raised maximum mm 9780
DOverall width mm 4585
EMinimum ground clearance mm 485
FBucket width mm 4935
G Dumping clearance (*3) Bucket end/tooth endmm 5040/4610
I Bucket angle in forward tilt (maximum position) Degree 49
Minimum turning radius (*4)
Tooth end mm
Center of outside tiremm
Allowable towing load kN {kgf}
Travel speed (P mode)
{69900}
1st (forward/reverse) km/h
2nd (forward/ reverse)
3rd (forward/reverse)
*1: Shows the value of the bare engine (without cooling fan).
*2: Shows the value at the minimum cooling fan speed.
REMARK
•The engine rated horsepower is shown in the net value and gross value. Gross is the rated horsepower measured on the basic engine unit while net is the value measured of an engine in the condition nearly the same as that when it is installed on a machine.
•The rated horsepower (net) at the maximum cooling fan speed is the value that follows. 620 kW{831 HP}/2050 min-1{2050 rpm}
*3: Shows the value when the bucket angle is 45 ° tilted forward.
*4: At 38 deg. of a maximum steering angle limit (It is set by STEERING STOPPER BOLT).
Machine
(front wheels and rear wheels)
Machine weight (front wheels) SAE travel posture
Machine weight (rear wheels) SAE travel posture
Performance
Gradeability
(center
*1: At 38 deg. of a maximum steering angle limit (It is set by STEERING STOPPER BOLT).
Dimensions
Dumping clearance (*1) (Bucket end/tooth end) mm 5145/4715
Dumping reach (*1) (Bucket end/tooth end) mm 2295/2580
Steering angle Degree 40
Bucket angle in forward tilt (maximum position) Degree 49
*1: Shows the value when the bucket angle is 45 ° tilted forward.
Engine
Model -
SAA12V140E-7
Type4-cycle, water-cooled, V type (12-cylinder), direct injection, with variable geometry turbocharger, air-cooled aftercooler, and water-cooled EGR
No. of cylinders - bore x stroke mm 12 - 140 x 165
Total piston displacement ℓ {cc} 30.48 {30480}
Performance P mode
Engine rated horsepower
• SAE J1995 (gross) (*1)
• ISO14396
• ISO 9249/SAE J1349 (net) (*2)
Maximum torque (*2)
kW {HP}/ min-1{rpm}
Nm{kgfm}/ min-1{rpm}
638.4{856.1}/2025{2025}
638.4{856.1}/2025{2025}
637.2{854.5}/2025{2025}
3805{388}/1400{1400}
Fuel consumption ratio at rated horsepower g/kWh{g/HPh} 216 {161}
Max. speed with no load min-1{rpm}
Min. speed with no load
2200 {2200}
680 {680}
Starting motor - 24 V, 11 kW x 2 pieces
Alternator - 24 V, 140 A
Battery (*3) - 12 V, 200 Ah x 4 pieces
*1: Shows the value of the bare engine (without cooling fan).
*2: Shows the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is shown in the 5-hour rate.
REMARK
The engine rated horsepower is shown in the net value and gross value. Gross is the rated horsepower measured on the basic engine unit while net is the value measured of an engine in the condition nearly the same as that when it is installed on a machine.
• The rated horsepower (net) at the maximum cooling fan speed is the value that follows. 594 kW{796.5 HP}/2025 min-1{2025 rpm}
Power train
Torque converterType 3-element, 1-stage, 1-phase
Transmission
- Type
Planetary type, constant mesh type, multiple disc type, hydraulic type, and modulation type
Number of speeds 3 forward and 3 reverse speeds
Speed reduction gearType
Spiral bevel gear type, splash lubrication type
DifferentialType Spur bevel gear type
Final driveType Planetary gear, 1-stage reduction type, splash lubrication type
Axle
Axle typeDrive shaft
Front wheels
Front and rear wheel drive
Frame fixed type, full floating type
Rear wheels Center pin support and full floating type
Tire Size -
Rim size
Tire inflation pressure
Front wheels
Rear wheels
Brake
Main
Braking type
Braking type
Operating type
kPa {kgf/cm2}
45/65R45★★
36.00 x 45WTB
650{6.6}
650{6.6}
4-wheel brake type, front and rear wheel separate system
brake type
Sealed, wet, disc type
Hydraulic actuation type
Operating method With hydraulic boost device
Parking -
Braking type
Transmission output shaft brake type
Braking type Wet, disc type
Operating type
Steering
Spring-control type, hydraulic release type
Steering typeArticulated type
Operating type
Hydraulic operation type
Hydraulic system
Pump assembly (to lubricate transmission and torque converter)
Type -Gear type
Discharged volume
Steering pump
Type
Discharged volume
Work equipment pump
3/rev 115 + 115 + 115
-Variable displacement swash plate tandem piston type
3/rev
x 2
Type -Variable displacement swash plate tandem piston type
Discharged volume
Cooling fan pump
3/rev
x 4
Type -Variable displacement swash plate piston type
Discharged
Secondary steering pump
Cooling pump
Pump assembly ( brake cooling) Type
Pilot and brake charge pump Type
Control valve
Type
Steering valve
Steering cylinder Type
type
type
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Lift cylinder
Bucket cylinder
Cooling fan motor
Type -Fixed displacement, swash plate, piston type
Work equipment
Link typeZ-bar single link
Bucket blade edge shape Spade nose with tooth
Specifications WA900-8E0
(front wheels and rear wheels)
Machine weight (front wheels) SAE travel posture
Machine weight (rear wheels) SAE travel posture
Performance
Travel
when torque converter is operated
Minimum turning radius (center of outside tire) (*1)
*1: At 38 deg. of a maximum steering angle limit (It is set by STEERING STOPPER BOLT).
Dimensions
Dumping reach (*1) (Bucket end/tooth end)
Steering angle Degree 40
Bucket angle in forward tilt (maximum position) Degree 49
*1: Shows the value when the bucket angle is 45 ° tilted forward.
Engine
Model
Type
SAA12V140E-7
4-cycle, water-cooled, V type (12-cylinder), direct injection, with variable geometry turbocharger, air-cooled aftercooler, and water-cooled EGR
No. of cylinders - bore x stroke mm 12 - 140 x 165
Total piston displacement
{cc} 30.48 {30480}
Performance P mode
Engine rated horsepower
• SAE J1995 (gross) (*1)
• ISO14396
kW {HP}/ min-1{rpm}
672{901}/2050{2050}
672{901}/2050{2050}
• ISO 9249/SAE J1349 (net) (*2) 671{899}/2050{2050}
Maximum torque (*2)
Nm{kgm}/ min-1{rpm}
4154{424}/1300{1300}
Fuel consumption ratio at rated horsepower g/kWh{g/HPh} 216 {161}
Max. speed with no load min-1{rpm} 2200 {2200}
Min. speed with no load 680 {680}
Starting motor - 24 V, 11 kW x 2 pieces
Alternator - 24 V, 140 A
Battery (*3) - 12 V, 200 Ah x 4 pieces
*1: Shows the value of the bare engine (without cooling fan).
*2: Shows the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is shown in the 5-hour rate.
REMARK
The engine rated horsepower is shown in the net value and gross value. Gross is the rated horsepower measured on the basic engine unit while net is the value measured of an engine in the condition nearly the same as that when it is installed on a machine.
• The rated horsepower (net) at the maximum cooling fan speed is the value that follows. 620 kW{831 HP}/2050 min-1{2050 rpm}
Power train
Torque converter -
Type
Transmission
Type
Number of speeds
Speed reduction gear
Type
3-element, 1-stage, 1-phase
Planetary type, constant mesh type, multiple disc type, hydraulic type, and modulation type
3 forward and 3 reverse speeds
Spiral bevel gear type, splash lubrication type
DifferentialType Spur bevel gear type
Final driveType Planetary gear, 1-stage reduction type, splash lubrication type
Axle
Axle type
Drive shaft
Front wheels
Rear wheels
Tire
Size -
Front and rear wheel drive
Frame fixed type, full floating type
Center pin support and full floating type
45/65R45★★
Rim size 36.00 x 45WTB
Tire inflation pressure
Front wheels
Rear wheels
Brake
Main
Braking type
Braking type
Operating type
kPa {kg/cm2}
650{6.6}
650{6.6}
4-wheel brake type, front and rear wheel separate system brake type
Sealed, wet, disc type
Hydraulic actuation type
Operating method With hydraulic boost device
Parking
Braking type
Transmission output shaft brake type
Braking type Wet, disc type
Operating type
Steering
Spring-control type, hydraulic release type
Steering typeArticulated type
Operating type
Hydraulic operation type
Hydraulic system
Pump assembly (to lubricate transmission and torque converter)
Type -Gear type
Discharged volume
Steering pump
3/rev 115 + 115 + 115
Type -Variable displacement swash plate tandem piston type
Discharged volume
Work equipment pump
3/rev 116 x 2
Type -Variable displacement swash plate tandem piston type
Discharged volume
Cooling fan pump
3/rev
x 4
Type -Variable displacement swash plate piston type
Discharged
Secondary steering pump
Pump assembly ( brake cooling)
Type
Pilot and brake charge pump
Control valve
Type
Steering valve Type
Steering cylinder
Type
type
Lift cylinder
Bucket cylinder
Type -Double-acting piston
Cooling fan motor Type
Work equipment
Link typeZ-bar single link
Bucket blade edge shape Spade nose with tooth
Weight Table
Weight Table WA800-8E0
k This weight table is for your reference when you handle or transport the components.
k This weight table shows the dry weight.
•
•
• Tire (45/65R45★★L-5) (1 piece)
• Rim (36.00 x 45WTB) (1 piece)
Weight Table WA900-8E0
k This weight table is for your reference when you handle or transport the components.
k This weight table shows the dry weight.
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Fuel, Coolant, Lubricant
How to Use Fuel, Coolant and Lubricants by Ambient Temperature
Reservoir
Engine oil pan
Engine oil for KDPF used in cold terrain (Oil Change interval 250 hours) (Note 1)
Engine oil for KDPF (Oil Change interval 500 hours)
Specified capacity is the total quantity of fluid that includes the fluid in the tank and the piping. Refill capacity is the quantity of fluid needed to fill the system during inspection and maintenance.
Note 1: KDPF engine oil for cold district and its filter cartridge must be replaced each 250 hours.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Axle oil AXO80 is capable to prevent the creak sound of the brake. When only AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.
If the daily operation hours of the machine at ambient temperature 45 °C or more are 12 hours, TO50 is recommended as an alternative for AXO80. If TO50 is used, the brake possibly creak, but there is no problem in the performance and durability of the brake.
Note 4: Hyper grease (G2-TE) is the high performance product. It can prevent creaks of pins and bushings.
Note 5: Non-Amine Engine Coolant (AF-NAC)
1. The coolant has the function to prevent corrosion and freeze. Even the machine is operated in an area where freeze is not an issue, use coolant. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent corrosion resistance, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. If you use coolant that is not recommended, it can cause dangerous defect such as the corrosion of the cooling system or engine.
2. Use the diluted Non-Amine Engine Coolant (AF-NAC). The supplied Non-Amine Engine Coolant (AF-NAC) is already diluted with pure water. Do not dilute NonAmine Engine Coolant with water.
Coolant Density Table
Min. atmospheric temperature (°C) -10 or more -15-20-25-30-35-40-45-50
Density (%) 303641465054586164
10 Structure and Function
Table of Contents
NOx Control System
Function of NOx Control System
Inducement Strategy
•The purpose of inducement is to prompt the operator to do the maintenance or repair on the emissions control system (NOx control system).
•Inducement strategy is a control function to ensure immediate correction of various failures in the engine emissions control system. It requires actions to limit engine performance and defines required indication such as warning lamps and messages, alarms while the control actions are imposed.
•The categories of abnormalities that causes Inducement are shown on the “NOx Control System Information” screen of the machine monitor.
Inducement Strategy When Abnormality is Found in the EGR System (EU Specification)
The table shows warning indications and engine power derations by each Inducement strategy status.
Display on machine monitor
Status Elapsed time (*1)
1Warning5 hours
Message of NOx control system (A) Caution lamp Action level Alarm buzzer sound
Red
1: EGR system inspection and maintenance
Long intermittently
Failure code for current abnormality (*2) (*3)
Failure code for Inducement strategy status (*4)
Engine deration (*5)
CA2271 CB2271 No display
Torque reduction rate: 25% or more Red
Red
2 Continuous Warning (Warning 2) 10 hours
2: EGR system inspection and maintenance
Long intermittently
CA2271 CB2271
AS00R2 (Warning 2 (NOx Control Device Abnormality))
Torque reduction rate: 25% or more
Yellow Red
3
Status
Elapsed time (*1)
Display on machine monitor
Message of NOx control system (A) Caution lamp Action level Alarm buzzer sound
Low-Level Inducement (Inducement 1) 20 hours
3: EGR system inspection and maintenance
Long intermittently
4
Severe Inducement (Inducement 2)
Until abnormality is repaired
4: Engine power is under heavy deration.
Continuously
Failure code for current abnormality (*2) (*3)
Failure code for Inducement strategy status (*4)
Engine deration (*5)
CA2271 CB2271
CA2271
CB2271
AS00R3 (Inducement 1 (NOx Control Device Abnormality))
Torque reduction rate: 25% or more
AS00R4 (Inducement 2 (NOx Control Device Abnormality))
Torque reduction rate: 50% or more
Engine speed reduction rate: 40% or more Red Red
*1: Elapsed time of each stage shows an accumulated time to advance to the next stage after “Warning” stage is started.
*2: The failure code is shown on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. The failure code shown here is an example of failure code when an abnormality occurs. For the failure codes, see Troubleshooting, “Troubleshooting Points for Aftertreatment System”, “Table of Failure Codes that is Applied to Inducement”.
*3: The failure code which starts with CB can be shown for the machine with aftertreatment devices branching off to 2 lines.
*4: The failure code is shown on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode.
*5: The percentage of torque shows a torque reduction ratio from the full torque curve. The percentage of engine speed shows an engine speed reduction ratio from the rated speed.
Function of Temporary Restoration from Inducement (EU Specification)
•Temporary restoration from Inducement during warning status is one of the Inducement strategies allowed to be included in the NOx control system. In case the NOx control system advances to “Severe
Red Red
Inducement”, engine power is derated heavily. This can cause difficulties to move the machine to a safe place for the maintenance and repair of the machine. For temporary remedies from these difficulties, the operator can restore engine power for a short time to the deration of “Low-Level Inducement” on the machine monitor. Temporary restoration from Inducement does not regain full engine power.
•“Temporary Restoration from Inducement” can be activated only when the machine is in “Severe Inducement”. The maximum operation period is up to 30 minutes in each restoration operation, and 3 operations can be done. All the abnormalities of the system need to be corrected to regain restoration capability
•To activate Temporary Restoration, see OPERATION, “Temporary Restoration from Inducement” in the Operation & Maintenance Manual.
Inducement Strategy for Abnormality Recurrence (EU Specification)
•The NOx control system continuously monitors its operation conditions and stores information on abnormal operations and malfunctions.
•The stored information is used to monitor recurrences of abnormalities. Those information are required by the authorities. The abnormality counting spans 40 hours and it monitors the abnormalities that trigger Inducement.
•If another abnormality is sensed within 40 hours after the previous abnormalities were corrected, regardless of the level of the previous Inducement and whether the new abnormality is the same as the previous ones or not, it is judged as a recurrence.
•If a recurrence occurs, the Inducement strategy will be activated.
•If the previous corrected abnormality is “Warning”, “Continuous Warning”, or “Low-Level Inducement”, the alerts resume from the previous Inducement.
•If the previous corrected abnormality is “Severe Inducement”, the alerts resume from “Low-Level Inducement”, but the remaining time to “Severe Inducement” is 1 hour. If the 1 hour is used up without correcting the new abnormality, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.
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Boot-up System
Layout Drawing of Boot-up System
1: KomVision controller (*1)
2: KOMTRAX Plus controller
3: KOMTRAX terminal
4: Work equipment controller
*1: For machines with KomVision
5: Monitor controller
6: Transmission controller
7: Fuse box
8: Engine shutdown secondary switch
9: Engine controller-B (right bank)
10: Engine controller-A (left bank)
11: Battery
12: Battery disconnect lamp
13: System operating lamp
*2: For machines with starting motor disconnect switch
*3: For emergency engine stop switches.
14: Emergency engine stop switch (left) (*3)
15: Starting motor disconnect switch (*2)
16: Battery disconnect switch
17: Circuit breaker
18: Emergency engine stop switch (right) (*3)
Pre-lubrication System
(Machines with pre-lubrication system)
Pre-lubrication System Diagram
1: Starting switch
2: Relay (neutral safety)
3: Relay (starting motor)
4: Starting motor
5: Pre-lube pump
6: Engine oil pressure switch
7: Relay (pre-lube)
8: Pre-lube motor
9: Ribbon heater
Function of Pre-lubrication System
10: Relay (heater)
11: Relay (engine preheating)
12: Relay (preheating)
13: Transmission controller
14: Engine controller
15: Monitor controller
16: Pressure sensor (engine oil pressure)
17: Temperature sensor (engine coolant temperature)
18: Pre-lube selector connector
In the pre-lubrication system, the transmission controller receives sensor signals through the network. The signals are transmitted from the sensors installed on the engine oil pressure switch and the engine parts. Before the engine starts, the pre-lube motor operates the pre-lube pump to lubricate each part of the engine. The system lubricates the parts before the engine starts. It reduces wear, and prevents seizure of the parts. The engine parts are lubricated after the periodic maintenance or the long term storage.
1. Input and output of the transmission controller
2. System flow of the pre-lubrication system
The system flow overview of the transmission controller is as follows.
Operation of Pre-lubrication System
When the starting switch of the machine is turned to the START position, the pre-lube function operates. The operation time changes in response to the status of the engine oil pressure switch or the engine oil temperature.
1. Status judgment of the engine oil pressure switch
The transmission controller recognizes the stopped state of the pre-lube operation by the signal of the engine oil pressure switch.
Oil pressure switch
Pressure threshold
Without pressure (CLOSE) Below 29.4 Pa (0.3 kg/cm2)
With pressure (OPEN)
2. Judgment of operation time
29.4 Pa (0.3 kg/cm2) or above
Status judgment
Pre-lube required
Pre-lube stopped (not required)
Maximum pre-lube operation time is set by the signal of the temperature sensor (engine oil) that is taken through the network.
Engine oil temperature Maximum operation time
44 °C or below 60 seconds
45 °C or above 10 seconds
3. Conditions to complete pre-lube
When all the conditions that follow are satisfied, the system recognizes that pre-lube is completed and the pre-lube operation stops.
•When the signal of the engine oil pressure switch is "with pressure" (OPEN) regardless of the remaining operation time after pre-lube starts to operate.
•When the engine oil temperature is 45 ºC or more, and after 10 seconds from the start of the pre-lube operation
•When the engine oil temperature is 44 ºC or below, and after 60 seconds from the start of the pre-lube operation
•When the engine oil temperature is 44 ºC or below, after 10 seconds from the start of the pre-lube operation, and a problem is found in the network
•If a failure is sensed on the relay (pre-lube)
4. Engine startup permission
When the pre-lube stops by the satisfied conditions to complete pre-lube, the transmission controller outputs the engine startup permission signal for 70 seconds. You can crank during the period if you turn the starting switch to the START position again.
But you cannot start the engine until the permission signal of the engine startup is output. Also, if the engine does not start for 70 seconds, pre-lube operation is required again.
5. Operation display
The status of the pre-lube function is shown with the pilot lamp on the monitor
State Pilot lamp
Pre-lube operation in standby Lit
During pre-lube Lit
Pre-lube is completed Not lit
Operation conditions
From the starting switch is turned to the ON position to pre-lube actuation
Pre-lube in operation
Pre-lube is completed
Preheating Function
For machines with pre-lubrication system, the transmission controller controls the preheating function as the alternative of the engine controller.
By this control, the timing of the start of the preheating operations changes to the time when the pre-lube complete conditions are established from the time when the starting switch is turned to the ON position.
Automatic preheating of the machine with the pre-lubrication system is operated as one of the pre-lube function. Manual preheating is not operated because the circuit is disconnected at the pre-lube selector connector.
Preheating operation time changes in response to the engine coolant temperature. Operation time is as follows.
REMARK
If preheating is done manually, an error is sensed and a failure code is shown.
System Operating Lamp System
System Diagram of System Operating
Lamp System
1: Battery disconnect switch
2: Battery
3: Circuit breaker
4: Fuse box
5: System operating lamp
6: Monitor controller
*1: For machines with KomVision
Function of Operation Lamp System
7: Engine controller
8: Transmission controller
9: Work equipment controller
10: KOMTRAX Plus controller
11: KOMTRAX terminal
12: KomVision controller (*1)
The system operation lamp shows the operation status of the controllers.
Even if you turn the starting switch to the OFF position and stop the engine, the controllers can continue the operation. The lamp lights up while one of the controllers is in operation.
REMARK
Do not operate the battery disconnect switch while the system operation lamp is lit. For details, see “Battery Disconnect Switch”.
Operation of System Operating Lamp System
The positive (+) pole of the system operating lamp (LED: Light-Emitting Diode) is connected to the battery through the fuse. Also, each controller is connected in parallel to the negative (-) pole of the LED.
When a controller is in operation, it outputs 0 V for the LED connect pin. Also, when a controller is stopped, it outputs 24 V for the LED connect pin.
When one of the controllers that is connected in parallel to the negative (-) pole of the LED is in operation, the LED lights up.
REMARK
•Even if the controller stops and it outputs 24 V for the LED connect pin, the LED looks slightly luminous. It is because of the minute leakage of current by the difference in the electrical potentials against the battery.
•The KOMTRAX terminal can start even if the starting switch is in the OFF position. The terminal can continue the operation about 1 hour in accordance with the communication condition. In that case, turn the starting switch to the ON position and turn it to the OFF position again. The KOMTRAX terminal stops in maximum of 6 minutes.
Battery Disconnect Switch
Function of Battery Disconnect Switch
The battery disconnect switch connects or disconnect the continuous power supply from the battery. When the switch is set to the OFF position, all the power supply to the machine is disconnected.
In the cases that follow, set the switch to the OFF position.
•When you store the machine for a long period of time (1 month or more)
•When you do maintenance or repair of the electrical system
•When you do electric welding
•When you handle the battery
•When you replace the electrical component such as fuse
REMARK
If the battery disconnect switch is set to the OFF position for a long period of time, the machine monitor and the clock of the radio are possibly initialized. In this case, set the clock again as necessary
Operation of Battery Disconnect Switch
OFF position
•The power supply circuit is disconnected. Remove the key before you start work such as machine maintenance.
•You can check that the machine is not energized by the battery disconnect lamp (1) that goes off.
ON position
•The power supply circuit is connected.
•You can start the engine of the machine.
NOTICE
•Do not turn the battery disconnect switch (1) to the “OFF” position while the system operating lamp is lit. The data in the controller can be lost and cause dangerous damage to the controller.
•Do not turn the battery disconnect switch (1) to the “OFF” position while the engine is in operation and immediately after the engine stops.
If you turn the battery disconnect switch (1) to the “OFF” position during the power generation by the alternator, the supplied current has no place to flow into. This can cause overvoltage, and also cause dangerous damage to the electrical devices and electrical system such as the controllers.
•While the fan rotates in reverse, do not turn the battery disconnect switch to the OFF position. Be sure to check that the cooling fan stopped. Then turn the battery disconnect switch to the OFF position. For protection of the cooling fan motor, the drive signal is sent to the solenoid valve (fan rotation in reverse). The signal rotates the fan in reverse for some period of time after you turn the starting switch to the OFF position.
Starting Motor Disconnect Switch
Function of Starting Motor Disconnect Switch
The starting motor disconnect switch is used to prevent incorrect operation. If you use this switch, the engine cannot be started by mistake when you do maintenance or repair of the electrical system.
OFF position
When the starting motor disconnect switch (1) is turned to the OFF position (connection is open), the starting switch terminal B is cut, and the engine cannot be started. ON position
Preheating System
System Diagram of Preheating System
1: Battery disconnect switch
2: Battery
3: Battery relay
4: Fuse box
5: Starting switch
6: Engine controller
7: Fuse box
8: Fuse box
9: Electrical intake air heater
10: Relay (preheating auxiliary)
11: Relay (heater)
12: Transmission controller
Function of Automatic Preheating System
• Automatic preheating system is installed for the engine to start easily in cold weather
•When the starting switch is turned to the ON position, the automatic preheating system makes the preheating time shorter. Also, the system sets the preheating time automatically in accordance with the intake air temperature.
•When the starting switch is turned to the ON position, the preheating pilot lamp on the machine monitor lights up and the electrical intake air heater preheats the intake air.
•The engine controller sets the preheating time in accordance with the sensed engine coolant temperature.
•While the pilot lamp lights up, preheating is in operation. Keep the starting switch in the ON position. When the starting switch is turned to the START position during this period, automatic preheating is canceled.
•When the pre-lubrication system is installed on the machine, the transmission controller drives the relay (preheating) after pre-lube is done.
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Operation of Automatic Preheating System
1. When the starting switch is turned to the ON position, the engine controller starts.
2. If the intake air temperature is -5 °C or below, the engine controller drives the relay (preheating) immediately after you turn the starting switch to the ON position.
3. The electrical intake air heater relay operates, and preheating starts.
4. The preheating operation time is as shown in the figure that follows.
REMARK
When the pre-lubrication system is installed on the machine, the transmission controller drives the relay (preheating) after pre-lube is done.
Function of Manual Preheating System
•When you want more preheating time than that of automatic preheating when you start the machine in cold weather, turn the starting switch to the position for manual preheating to extend the preheating time.
•When you turn the starting switch to the position for manual preheating, the preheating pilot lamp on the machine monitor lights up and the electrical intake air heater preheats the intake air
•When the starting switch is turned to the OFF position, the pilot lamp goes off and manual preheating is canceled.
Operation of Manual Preheating System
When you turn the starting switch to the position for manual preheating, the electrical intake air heater relay operates and preheating by the electrical intake air heater starts.
REMARK
If preheating is done manually for the machine with the pre-lubrication system, the error is sensed and the failure code is shown.
Engine Shutdown Secondary Switch
Function of Engine Shutdown Secondary Switch
The engine shutdown secondary switch is used to stop the engine if the engine does not stop even when you turn the starting switch to the OFF position.
Operation of Engine Shutdown Secondary Switch
NOTICE
Use this switch only when a problem is found in the machine.
When you open the cover (1) and set the engine shutdown secondary switch (2) to the position (a), the engine stops. (a): Engine stopped (b): Normal
Three seconds after the engine stops, “Engine Shutdown Secondary SW in Operation” is shown on the machine monitor, and the alarm buzzer operates intermittently. When this screen is shown, return the switch (2) to the (b) position.
REMARK
When you close the cover (1), the switch (2) returns to the (b) position.
When the engine shutdown secondary switch is at the (a) position, you cannot start the engine even if you turn the starting switch to the ON position. “Engine Shutdown Secondary SW in Operation” is shown on the machine monitor, and the alarm buzzer operates intermittently.
Emergency Engine Stop Switch
(Machines with the emergency engine stop switch)
Function of Emergency Engine Stop Switch
The emergency engine stop switch is used when the engine does not stop even if you turn the starting switch to the “OFF” position.
NOTICE
If you set this switch to the position for engine stop while the machine is in normal operation, “Engine Shutdown Secondary SW in Operation” is shown on the machine monitor. If “Engine Shutdown Secondary SW in Operation” is shown on the machine monitor, check that the switch cover is closed, or the switch is at the normal position. When the switch is set to the position for engine stoop, put it back to the normal position.
Operation of Emergency Engine Stop Switch
NOTICE
Use this switch only when a problem is found in the machine. When you push down the emergency engine stop switch (a), the engine stops.
Three seconds after the engine stops, “Engine Shutdown Secondary SW in Operation” is shown on the machine monitor, and the alarm buzzer operates intermittently.
To reset the emergency engine stop switch, turn the switch to the right (b). The switch goes back to the normal position.
REMARK
When the emergency engine stop switch is pushed down, you cannot start the engine even if you turn the starting switch to the ON position. “Engine Shutdown Secondary SW in Operation” is shown on the machine monitor, and the alarm buzzer operates intermittently.
External Power Supply Engine Preheater
(Machines with the external power supply engine preheater)
Function of External Power Supply Engine Preheater
When the machine is stopped in cold whether, the external power supply engine preheater keeps the coolant and lubricant that follow warm. This helps you to easily start the machine again.
•Engine coolant
•Engine oil
•Hydraulic Oil
•Transmission oil
REMARK
•To use this preheater, installation of the external power supply system is required.
•For installation procedure, see the “Operation and Maintenance Manual”.
Engine System
Layout Drawing of Engine System
1: Air cleaner
2: KDPF-A (left bank side)
3: KDPF-B (right bank side)
4: Engine controller-A (left bank side)
5: Engine controller-B (right bank side)
6: Vibration damper
7: Alternator
10:
11: VGT-B (right bank side)
12: EGR cooler
13: Damper
14: Starting motor
8: Engine oil filter
9: KCCV
VGT-A (left bank side)
REMARK
For machine models with two systems of aftertreatment devices, the relation of the part names of the aftertreatment devices and the failure codes shown on the machine monitor for the engine controller are as follows.
•When “left bank side” is shown at the end of the part name
Failure codes start with “CA” and no fixed symbol is shown at the end of a failure display.
Example:
Name of the part: KDPF differential pressure sensor (left bank side)
The terminal B of the starting switch (5) is connected to the positive pole of the battery (2) through the fuse box (4). When the starting switch (5) is turned to the ON position, the terminal B and terminal BR are connected, and the battery relay (3) operates. When the battery relay (3) operates, the battery voltage is applied to the terminal B of the starting motor (21).
Also, when the starting switch (5) is turned to the ON position, the terminal B and terminal ACC are connected. The engine controller (10), transmission controller (11), and monitor controller (14) start.
When the directional selector switch is in the N position, and when the frame articulation angle and the AJSS lever position are aligned (the AJSS lever is neutral state against the frame), the transmission controller (11) activates the relay (neutral safety) (18).
When the starting switch (5) is turned to the START position, the terminal B and terminal C are connected. The terminal C of the starting switch (5) is connected to the terminal C of the starting motor (21) through the relay (neutral safety) (18) and relay (personal lock) (19).
When the starting switch (5) and terminal C of the starting motor (21) are connected, the starting motor (21) starts, and then the engine starts. At this time, the relay (neutral hold) (17) holds the operation of the relay (neutral safety) (18).
Engine Stop
When the starting switch (5) is turned to the OFF position, the terminal B and terminal ACC are blocked. The engine controller (10) stops the engine. At this time, the alternator (22) stops power generation, and the voltage supply from the terminal R of the alternator (22) is blocked.
When the starting switch (5) is turned to the OFF position, the terminal B and terminal BR are blocked, the contact of the battery relay (3) opens, and then the power supply from the battery (2) is blocked.
Also, when the engine shutdown secondary switch (7) is turned to the “STOP ENGINE” position, the terminal ACC circuit of the starting switch (5) is blocked. The engine controller (10) stops the engine.
Engine Output Torque Control Function
Engine Torque Control in Accordance with Work Phases
The engine torque control is a function that controls the engine output torque to supply the necessary and sufficient torque for each phase. For torque control, work phases such as the engine speed, travel speed, pump discharged pressure, and travel direction are judged.
Engine Automatic Warm-up Function
The engine automatic warm-up function is a function that does warm-up operation automatically in response to the engine coolant temperature immediately after the engine start.
When you start the engine, if the engine coolant temperature is 20 °C or lower, the engine low idle speed is raised to 1020 rpm. During automatic warm-up, if the engine coolant temperature is 30 °C or more, or if the accelerator pedal is pushed by 70% or more for 3 seconds or more, the engine automatic warm-up is canceled and the engine speed decreases.
The standard engine speed is 680 rpm when the automatic warm-up is canceled. You can change the standard engine speed by the “RPM SET” function.
Engine Power Mode Selector System
Engine Power Mode Selector System Diagram
Input and output signals
a: Power mode selector signal
b: Engine torque control signal
1: Machine monitor
2: Transmission controller
c: Engine output mode display signal
3: Engine controller
Function of Engine Power Mode Selector System
You can set the power mode on “Option Setting” in “Default” on the service mode of the machine monitor.
Operation of Engine Power Mode Selector System
1. When you set the power mode on the machine monitor, the CAN signal is sent to the transmission controller
2. The transmission controller sets the engine mode, and changes the engine torque performance curve to the P mode.
3. The transmission controller sends the display signal of the engine output mode to the machine monitor.
Automatic Idle Stop System
Function of Automatic Idle Stop System
•When the operation conditions are satisfied, the system stops the engine at the specified time.
•After the engine is stopped, and when the parking brake switch is in the OFF position, the system operates the parking brake.
•After the engine is stopped, and if the work equipment lever lock is canceled, the system operates the work equipment control lever lock.
REMARK
For the adjustment procedure of the time setting, see Testing and Adjusting, “Set and Operate Machine Monitor”.
This function operates when conditions 1 to 4 are satisfied at the same time.
Condition 1 Accelerator pedal is not pushed.
Condition 2 Transmission is at neutral (N).
Condition 3 The machine is stopped.
Condition 4 Aftertreatment device regeneration is not in operation.
Procedure When You Start Again
To start again, turn the starting switch from the ON position to the START position.
RPM Set
Function of RPM Set
•You can keep the engine speed at a specified speed to increase the work efficiency.
•The engine speed is set by the push of the accelerator pedal and the operation of the RPM set switch.
•When the R.H. brake pedal is pushed, RPM set is canceled temporarily.
•If the transmission is neutral and the work equipment control lever is neutral state in this time, RPM set is disabled after 4 seconds.
•When the auto-deceleration function is activated, and if the conditions that follow are satisfied, the RPM set function is canceled temporarily and the engine runs at low idle to reduce the fuel consumption.
•The transmission is kept in neutral for 4 seconds, and the work equipment is kept in neutral for 4 seconds or more.
•During the period, the RPM set switch and the accelerator pedal are not operated.
•The travel speed is 5 km/h or below.
•During the auto-deceleration state, when the conditions that follow are satisfied, the RPM set control is restored automatically.
•The directional selector switch of the transmission is shifted to the position other than neutral.
•The control lever of the work equipment is shifted to the position other than neutral.
•When the accelerator pedal is operated
Components list Switch configuration Logic of switch Function
RPM set function selection
Auto-deceleration activated/disabled
Function switches on the switch panel User mode
The work equipment controller receives the signal of whether the machine has the auto-deceleration function or not. The signal is received on the machine monitor by KOMNET
• When the work equipment controller receives the signal of without auto-deceleration, it operates the work equipment as without auto-deceleration function.
• When the work equipment controller receives the signal of with auto-deceleration, it operates the work equipment as with auto-deceleration function.
Components list
RPM set switch
SET/ACCEL
Switch configuration
RPM set switch
RESUME/ DECEL
Momentary seesaw switch ON: GND OFF: OPEN
R.H. brake pedal operation switch
Momentary proximity switch
RPM set pilot lamp Pilot lamp
Brake operated: GND
Brake not operated: OPEN
The work equipment controller sends the indicator command from KOMNET to machine monitor
Function
Throttle lower limit value set function
• The throttle level is saved when SET/ACCEL of the RPM set switch is set to ON.
• While the RPM set function is canceled temporarily by the R.H. brake pedal operation, push the SET/ACCEL position of the RPM set switch to restore the RPM set function. (The destination changes in accordance with whether the accelerator pedal is pushed or not.)
• The input signal is controlled in 0.5 seconds or below.
Acceleration function
• The specified throttle lower limit value is increased in accordance with the engine speed. The engine speed used at this time is the speed when you push the SET/ACCEL position of the RPM set switch for 0.5 seconds or more, and then release it.
• But the throttle lower limit value cannot be set to 100% or more.
Resume function
• While the RPM set function is canceled temporarily or during the auto-deceleration state by the R.H. brake pedal operation, push the RESUME/DECEL position of the RPM set switch to restore the RPM set function.
• The input signal is controlled in 0.5 seconds or below Deceleration function
• The specified throttle lower limit value is decreased in accordance with the engine speed. The engine speed used at this time is the speed when you push the RESUME/DECEL position of the RPM set switch for 0.5 seconds or more, and then release it.
• But the throttle lower limit value cannot be set below 0 %.
Push the R.H. brake pedal to cancel the RPM set function temporarily
• While the throttle lower limit value is specified, the RPM set pilot lamp lights up in green.
• When the RPM set function is canceled temporarily by R.H. brake pedal operation or by the auto-deceleration function, the RPM set pilot lamp lights up in yellow
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Component Parts of Engine System
Damper
Structure of Damper
General View and Sectional View
1: Breather
2: Cover
3: Outer body
4: Inner body
Function of Damper
5: Rubber cushion (large)
6: Rubber cushion (small)
7: Shaft
The damper reduces the torsional vibration caused by the change in the engine torque and the impact torque caused by sudden acceleration or by heavy-duty excavation. The damper protects the torque converter, transmission, and other parts of the power train.
Operation of Damper
1. The power from the engine is sent to the outer body (3) through the flywheel.
2. The power sent to the outer body (3) is then sent to the inner body (4) through the rubber cushions (5) and (6).
At this time, the rubber cushions (5) and (6) absorb the torsional vibration of the engine.
3. The power sent to the inner body (4) is then sent to the spline-connected shaft (7).
VGT
VGT
Abbreviation for Variable Geometry Turbocharger
Structure of VGT
General View and Sectional View
1:
3:
A: Exhaust gas outlet
B: Exhaust gas inlet
C: Intake air outlet
D: Intake air inlet
Turbine housing
2: Hydraulic actuator
Speed sensor (VGT)
4: Blower housing
5: Shaft
6: Blower impeller
7: Push rod
8: Nozzle ring
9: Plate
10: Vane
11: Turbine impeller
12: Piston
Function of VGT
C: Blower impeller
1: Air cleaner
2: VGT
3: KDPF
T: Turbine impeller
4: EGR cooler
5: EGR valve
•By the rules of exhaust gas emission, not only the gas exhausted at the high engine speed is restricted, but also the gas exhausted at the low engine speed is restricted. To obey the rules, the EGR ratio is enhanced. (EGR ratio = Quantity of EGR against quantity of air intake)
•To get high EGR ratio especially during low engine speed, the turbine inlet pressure (P3) must be set higher than the boost pressure (P2) (P3 > P2). The variable turbocharger (VGT) is used to adjust the exhaust gas pressure that flows to the turbine impeller (T).
Also, the VGT increases the boost pressure more quickly, and reduces the generation of PM (Particulate Matter) that occurs when oxygen is not sufficient during low engine speed.
•The blower impeller (C) is driven through the shaft connected to the turbine impeller (T), and the large quantity of air is sent to the cylinder for combustion.
If the air sent by the VGT (2) increases, the fuel injection rate is increased, and the engine output will be enhanced.
Also, the density of air cooled by the aftercooler is increased, and the quantity of oxygen is also increased. The fuel injection rate can be increased and the engine output will be enhanced.
NOTICE
Sufficient quantity of high-quality and clean oil is required to keep the VGT performance. Be sure to use the Komatsu-genuine high-quality oil. Replace the oil and oil filter as in the “Operation and Maintenance Manual”.
REMARK
After the relief operation, you hear sound from the VGT or boost piping as if air leaks. It is not a failure.
Operation of VGT
1. The exhaust gas enters through (C) of the turbine housing (4), and flows out from (D) through the part (P). The part (P) is surrounded by the plate (5), nozzle ring (7), and vanes (6) fixed to the turbine housing (4). The path area changes when the push rod (8) slides to the right or left.
2. The hydraulic actuator (3) raises or lowers the piston (12) in the actuator by the oil pressure controlled with the EPC valve, and thereby controls the push rod (8) to slide right or left.
3. The exhaust gas that passed through the vanes (6) rotates the blower impeller (10) through the shaft (9) connected to the turbine impeller (11). As a result, it works as the compressor, the intake air that entered through (A) is compressed and flows out from (B).
4. When the exhaust gas pressure is low (low engine speed range) at the inlet (C) of the turbine housing (4), the push rod (8) slides right to narrow the part (P).
5. The exhaust gas pressure that acts on the turbine impeller (11) becomes high, and the turbocharger speed increases so that the larger quantity of air (oxygen) is taken in than before. The turbocharger speed is sensed by the VGT speed sensor (2).
Nozzle Ring (Close) State
1. When the engine speed is low, the exhaust gas inlet path (P) is narrow (L1). (Not fully closed)
2. When the turbine inlet pressure increases while the nozzle ring is closed, the flow of the exhaust gas into the turbine increases, and the turbocharger speed increases.
Nozzle Ring (Open) State
1. When the engine speed is high, the exhaust gas inlet path (P) is wide (L2).
2. When the engine speed increases, the turbine inlet pressure (exhaust gas pressure) increases. Accordingly, the exhaust gas inlet path (P) becomes wide (L2), and the exhaust gas pressure acts on the turbine impeller (11) effectively.
REMARK
•The nozzle ring (7), vanes (6), and push rod (8) are all-inone unit. They can slide only but do not rotate.
•The VGT position sensor is installed to the hydraulic actuator (3). The VGT position sensor and the variable mechanism of VGT are calibrated, and the calibration value is saved in the memory of the VGT position sensor. If a failure of the hydraulic actuator (3), VGT position sensor, or VGT main unit is found, the VGT must be replaced as a unit.
Operation of Hydraulic Actuator
1. The hydraulic actuator (6) operates by the hydraulic pressure controlled by the EPC valve (3).
2. The force to stroke changes in response to the hydraulic pressure supplied by the engine boost oil pump (12).
3. The position of the hydraulic actuator (6) is sent to the engine controller by the signal from the VGT position sensor (5) as feedback.
EGR System
EGR
Abbreviation for Exhaust Gas Recirculation
Layout Drawing of EGR System
REMARK
The figure shows the R.H. bank.
2:
3:
4:
1: Intake connector
EGR valve
VGT
EGR cooler
5: Exhaust manifold
6: Intake manifold
7: Mixing connector
REMARK
The figure shows the L.H. bank.
1: Intake connector
2: EGR valve
3: VGT
4: EGR cooler
Function of EGR System
5: Exhaust manifold
6: Intake manifold
7: Mixing connector
• The EGR valve (hydrostatic drive type) (2) controls the gas flow from exhaust to intake. Because the exhaust gas pressure is higher than the boost pressure, the exhaust gas flows to the intake side.
•The EGR cooler (4) cools the exhaust gas. Engine coolant is used for cooling.
•The mixing connector (7) sends the air from the air-cooled aftercooler and the exhaust gas from the EGR valve (2) back to the intake side.
•Exhaust gas is always clean by the system that controls the EGR circuit based on the data from the sensors installed on parts to get the EGR ratio in response to the operation condition. (EGR ratio shows the ratio of the EGR gas contained in the intake gas.)
•To prevent dangerous failures, sensors installed on parts monitor the EGR circuit condition for troubleshooting.
EGR System Circuit Diagram
B: Blower impeller
1: Air cleaner
2: Mass air flow and temperature sensor
3: VGT
4: Engine boost oil pump
5: Hydraulic actuator (power piston)
6: EPC valve
7: EGR valve lift sensor
8: EGR valve
9: EGR valve assembly
10: Engine controller
T: Turbine impeller
11: Air-cooled aftercooler
12: Mixing connector
13: Intake manifold
14: Engine
15: Exhaust manifold
16: Pressure sensor (atmosphere)
17: Temperature sensor (charge), pressure sensor (charge)
18: EGR cooler
19: KDPF
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