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VENBM55000

WHEEL LOADER

WA500 -8E0 SERIAL NUMBERS

H50151

and up

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00 INDEX AND FOREWORD

WA500-8E0

00-1

INDEX

00 INDEX AND FOREWORD

INDEX 00 INDEX AND FOREWORD ........................................................................................................................ 00-1 ABBREVIATION LIST ........................................................................................................................... 00-26 FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-32 HOW TO READ THE SHOP MANUAL........................................................................................... 00-32 SAFETY NOTICE FOR OPERATION............................................................................................. 00-34 PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-42 ACTIONS IF FIRE OCCURS ......................................................................................................... 00-44 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-45 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-46 PRECAUTIONS FOR DEF............................................................................................................. 00-47 STORE AdBlue/DEF ...................................................................................................................... 00-48 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-49 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-52 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-59 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-61 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-62 PRACTICAL USE OF KOMTRAX .................................................................................................. 00-63 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-64 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-68 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-72 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-73 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-75 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-76 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . ................................................................................................................................................... 00-78 HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-79 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-83 STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-86 CONVERSION TABLE ................................................................................................................... 00-93 01 SPECIFICATIONS .................................................................................................................................... 01-1 CONTENTS ............................................................................................................................................ 01-2 ABBREVIATION LIST ............................................................................................................................. 01-3 SPECIFICATIONS .................................................................................................................................. 01-9 SPECIFICATION DRAWING............................................................................................................ 01-9 SPECIFICATIONS ..........................................................................................................................01-11 WEIGHT TABLE ............................................................................................................................ 01-16 TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-18 10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1 CONTENTS ............................................................................................................................................ 10-2 ABBREVIATION LIST ............................................................................................................................. 10-7 UREA SCR SYSTEM............................................................................................................................ 10-13 LAYOUT DRAWING OF UREA SCR SYSTEM .............................................................................. 10-13 UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-16 FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-17 COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-33 BOOT-UP SYSTEM .............................................................................................................................. 10-42 LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL).............. 10-42 LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ........................................................................................................................................... 10-44 LAYOUT DRAWING OF BOOT-UP SYSTEM (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) ................................................................................. 10-46 LAYOUT DRAWING OF BOOT-UP SYSTEM (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) ................................................................................. 10-48 SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-50 BATTERY DISCONNECT SWITCH ............................................................................................... 10-53 PREHEATING SYSTEM ................................................................................................................ 10-55 00-2

WA500-8E0

00 INDEX AND FOREWORD

INDEX

ENGINE SHUTDOWN SECONDARY SWITCH ............................................................................. 10-57 ENGINE SYSTEM ................................................................................................................................ 10-59 LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-59 ENGINE CONTROL SYSTEM ....................................................................................................... 10-61 ENGINE POWER MODE SELECTOR SYSTEM............................................................................ 10-68 AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-69 RPM SET....................................................................................................................................... 10-70 COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-74 COOLING SYSTEM.............................................................................................................................. 10-93 LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-93 COOLING FAN CONTROL SYSTEM............................................................................................. 10-95 COMPONENT PARTS OF COOLING SYSTEM............................................................................10-100 CONTROL SYSTEM............................................................................................................................10-114 LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) ...........10-114 LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ..........................................................................................................................................10-116 MACHINE MONITOR SYSTEM ....................................................................................................10-118 REARVIEW MONITOR SYSTEM..................................................................................................10-120 KOMTRAX SYSTEM.....................................................................................................................10-121 LOAD METER SYSTEM ...............................................................................................................10-123 COMPONENT PARTS OF CONTROL SYSTEM...........................................................................10-130 HYDRAULIC SYSTEM.........................................................................................................................10-182 LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-182 CLSS ............................................................................................................................................10-183 WORK EQUIPMENT PUMP CONTROL SYSTEM........................................................................10-187 COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-188 POWER TRAIN SYSTEM ....................................................................................................................10-257 LAYOUT DRAWING OF POWER TRAIN SYSTEM.......................................................................10-257 OPERATION OF POWER TRAIN SYSTEM..................................................................................10-261 TRANSMISSION CONTROL SYSTEM .........................................................................................10-262 TRANSMISSION GEAR SHIFT CONTROL SYSTEM...................................................................10-264 TRANSMISSION PROTECTION FUNCTION ...............................................................................10-270 DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION......................................................10-273 TRANSMISSION CUT-OFF FUNCTION .......................................................................................10-275 COMPONENT PARTS OF POWER TRAIN SYSTEM ...................................................................10-277 WORK EQUIPMENT SYSTEM ............................................................................................................10-340 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-340 WORK EQUIPMENT SYSTEM DIAGRAM....................................................................................10-342 WORK EQUIPMENT CONTROL SYSTEM ...................................................................................10-344 WORK EQUIPMENT NEUTRAL LOCK SYSTEM .........................................................................10-349 REMOTE POSITIONER SYSTEM ................................................................................................10-351 BUCKET POSITIONER AND BOOM POSITIONER......................................................................10-356 AUTO-DIGGING SYSTEM............................................................................................................10-357 ECSS ............................................................................................................................................10-359 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-361 STEERING SYSTEM ...........................................................................................................................10-372 LAYOUT DRAWING OF STEERING SYSTEM .............................................................................10-372 SECONDARY STEERING SYSTEM.............................................................................................10-374 JOYSTICK STEERING SYSTEM..................................................................................................10-375 AJSS ............................................................................................................................................10-381 STEERING COLUMN ...................................................................................................................10-388 COMPONENT PARTS OF STEERING SYSTEM..........................................................................10-389 BRAKE SYSTEM .................................................................................................................................10-418 LAYOUT DRAWING OF BRAKE SYSTEM ...................................................................................10-418 PARKING BRAKE CONTROL SYSTEM .......................................................................................10-421 COMPONENT PARTS OF BRAKE SYSTEM................................................................................10-423 AUTO-GREASING SYSTEM ...............................................................................................................10-442 LAYOUT DRAWING OF AUTO-GREASING SYSTEM ..................................................................10-442 WA500-8E0

00-3

INDEX

00 INDEX AND FOREWORD

SPECIFICATIONS OF AUTO-GREASING SYSTEM ....................................................................10-443 FUNCTION OF AUTO-GREASING SYSTEM ...............................................................................10-445 COMPONENT PARTS OF AUTO-GREASING SYSTEM ..............................................................10-446 UNDERCARRIAGE AND FRAME........................................................................................................10-447 FRAME, AXLE MOUNT AND CENTER HINGE PIN .....................................................................10-447 TIRE .............................................................................................................................................10-449 WORK EQUIPMENT............................................................................................................................10-451 STRUCTURE OF WORK EQUIPMENT ........................................................................................10-451 STRUCTURE OF BUCKET...........................................................................................................10-452 STRUCTURE OF WORK EQUIPMENT LUBRICATION................................................................10-454 CAB AND ITS ATTACHMENTS ...........................................................................................................10-456 ROPS CAB ...................................................................................................................................10-456 20 STANDARD VALUE TABLE ...................................................................................................................... 20-1 CONTENTS ............................................................................................................................................ 20-2 ABBREVIATION LIST ............................................................................................................................. 20-3 STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9 STANDARD VALUE TABLE FOR ENGINE: WA500-8E0 ................................................................. 20-9 STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-12 STANDARD VALUE TABLE FOR MACHINE: WA500-8E0............................................................. 20-12 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-33 30 TESTING AND ADJUSTING ..................................................................................................................... 30-1 CONTENTS ............................................................................................................................................ 30-2 ABBREVIATION LIST ............................................................................................................................. 30-6 RELATED INFORMATION ON TESTING AND ADJUSTING ................................................................ 30-12 TOOLS FOR TESTING AND ADJUSTING..................................................................................... 30-12 SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-22 ENGINE AND COOLING SYSTEM....................................................................................................... 30-23 TEST ENGINE SPEED .................................................................................................................. 30-23 TEST BOOST PRESSURE............................................................................................................ 30-30 TESTING EXHAUST GAS TEMPERATURE.................................................................................. 30-34 TEST EXHAUST GAS COLOR ...................................................................................................... 30-36 TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-39 TEST COMPRESSION PRESSURE.............................................................................................. 30-41 TEST BLOWBY PRESSURE ......................................................................................................... 30-44 TEST ENGINE OIL PRESSURE .................................................................................................... 30-47 TEST EGR VALVE AND VGT OIL PRESSURE ............................................................................. 30-49 TEST FUEL PRESSURE ............................................................................................................... 30-51 TEST FUEL RETURN RATE AND LEAKAGE................................................................................ 30-53 BLEEDING AIR FROM FUEL SYSTEM ......................................................................................... 30-57 TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-59 HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-61 HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-62 TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE............................ 30-63 TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS ................................. 30-64 TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS .......................................................... 30-65 CLEAN FUEL DOSER ................................................................................................................... 30-66 WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER.................................. 30-69 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-76 TEST SCR RELATED FUNCTIONS............................................................................................... 30-77 CLEAN AdBlue/DEF TANK ...........................................................................................................30-109 POWER TRAIN....................................................................................................................................30-113 TEST AND ADJUST POWER TRAIN OIL PRESSURE ................................................................30-113 ADJUST TRANSMISSION INPUT SPEED SENSOR....................................................................30-131 ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR ...................................................30-133 FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT ..........................30-135 MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE..................................30-137 TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE.......................................30-139 STEERING SYSTEM ...........................................................................................................................30-140 00-4

WA500-8E0

00 INDEX AND FOREWORD

INDEX

TEST STEERING WHEEL ............................................................................................................30-140 TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE ........................................................30-142 BLEED AIR FROM STEERING CYLINDER CIRCUIT...................................................................30-148 TEST AND ADJUST STEERING STOP VALVE ............................................................................30-149 BRAKE SYSTEM .................................................................................................................................30-151 RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT ...............................30-151 TEST WHEEL BRAKE OIL PRESSURE .......................................................................................30-152 TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE ........................................30-154 TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE ..................30-156 BLEED AIR FROM BRAKE CIRCUIT ...........................................................................................30-165 TEST BRAKING PERFORMANCE ...............................................................................................30-168 TEST BRAKE PEDAL ...................................................................................................................30-169 TEST AND ADJUST BRAKE PEDAL AND LINKAGE ...................................................................30-170 ADJUST LEFT BRAKE PEDAL OPERATION SWITCH ................................................................30-171 TEST LOWERING OF WHEEL BRAKE PRESSURE....................................................................30-172 TEST WEAR OF WHEEL BRAKE DISC .......................................................................................30-175 TEST PARKING BRAKE OIL PRESSURE ....................................................................................30-177 TEST PARKING BRAKE PERFORMANCE...................................................................................30-179 RELEASE PARKING BRAKE MANUALLY ....................................................................................30-180 TEST WEAR AMOUNT OF PARKING BRAKE DISC....................................................................30-183 HYDRAULIC SYSTEM.........................................................................................................................30-185 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT ...............................30-185 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE ........................................................30-187 TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE ................................................30-193 BLEED AIR FROM WORK EQUIPMENT CIRCUIT.......................................................................30-196 TEST COOLING FAN SPEED .....................................................................................................30-198 TEST COOLING FAN CIRCUIT OIL PRESSURE .........................................................................30-199 BLEED AIR FROM COOLING FAN CIRCUIT ...............................................................................30-203 TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS .......................................................................................................................30-205 WORK EQUIPMENT............................................................................................................................30-219 TEST AND ADJUST BUCKET POTENTIOMETER LEVER ..........................................................30-219 TEST AND ADJUST BOOM POTENTIOMETER LEVER..............................................................30-221 CAB AND ITS ATTACHMENTS ...........................................................................................................30-222 TEST DIRECTIONAL LEVER .......................................................................................................30-222 TEST WORK EQUIPMENT CONTROL LEVER............................................................................30-223 TEST MULTIFUNCTION MONO-LEVER ......................................................................................30-224 TEST AJSS LEVER (FOR AJSS SPEC) .......................................................................................30-226 TEST STEERING LOCK LEVER(FOR AJSS SPEC) ....................................................................30-229 TEST AND ADJUST AJSS LEVER/FRAME ANGLE SENSOR (FOR AJSS SPEC)......................30-230 TEST AND AJUST STEERING STOPPER BOLT (FOR AJSS SPEC) ..........................................30-232 ADJUST RATTLING OPERATOR'S SEAT ....................................................................................30-234 ELECTRICAL SYSTEM .......................................................................................................................30-235 SET AND ADJUST EACH EQUIPMENT.......................................................................................30-235 SET AND OPERATE MACHINE MONITOR..................................................................................30-240 START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) ............................30-381 STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL)..................30-385 START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).......30-387 STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ....... ..................................................................................................................................................30-393 ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-395 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-396 HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) ............30-397 HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ..........................................................................................................................................30-398 TEST DIODES ..............................................................................................................................30-399 AUTO-GREASING DEVICE .................................................................................................................30-400 BLEED THE AIR OF AUTO-GREASING SYSTEM .......................................................................30-400 WA500-8E0

00-5

INDEX

00 INDEX AND FOREWORD

CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES ............................30-403 Pm CLINIC...........................................................................................................................................30-406 Pm CLINIC SERVICE ...................................................................................................................30-406 40 TROUBLESHOOTING .............................................................................................................................. 40-1 CONTENTS ............................................................................................................................................ 40-2 ABBREVIATION LIST ........................................................................................................................... 40-16 RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-22 GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-22 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-23 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-35 CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-37 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-39 TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-41 ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION ................................................. 40-67 PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-80 SYMPTOM AND TROUBLESHOOTING NUMBERS ..................................................................... 40-82 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-87 CONNECTOR LIST AND LAYOUT (MACHINE WITH KOMTRAX TERMINAL) ............................. 40-89 CONNECTOR LIST AND LAYOUT (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ...40-117 CONNECTOR CONTACT IDENTIFICATION ................................................................................40-145 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-185 FUSE LOCATION TABLE(MACHINE WITH KOMTRAX TERMINAL)............................................40-191 FUSE LOCATION TABLE(MACHINE WITH GATEWAY FUNCTION CONTROLLER)...................40-195 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..........................40-199 PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR .......................................40-203 PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT...40-205 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])..........................................................................................................................40-211 FAILURE CODES TABLE .............................................................................................................40-213 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-237 FAILURE CODE [1500L0] .............................................................................................................40-237 FAILURE CODE [15B0NX]............................................................................................................40-238 FAILURE CODE [15SAL1] ............................................................................................................40-240 FAILURE CODE [15SALH]............................................................................................................40-242 FAILURE CODE [15SBL1] ............................................................................................................40-244 FAILURE CODE [15SBLH]............................................................................................................40-246 FAILURE CODE [15SEL1] ............................................................................................................40-248 FAILURE CODE [15SELH]............................................................................................................40-250 FAILURE CODE [15SFL1] ............................................................................................................40-252 FAILURE CODE [15SFLH]............................................................................................................40-254 FAILURE CODE [15SGL1]............................................................................................................40-256 FAILURE CODE [15SGLH] ...........................................................................................................40-258 FAILURE CODE [15SHL1] ............................................................................................................40-260 FAILURE CODE [15SHLH] ...........................................................................................................40-262 FAILURE CODE [2F00MA] ...........................................................................................................40-265 FAILURE CODE [2F00MB] ...........................................................................................................40-269 FAILURE CODE [2G42ZG] ...........................................................................................................40-272 FAILURE CODE [2G43ZG] ...........................................................................................................40-274 FAILURE CODE [879AKA]............................................................................................................40-276 FAILURE CODE [879AKB]............................................................................................................40-278 FAILURE CODE [879BKA]............................................................................................................40-280 FAILURE CODE [879BKB]............................................................................................................40-282 FAILURE CODE [879CKA]............................................................................................................40-284 FAILURE CODE [879CKB]............................................................................................................40-286 FAILURE CODE [879DKZ]............................................................................................................40-288 FAILURE CODE [879EMC] ...........................................................................................................40-290 FAILURE CODE [879FMC] ...........................................................................................................40-293 FAILURE CODE [989A00].............................................................................................................40-296 00-6

WA500-8E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [989L00] .............................................................................................................40-297 FAILURE CODE [989M00] ............................................................................................................40-298 FAILURE CODE [989N00] ............................................................................................................40-299 FAILURE CODE [A1U0N3] ...........................................................................................................40-300 FAILURE CODE [A1U0N4] ...........................................................................................................40-302 FAILURE CODE [AA10NX] ...........................................................................................................40-304 FAILURE CODE [AB00KE] ...........................................................................................................40-306 FAILURE CODE [AB00KY] ...........................................................................................................40-308 FAILURE CODE [AQ10N3] ...........................................................................................................40-310 FAILURE CODE [AS00N3]............................................................................................................40-312 FAILURE CODE [AS00R2]............................................................................................................40-314 FAILURE CODE [AS00R3]............................................................................................................40-315 FAILURE CODE [AS00R4]............................................................................................................40-316 FAILURE CODE [AS00R5]............................................................................................................40-317 FAILURE CODE [AS00R6]............................................................................................................40-318 FAILURE CODE [AS00ZK]............................................................................................................40-319 FAILURE CODE [AS10KM]...........................................................................................................40-320 FAILURE CODE [AS10NR] ...........................................................................................................40-321 FAILURE CODE [AS10NT] ...........................................................................................................40-322 FAILURE CODE [B@BAZG] .........................................................................................................40-323 FAILURE CODE [B@BCNS] .........................................................................................................40-324 FAILURE CODE [B@BCQA].........................................................................................................40-325 FAILURE CODE [B@BCZK] .........................................................................................................40-327 FAILURE CODE [B@C7NS] .........................................................................................................40-329 FAILURE CODE [B@CENS] .........................................................................................................40-331 FAILURE CODE [B@HANS] .........................................................................................................40-332 FAILURE CODE [CA115] ..............................................................................................................40-333 FAILURE CODE [CA122] ..............................................................................................................40-337 FAILURE CODE [CA123] ..............................................................................................................40-339 FAILURE CODE [CA131] ..............................................................................................................40-341 FAILURE CODE [CA132] ..............................................................................................................40-343 FAILURE CODE [CA135] ..............................................................................................................40-345 FAILURE CODE [CA141] ..............................................................................................................40-347 FAILURE CODE [CA144] ..............................................................................................................40-349 FAILURE CODE [CA145] ..............................................................................................................40-351 FAILURE CODE [CA153] ..............................................................................................................40-353 FAILURE CODE [CA154] ..............................................................................................................40-356 FAILURE CODE [CA187] ..............................................................................................................40-358 FAILURE CODE [CA221] ..............................................................................................................40-360 FAILURE CODE [CA222] ..............................................................................................................40-362 FAILURE CODE [CA227] ..............................................................................................................40-364 FAILURE CODE [CA234] ..............................................................................................................40-366 FAILURE CODE [CA238] ..............................................................................................................40-367 FAILURE CODE [CA239] ..............................................................................................................40-368 FAILURE CODE [CA249] ..............................................................................................................40-369 FAILURE CODE [CA256] ..............................................................................................................40-371 FAILURE CODE [CA271] ..............................................................................................................40-373 FAILURE CODE [CA272] ..............................................................................................................40-375 FAILURE CODE [CA273] ..............................................................................................................40-376 FAILURE CODE [CA274] ..............................................................................................................40-378 FAILURE CODE [CA322] ..............................................................................................................40-379 FAILURE CODE [CA323] ..............................................................................................................40-381 FAILURE CODE [CA324] ..............................................................................................................40-383 FAILURE CODE [CA325] ..............................................................................................................40-385 FAILURE CODE [CA331] ..............................................................................................................40-387 FAILURE CODE [CA332] ..............................................................................................................40-389 FAILURE CODE [CA343] ..............................................................................................................40-391 FAILURE CODE [CA351] ..............................................................................................................40-393 WA500-8E0

00-7

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [CA352] ..............................................................................................................40-395 FAILURE CODE [CA356] ..............................................................................................................40-397 FAILURE CODE [CA357] ..............................................................................................................40-399 FAILURE CODE [CA386] ..............................................................................................................40-401 FAILURE CODE [CA431] ..............................................................................................................40-403 FAILURE CODE [CA432] ..............................................................................................................40-406 FAILURE CODE [CA441] ..............................................................................................................40-410 FAILURE CODE [CA442] ..............................................................................................................40-412 FAILURE CODE [CA449] ..............................................................................................................40-414 FAILURE CODE [CA451] ..............................................................................................................40-415 FAILURE CODE [CA452] ..............................................................................................................40-417 FAILURE CODE [CA515] ..............................................................................................................40-419 FAILURE CODE [CA516] ..............................................................................................................40-421 FAILURE CODE [CA553] ..............................................................................................................40-423 FAILURE CODE [CA555] ..............................................................................................................40-424 FAILURE CODE [CA556] ..............................................................................................................40-426 FAILURE CODE [CA559] ..............................................................................................................40-428 FAILURE CODE [CA595] ..............................................................................................................40-433 FAILURE CODE [CA687] ..............................................................................................................40-435 FAILURE CODE [CA689] ..............................................................................................................40-437 FAILURE CODE [CA691] ..............................................................................................................40-439 FAILURE CODE [CA692] ..............................................................................................................40-441 FAILURE CODE [CA697] ..............................................................................................................40-443 FAILURE CODE [CA698] ..............................................................................................................40-444 FAILURE CODE [CA731] ..............................................................................................................40-445 FAILURE CODE [CA778] ..............................................................................................................40-449 FAILURE CODE [CA1117] ............................................................................................................40-451 FAILURE CODE [CA1664] ............................................................................................................40-453 FAILURE CODE [CA1669] ............................................................................................................40-456 FAILURE CODE [CA1673] ............................................................................................................40-457 FAILURE CODE [CA1677] ............................................................................................................40-458 FAILURE CODE [CA1678] ............................................................................................................40-459 FAILURE CODE [CA1682] ............................................................................................................40-460 FAILURE CODE [CA1683] ............................................................................................................40-464 FAILURE CODE [CA1684] ............................................................................................................40-466 FAILURE CODE [CA1686] ............................................................................................................40-468 FAILURE CODE [CA1691] ............................................................................................................40-469 FAILURE CODE [CA1694] ............................................................................................................40-471 FAILURE CODE [CA1695] ............................................................................................................40-473 FAILURE CODE [CA1696] ............................................................................................................40-475 FAILURE CODE [CA1712] ............................................................................................................40-477 FAILURE CODE [CA1713] ............................................................................................................40-480 FAILURE CODE [CA1714] ............................................................................................................40-483 FAILURE CODE [CA1715] ............................................................................................................40-484 FAILURE CODE [CA1776] ............................................................................................................40-485 FAILURE CODE [CA1777] ............................................................................................................40-488 FAILURE CODE [CA1843] ............................................................................................................40-491 FAILURE CODE [CA1844] ............................................................................................................40-493 FAILURE CODE [CA1879] ............................................................................................................40-495 FAILURE CODE [CA1881] ............................................................................................................40-497 FAILURE CODE [CA1883] ............................................................................................................40-499 FAILURE CODE [CA1885] ............................................................................................................40-502 FAILURE CODE [CA1887] ............................................................................................................40-504 FAILURE CODE [CA1921] ............................................................................................................40-506 FAILURE CODE [CA1922] ............................................................................................................40-509 FAILURE CODE [CA1923] ............................................................................................................40-514 FAILURE CODE [CA1924] ............................................................................................................40-516 FAILURE CODE [CA1925] ............................................................................................................40-518 00-8

WA500-8E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [CA1927] ............................................................................................................40-520 FAILURE CODE [CA1928] ............................................................................................................40-522 FAILURE CODE [CA1942] ............................................................................................................40-524 FAILURE CODE [CA1963] ............................................................................................................40-526 FAILURE CODE [CA1977] ............................................................................................................40-530 FAILURE CODE [CA1993] ............................................................................................................40-532 FAILURE CODE [CA2185] ............................................................................................................40-535 FAILURE CODE [CA2186] ............................................................................................................40-537 FAILURE CODE [CA2249] ............................................................................................................40-539 FAILURE CODE [CA2265] ............................................................................................................40-544 FAILURE CODE [CA2266] ............................................................................................................40-546 FAILURE CODE [CA2271] ............................................................................................................40-548 FAILURE CODE [CA2272] ............................................................................................................40-550 FAILURE CODE [CA2349] ............................................................................................................40-552 FAILURE CODE [CA2353] ............................................................................................................40-554 FAILURE CODE [CA2357] ............................................................................................................40-556 FAILURE CODE [CA2381] ............................................................................................................40-558 FAILURE CODE [CA2382] ............................................................................................................40-560 FAILURE CODE [CA2383] ............................................................................................................40-562 FAILURE CODE [CA2386] ............................................................................................................40-564 FAILURE CODE [CA2387] ............................................................................................................40-566 FAILURE CODE [CA2555] ............................................................................................................40-568 FAILURE CODE [CA2556] ............................................................................................................40-570 FAILURE CODE [CA2637] ............................................................................................................40-572 FAILURE CODE [CA2639] ............................................................................................................40-574 FAILURE CODE [CA2732] ............................................................................................................40-576 FAILURE CODE [CA2733] ............................................................................................................40-578 FAILURE CODE [CA2741] ............................................................................................................40-580 FAILURE CODE [CA2765] ............................................................................................................40-581 FAILURE CODE [CA2771] ............................................................................................................40-582 FAILURE CODE [CA2777] ............................................................................................................40-588 FAILURE CODE [CA2878] ............................................................................................................40-591 FAILURE CODE [CA2881] ............................................................................................................40-594 FAILURE CODE [CA2976] ............................................................................................................40-597 FAILURE CODE [CA3133] ............................................................................................................40-599 FAILURE CODE [CA3134] ............................................................................................................40-601 FAILURE CODE [CA3135] ............................................................................................................40-603 FAILURE CODE [CA3142] ............................................................................................................40-606 FAILURE CODE [CA3143] ............................................................................................................40-607 FAILURE CODE [CA3144] ............................................................................................................40-608 FAILURE CODE [CA3146] ............................................................................................................40-611 FAILURE CODE [CA3147] ............................................................................................................40-612 FAILURE CODE [CA3148] ............................................................................................................40-613 FAILURE CODE [CA3151] ............................................................................................................40-616 FAILURE CODE [CA3165] ............................................................................................................40-621 FAILURE CODE [CA3167] ............................................................................................................40-624 FAILURE CODE [CA3229] ............................................................................................................40-628 FAILURE CODE [CA3231] ............................................................................................................40-631 FAILURE CODE [CA3232] ............................................................................................................40-634 FAILURE CODE [CA3235] ............................................................................................................40-639 FAILURE CODE [CA3239] ............................................................................................................40-641 FAILURE CODE [CA3241] ............................................................................................................40-644 FAILURE CODE [CA3242] ............................................................................................................40-647 FAILURE CODE [CA3251] ............................................................................................................40-650 FAILURE CODE [CA3253] ............................................................................................................40-653 FAILURE CODE [CA3254] ............................................................................................................40-658 FAILURE CODE [CA3255] ............................................................................................................40-662 FAILURE CODE [CA3256] ............................................................................................................40-665 WA500-8E0

00-9

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [CA3311] ............................................................................................................40-668 FAILURE CODE [CA3312] ............................................................................................................40-671 FAILURE CODE [CA3313] ............................................................................................................40-674 FAILURE CODE [CA3314] ............................................................................................................40-675 FAILURE CODE [CA3315] ............................................................................................................40-676 FAILURE CODE [CA3316] ............................................................................................................40-680 FAILURE CODE [CA3317] ............................................................................................................40-681 FAILURE CODE [CA3318] ............................................................................................................40-682 FAILURE CODE [CA3319] ............................................................................................................40-686 FAILURE CODE [CA3321] ............................................................................................................40-687 FAILURE CODE [CA3322] ............................................................................................................40-688 FAILURE CODE [CA3419] ............................................................................................................40-692 FAILURE CODE [CA3421] ............................................................................................................40-694 FAILURE CODE [CA3497] ............................................................................................................40-696 FAILURE CODE [CA3498] ............................................................................................................40-697 FAILURE CODE [CA3543] ............................................................................................................40-698 FAILURE CODE [CA3545] ............................................................................................................40-703 FAILURE CODE [CA3547] ............................................................................................................40-705 FAILURE CODE [CA3558] ............................................................................................................40-706 FAILURE CODE [CA3559] ............................................................................................................40-708 FAILURE CODE [CA3562] ............................................................................................................40-710 FAILURE CODE [CA3563] ............................................................................................................40-712 FAILURE CODE [CA3567] ............................................................................................................40-715 FAILURE CODE [CA3568] ............................................................................................................40-719 FAILURE CODE [CA3571] ............................................................................................................40-725 FAILURE CODE [CA3572] ............................................................................................................40-727 FAILURE CODE [CA3574] ............................................................................................................40-729 FAILURE CODE [CA3575] ............................................................................................................40-732 FAILURE CODE [CA3577] ............................................................................................................40-734 FAILURE CODE [CA3578] ............................................................................................................40-736 FAILURE CODE [CA3582] ............................................................................................................40-738 FAILURE CODE [CA3583] ............................................................................................................40-745 FAILURE CODE [CA3596] ............................................................................................................40-747 FAILURE CODE [CA3649] ............................................................................................................40-751 FAILURE CODE [CA3681] ............................................................................................................40-754 FAILURE CODE [CA3682] ............................................................................................................40-759 FAILURE CODE [CA3713] ............................................................................................................40-765 FAILURE CODE [CA3717] ............................................................................................................40-768 FAILURE CODE [CA3718] ............................................................................................................40-769 FAILURE CODE [CA3725] ............................................................................................................40-770 FAILURE CODE [CA3748] ............................................................................................................40-773 FAILURE CODE [CA3751] ............................................................................................................40-776 FAILURE CODE [CA3755] ............................................................................................................40-778 FAILURE CODE [CA3866] ............................................................................................................40-780 FAILURE CODE [CA3867] ............................................................................................................40-784 FAILURE CODE [CA3868] ............................................................................................................40-787 FAILURE CODE [CA3899] ............................................................................................................40-791 FAILURE CODE [CA3911] ............................................................................................................40-793 FAILURE CODE [CA3912] ............................................................................................................40-797 FAILURE CODE [CA3932] ............................................................................................................40-799 FAILURE CODE [CA3933] ............................................................................................................40-801 FAILURE CODE [CA3934] ............................................................................................................40-803 FAILURE CODE [CA3935] ............................................................................................................40-806 FAILURE CODE [CA3936] ............................................................................................................40-808 FAILURE CODE [CA4151] ............................................................................................................40-810 FAILURE CODE [CA4152] ............................................................................................................40-814 FAILURE CODE [CA4155] ............................................................................................................40-818 FAILURE CODE [CA4156] ............................................................................................................40-820 00-10

WA500-8E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [CA4157] ............................................................................................................40-823 FAILURE CODE [CA4158] ............................................................................................................40-825 FAILURE CODE [CA4159] ............................................................................................................40-826 FAILURE CODE [CA4161] ............................................................................................................40-827 FAILURE CODE [CA4162] ............................................................................................................40-830 FAILURE CODE [CA4163] ............................................................................................................40-833 FAILURE CODE [CA4164] ............................................................................................................40-835 FAILURE CODE [CA4165] ............................................................................................................40-838 FAILURE CODE [CA4166] ............................................................................................................40-841 FAILURE CODE [CA4168] ............................................................................................................40-843 FAILURE CODE [CA4169] ............................................................................................................40-848 FAILURE CODE [CA4171] ............................................................................................................40-853 FAILURE CODE [CA4249] ............................................................................................................40-858 FAILURE CODE [CA4251] ............................................................................................................40-863 FAILURE CODE [CA4259] ............................................................................................................40-868 FAILURE CODE [CA4261] ............................................................................................................40-872 FAILURE CODE [CA4277] ............................................................................................................40-875 FAILURE CODE [CA4281] ............................................................................................................40-878 FAILURE CODE [CA4459] ............................................................................................................40-882 FAILURE CODE [CA4461] ............................................................................................................40-884 FAILURE CODE [CA4658] ............................................................................................................40-887 FAILURE CODE [CA4731] ............................................................................................................40-891 FAILURE CODE [CA4732] ............................................................................................................40-892 FAILURE CODE [CA4739] ............................................................................................................40-893 FAILURE CODE [CA4768] ............................................................................................................40-894 FAILURE CODE [CA4769] ............................................................................................................40-896 FAILURE CODE [CA4842] ............................................................................................................40-899 FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL) .........................................40-902 FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ................40-904 FAILURE CODE [CA5115] ............................................................................................................40-906 FAILURE CODE [CA5179] ............................................................................................................40-909 FAILURE CODE [CA5181] ............................................................................................................40-911 FAILURE CODE [CA5383] ............................................................................................................40-913 FAILURE CODE [D160KA]............................................................................................................40-915 FAILURE CODE [D160KB]............................................................................................................40-917 FAILURE CODE [D160KY]............................................................................................................40-919 FAILURE CODE [D191KA]............................................................................................................40-921 FAILURE CODE [D191KB]............................................................................................................40-924 FAILURE CODE [D191KY]............................................................................................................40-927 FAILURE CODE [D192KA]............................................................................................................40-929 FAILURE CODE [D192KB]............................................................................................................40-931 FAILURE CODE [D192KY]............................................................................................................40-933 FAILURE CODE [D193KA]............................................................................................................40-934 FAILURE CODE [D193KB]............................................................................................................40-936 FAILURE CODE [D193KY]............................................................................................................40-938 FAILURE CODE [D193MC]...........................................................................................................40-940 FAILURE CODE [D19JKZ] ............................................................................................................40-942 FAILURE CODE [D1E6KA] ...........................................................................................................40-944 FAILURE CODE [D1E6KB] ...........................................................................................................40-946 FAILURE CODE [D1E6KY] ...........................................................................................................40-948 FAILURE CODE [D5ZHKA]...........................................................................................................40-950 FAILURE CODE [D5ZHKB]...........................................................................................................40-952 FAILURE CODE [D5ZHKZ] ...........................................................................................................40-954 FAILURE CODE [D5ZHL6]............................................................................................................40-957 FAILURE CODE [D5ZMLD]...........................................................................................................40-959 FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) ........................................40-961 FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ...............40-962 FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL).........................................40-963 WA500-8E0

00-11

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)................40-964 FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) ........................................40-965 FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ...............40-967 FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) ........................................40-969 FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ...............40-971 FAILURE CODE [D8AQK4] (MACHINE WITH KOMTRAX TERMINAL) ........................................40-973 FAILURE CODE [D8AQK4] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ...............40-974 FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) .......................................40-975 FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ..............40-977 FAILURE CODE [D8G1KT] ...........................................................................................................40-979 FAILURE CODE [D8G6KT] ...........................................................................................................40-980 FAILURE CODE [DAF0KT] ...........................................................................................................40-981 FAILURE CODE [DAF0MB] ..........................................................................................................40-982 FAILURE CODE [DAF0MC] ..........................................................................................................40-983 FAILURE CODE [DAF3KK] ...........................................................................................................40-984 FAILURE CODE [DAF8KB] ...........................................................................................................40-986 FAILURE CODE [DAFDKB] ..........................................................................................................40-988 FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL).......................................40-990 FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)..............40-991 FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) ........................................40-992 FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ...............40-994 FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) ........................................40-996 FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ...............40-998 FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) .....................................40-1000 FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ............40-1001 FAILURE CODE [DAQ0KK] ........................................................................................................40-1002 FAILURE CODE [DAQ0KT].........................................................................................................40-1005 FAILURE CODE [DAQ0MC]........................................................................................................40-1006 FAILURE CODE [DAQ1KA] ........................................................................................................40-1007 FAILURE CODE [DAQ2KK] ........................................................................................................40-1010 FAILURE CODE [DAQ4KB] ........................................................................................................40-1013 FAILURE CODE [DAQ9KQ] ........................................................................................................40-1015 FAILURE CODE [DAQLKA] (MACHINE WITH KOMTRAX TERMINAL)......................................40-1016 FAILURE CODE [DAQLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER).............40-1018 FAILURE CODE [DAQLKB] (MACHINE WITH KOMTRAX TERMINAL)......................................40-1020 FAILURE CODE [DAQLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER).............40-1022 FAILURE CODE [DAQQKR] .......................................................................................................40-1024 FAILURE CODE [DAQRKR]........................................................................................................40-1025 FAILURE CODE [DAQRMA] .......................................................................................................40-1026 FAILURE CODE [DAZ9KQ].........................................................................................................40-1027 FAILURE CODE [DAZQKR] ........................................................................................................40-1028 FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) .....................................40-1029 FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ............40-1034 FAILURE CODE [DB2RKR] ........................................................................................................40-1039 FAILURE CODE [DB90KK] .........................................................................................................40-1045 FAILURE CODE [DB90KT] .........................................................................................................40-1048 FAILURE CODE [DB90MC] ........................................................................................................40-1049 FAILURE CODE [DB91KA] .........................................................................................................40-1050 FAILURE CODE [DB92KK] .........................................................................................................40-1053 FAILURE CODE [DB95KX] .........................................................................................................40-1056 FAILURE CODE [DB96KX] .........................................................................................................40-1059 FAILURE CODE [DB99KQ].........................................................................................................40-1061 FAILURE CODE [DB9LKA] (MACHINE WITH KOMTRAX TERMINAL) ......................................40-1062 FAILURE CODE [DB9LKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .............40-1064 FAILURE CODE [DB9LKB] (MACHINE WITH KOMTRAX TERMINAL) ......................................40-1066 FAILURE CODE [DB9LKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .............40-1068 FAILURE CODE [DB9QKR] ........................................................................................................40-1070 FAILURE CODE [DB9RKR] ........................................................................................................40-1071 00-12

WA500-8E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [DB9RMA] ........................................................................................................40-1072 FAILURE CODE [DBE5KX].........................................................................................................40-1073 FAILURE CODE [DBE6KX].........................................................................................................40-1075 FAILURE CODE [DD1ALD].........................................................................................................40-1077 FAILURE CODE [DDA8KY].........................................................................................................40-1079 FAILURE CODE [DDA9KY].........................................................................................................40-1081 FAILURE CODE [DDAAL6] .........................................................................................................40-1083 FAILURE CODE [DDAAL6] .........................................................................................................40-1085 FAILURE CODE [DDB6L4] .........................................................................................................40-1088 FAILURE CODE [DDD1LD].........................................................................................................40-1091 FAILURE CODE [DDE5KA].........................................................................................................40-1093 FAILURE CODE [DDK3KA].........................................................................................................40-1095 FAILURE CODE [DDK3KB].........................................................................................................40-1098 FAILURE CODE [DDK4KA].........................................................................................................40-1101 FAILURE CODE [DDK4KB].........................................................................................................40-1104 FAILURE CODE [DDK5L4] .........................................................................................................40-1106 FAILURE CODE [DDK6KA].........................................................................................................40-1108 FAILURE CODE [DDK6KB]......................................................................................................... 40-1111 FAILURE CODE [DDKLKA]......................................................................................................... 40-1114 FAILURE CODE [DDKLKB]......................................................................................................... 40-1116 FAILURE CODE [DDNRKY]........................................................................................................ 40-1118 FAILURE CODE [DDP5KA].........................................................................................................40-1120 FAILURE CODE [DDT0L4]..........................................................................................................40-1122 FAILURE CODE [DDT4LD] .........................................................................................................40-1124 FAILURE CODE [DDT9LD] .........................................................................................................40-1126 FAILURE CODE [DDTALD].........................................................................................................40-1128 FAILURE CODE [DDW9LD]........................................................................................................40-1130 FAILURE CODE [DDWLLD]........................................................................................................40-1132 FAILURE CODE [DF10KA] .........................................................................................................40-1134 FAILURE CODE [DF10KB] .........................................................................................................40-1137 FAILURE CODE [DGF1KA].........................................................................................................40-1140 FAILURE CODE [DGF1KB].........................................................................................................40-1142 FAILURE CODE [DGH2KX] ........................................................................................................40-1144 FAILURE CODE [DGR2KB] ........................................................................................................40-1146 FAILURE CODE [DGR2KZ] ........................................................................................................40-1148 FAILURE CODE [DGT1KA].........................................................................................................40-1150 FAILURE CODE [DGT1KB].........................................................................................................40-1152 FAILURE CODE [DH21KA] .........................................................................................................40-1154 FAILURE CODE [DH21KB] .........................................................................................................40-1157 FAILURE CODE [DHA4KA].........................................................................................................40-1159 FAILURE CODE [DHAAMA]........................................................................................................40-1161 FAILURE CODE [DHACMA] .......................................................................................................40-1163 FAILURE CODE [DHPCKX] ........................................................................................................40-1165 FAILURE CODE [DHPDKX] ........................................................................................................40-1168 FAILURE CODE [DHQ2KX] ........................................................................................................40-1171 FAILURE CODE [DHT1KX].........................................................................................................40-1173 FAILURE CODE [DHT2L6]..........................................................................................................40-1176 FAILURE CODE [DHT5KX].........................................................................................................40-1178 FAILURE CODE [DHT7KX].........................................................................................................40-1181 FAILURE CODE [DHT8KA].........................................................................................................40-1184 FAILURE CODE [DHT8KB].........................................................................................................40-1187 FAILURE CODE [DHT8ZG].........................................................................................................40-1189 FAILURE CODE [DJF1KA]..........................................................................................................40-1190 FAILURE CODE [DK30KA] .........................................................................................................40-1192 FAILURE CODE [DK30KY] .........................................................................................................40-1194 FAILURE CODE [DK55KA] .........................................................................................................40-1196 FAILURE CODE [DK55KY] .........................................................................................................40-1199 FAILURE CODE [DK55L5] ..........................................................................................................40-1201 WA500-8E0

00-13

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INDEX

00 INDEX AND FOREWORD

FAILURE CODE [DK59KA] .........................................................................................................40-1202 FAILURE CODE [DK59KY] .........................................................................................................40-1206 FAILURE CODE [DK59L8] ..........................................................................................................40-1210 FAILURE CODE [DK5AKA].........................................................................................................40-1215 FAILURE CODE [DK5AKY].........................................................................................................40-1219 FAILURE CODE [DK5BKA].........................................................................................................40-1223 FAILURE CODE [DK5BKY].........................................................................................................40-1227 FAILURE CODE [DK5BL8]..........................................................................................................40-1231 FAILURE CODE [DK5CKA].........................................................................................................40-1236 FAILURE CODE [DK5CKY].........................................................................................................40-1240 FAILURE CODE [DK5DKA].........................................................................................................40-1244 FAILURE CODE [DK5DKY].........................................................................................................40-1247 FAILURE CODE [DK5DL8] .........................................................................................................40-1250 FAILURE CODE [DK5EKA].........................................................................................................40-1255 FAILURE CODE [DK5EKY].........................................................................................................40-1258 FAILURE CODE [DK5FKA] .........................................................................................................40-1261 FAILURE CODE [DK5FKY] .........................................................................................................40-1264 FAILURE CODE [DK5FL8]..........................................................................................................40-1267 FAILURE CODE [DK5GKA] ........................................................................................................40-1271 FAILURE CODE [DK5GKY] ........................................................................................................40-1274 FAILURE CODE [DKA0KA].........................................................................................................40-1277 FAILURE CODE [DKA0KY].........................................................................................................40-1280 FAILURE CODE [DKA0L0]..........................................................................................................40-1283 FAILURE CODE [DKA1KA].........................................................................................................40-1286 FAILURE CODE [DKA1KY].........................................................................................................40-1289 FAILURE CODE [DKD0KA].........................................................................................................40-1292 FAILURE CODE [DKD0KY].........................................................................................................40-1294 FAILURE CODE [DKD0L8] .........................................................................................................40-1296 FAILURE CODE [DLF1KA] .........................................................................................................40-1297 FAILURE CODE [DLF1LC]..........................................................................................................40-1299 FAILURE CODE [DLM3KA].........................................................................................................40-1301 FAILURE CODE [DLM3LC].........................................................................................................40-1303 FAILURE CODE [DLT3KA]..........................................................................................................40-1305 FAILURE CODE [DLT3LC]..........................................................................................................40-1307 FAILURE CODE [DPQ1KR] ........................................................................................................40-1309 FAILURE CODE [DPQ2KR] ........................................................................................................40-1312 FAILURE CODE [DPQ3KR] ........................................................................................................40-1315 FAILURE CODE [DSJ0KR] .........................................................................................................40-1319 FAILURE CODE [DT20KB] .........................................................................................................40-1323 FAILURE CODE [DT22KB] .........................................................................................................40-1325 FAILURE CODE [DT23KB] .........................................................................................................40-1327 FAILURE CODE [DV00KB] .........................................................................................................40-1329 FAILURE CODE [DW2BKA]........................................................................................................40-1331 FAILURE CODE [DW2BKB]........................................................................................................40-1332 FAILURE CODE [DW2BKY]........................................................................................................40-1333 FAILURE CODE [DW2BL1].........................................................................................................40-1334 FAILURE CODE [DW2BLH] ........................................................................................................40-1336 FAILURE CODE [DW4PKA]........................................................................................................40-1338 FAILURE CODE [DW4PKB]........................................................................................................40-1340 FAILURE CODE [DW4PKY]........................................................................................................40-1342 FAILURE CODE [DW4QKA] .......................................................................................................40-1344 FAILURE CODE [DW4QKB] .......................................................................................................40-1346 FAILURE CODE [DW4QKY] .......................................................................................................40-1348 FAILURE CODE [DW4RKA]........................................................................................................40-1350 FAILURE CODE [DW4RKB]........................................................................................................40-1352 FAILURE CODE [DW4RKY]........................................................................................................40-1354 FAILURE CODE [DW4SKA]........................................................................................................40-1356 FAILURE CODE [DW4SKB]........................................................................................................40-1358 00-14

WA500-8E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [DW4SKY]........................................................................................................40-1360 FAILURE CODE [DW7BKA]........................................................................................................40-1362 FAILURE CODE [DW7BKB]........................................................................................................40-1364 FAILURE CODE [DW7BKY]........................................................................................................40-1366 FAILURE CODE [DWM1KA] .......................................................................................................40-1367 FAILURE CODE [DWM1KB] .......................................................................................................40-1369 FAILURE CODE [DWM1KY] .......................................................................................................40-1371 FAILURE CODE [DWN6KA]........................................................................................................40-1373 FAILURE CODE [DWN6KB]........................................................................................................40-1375 FAILURE CODE [DWN6KY]........................................................................................................40-1377 FAILURE CODE [DWN8KA]........................................................................................................40-1379 FAILURE CODE [DWN8KB]........................................................................................................40-1381 FAILURE CODE [DWN8KY]........................................................................................................40-1383 FAILURE CODE [DX16KA] .........................................................................................................40-1385 FAILURE CODE [DX16KB] .........................................................................................................40-1387 FAILURE CODE [DX16KY] .........................................................................................................40-1389 FAILURE CODE [DXA1KA].........................................................................................................40-1391 FAILURE CODE [DXA1KB].........................................................................................................40-1393 FAILURE CODE [DXA1KY].........................................................................................................40-1395 FAILURE CODE [DXF0KA] .........................................................................................................40-1397 FAILURE CODE [DXF0KB] .........................................................................................................40-1399 FAILURE CODE [DXF0KY] .........................................................................................................40-1401 FAILURE CODE [DXH1KA].........................................................................................................40-1403 FAILURE CODE [DXH1KB].........................................................................................................40-1405 FAILURE CODE [DXH1KY].........................................................................................................40-1407 FAILURE CODE [DXH4KA].........................................................................................................40-1409 FAILURE CODE [DXH4KB].........................................................................................................40-1411 FAILURE CODE [DXH4KY].........................................................................................................40-1413 FAILURE CODE [DXH5KA].........................................................................................................40-1415 FAILURE CODE [DXH5KB].........................................................................................................40-1417 FAILURE CODE [DXH5KY].........................................................................................................40-1419 FAILURE CODE [DXH6KA].........................................................................................................40-1421 FAILURE CODE [DXH6KB].........................................................................................................40-1423 FAILURE CODE [DXH6KY].........................................................................................................40-1425 FAILURE CODE [DXH7KA].........................................................................................................40-1427 FAILURE CODE [DXH7KB].........................................................................................................40-1429 FAILURE CODE [DXH7KY].........................................................................................................40-1431 FAILURE CODE [DXH8KA].........................................................................................................40-1433 FAILURE CODE [DXH8KB].........................................................................................................40-1435 FAILURE CODE [DXH8KY].........................................................................................................40-1437 FAILURE CODE [DXHHKA] ........................................................................................................40-1439 FAILURE CODE [DXHHKB] ........................................................................................................40-1441 FAILURE CODE [DXHHKY] ........................................................................................................40-1443 FAILURE CODE [DXHJKA].........................................................................................................40-1445 FAILURE CODE [DXHJKB].........................................................................................................40-1447 FAILURE CODE [DXHJKY].........................................................................................................40-1449 FAILURE CODE [DXHKKA] ........................................................................................................40-1451 FAILURE CODE [DXHKKB] ........................................................................................................40-1453 FAILURE CODE [DXHKKY] ........................................................................................................40-1455 FAILURE CODE [DXHLKA].........................................................................................................40-1457 FAILURE CODE [DXHLKB].........................................................................................................40-1459 FAILURE CODE [DXHLKY].........................................................................................................40-1461 FAILURE CODE [DXHMKA]........................................................................................................40-1463 FAILURE CODE [DXHMKB]........................................................................................................40-1465 FAILURE CODE [DXHMKY]........................................................................................................40-1467 FAILURE CODE [F313KA] ..........................................................................................................40-1469 FAILURE CODE [F313KB] ..........................................................................................................40-1471 FAILURE CODE [F318KB] ..........................................................................................................40-1472 WA500-8E0

00-15

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [F318KY] ..........................................................................................................40-1474 FAILURE CODE [LA00L3]...........................................................................................................40-1475 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .........................................................40-1476 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ..............................................40-1476 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK........................................................40-1485 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ..................................................40-1488 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.....40-1491 E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING ................................................................................................................................................40-1493 E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (FOR MACHINES EQUIPPED WITH EMERGENCY ENGINE STOP SWITCH)......................40-1496 E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING ................................................40-1499 E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) .......................................................................................................................40-1502 E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY ......................................40-1505 E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL ...................................40-1508 E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL ..... 40-1511 E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL ..............................................40-1515 E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY .........................................................................40-1517 E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION........................................................................................................................................40-1520 E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL ................................40-1523 E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY ..............................................................................................................40-1526 E-17 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY.......................................................40-1527 E-18 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS.....................40-1530 E-19 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY ..................................40-1534 E-20 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED......................................40-1538 E-21 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL ...............................40-1542 E-22 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP ............................40-1544 E-23 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP ...........................40-1546 E-24 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION ................................................................................................40-1548 E-25 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP ......................................................................40-1552 E-26 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP.................................................................................40-1553 E-27 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .....................................40-1554 E-28 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP........................40-1556 E-29 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ....................................40-1557 E-30 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL ...............................................40-1559 E-31 ALARM BUZZER DOES NOT SOUND ..............................................................................40-1561 E-32 ALARM BUZZER DOES NOT STOP SOUNDING ..............................................................40-1563 E-33 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON ...............40-1564 E-34 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED .............................................40-1566 E-35 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED...........................................................40-1568 E-36 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED..................40-1572 E-37 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED ......................................40-1574 E-38 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED..... ................................................................................................................................................40-1576 E-39 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED............................................................40-1578 E-40 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE............40-1580 E-41 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED .....................40-1581 00-16

WA500-8E0

00 INDEX AND FOREWORD

INDEX

E-42 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED (FOR AJSS SPEC) ... ................................................................................................................................................40-1583 E-43 HORN DOES NOT SOUND................................................................................................40-1585 E-44 HORN DOES NOT SOUND (FOR AJSS SPEC) ................................................................40-1588 E-45 HORN DOES NOT STOP SOUNDING...............................................................................40-1591 E-46 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS............................40-1594 E-47 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS (FOR AJSS SPEC) ......... ................................................................................................................................................40-1596 E-48 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT...........................40-1598 E-49 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) ........ ................................................................................................................................................40-1602 E-50 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT .........40-1606 E-51 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) .....................................................................................................................................40-1610 E-52 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT ....................................40-1614 E-53 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC).....40-1616 E-54 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT ...................................40-1618 E-55 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) ....40-1620 E-56 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT ........................................40-1622 E-57 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT...........................................40-1626 E-58 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT40-1630 E-59 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) ...........................................................................................................................40-1633 E-60 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT .................................................40-1636 E-61 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) ..................40-1639 E-62 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT ........................................................40-1643 E-63 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED ...................................................40-1647 E-64 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT.....................................40-1651 E-65 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND.............................40-1655 E-66 FRONT WIPER DOES NOT OPERATE .............................................................................40-1657 E-67 FRONT WIPER DOES NOT OPERATE (FOR AJSS SPEC) ..............................................40-1661 E-68 REAR WIPER DOES NOT OPERATE................................................................................40-1665 E-69 REAR WIPER DOES NOT OPERATE (FOR AJSS SPEC).................................................40-1668 E-70 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY .........................40-1671 E-71 WINDOW WASHER DOES NOT OPERATE ......................................................................40-1674 E-72 WINDOW WASHER DOES NOT OPERATE (FOR AJSS SPEC) .......................................40-1677 E-73 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1680 E-74 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP............................40-1681 E-75 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP.............................40-1683 E-76 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP ........................................40-1684 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1686 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1686 FAILURE MODE AND CAUSE TABLE........................................................................................40-1687 H-1 MACHINE DOES NOT START .............................................................................................40-1710 H-2 LOCKUP IS NOT RELEASED..............................................................................................40-1713 H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE ....................................40-1714 H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT ..........................................................................................40-1715 H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED ...........40-1718 H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED ..40-1721 H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH ................................................40-1724 H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) ........................................40-1726 H-9 MACHINE DOES NOT TURN (JOYSTICKSTEERING SPECIFICATION) ............................40-1728 H-10 MACHINE DOES NOT TURN (AJSS SPECIFICATION).....................................................40-1730 H-11 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) .................................40-1732 H-12 TURNING RESPONSE IS POOR (JOYSTICKSTEERING SPECIFICATION) ....................40-1734 H-13 TURNING RESPONSE IS POOR (AJSS SPECIFICATION)...............................................40-1736 H-14 STEERING WHEEL IS HEAVY TO OPERATE ...................................................................40-1738 WA500-8E0

00-17

INDEX

00 INDEX AND FOREWORD

H-15 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) ................................................................................................................40-1739 H-16 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (JOYSTICKSTEERING SPECIFICATION)......................................................................................................40-1741 H-17 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (AJSS SPECIFICATION)...............................................................................................................................40-1743 H-18 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS ...............................40-1745 H-19 WHEEL BRAKES DO NOT WORK OR ARE WEAK...........................................................40-1746 H-20 WHEEL BRAKES ARE NOT RELEASED OR DRAG .........................................................40-1748 H-21 PARKING BRAKE DOES NOT WORK OR IT IS WEAK .....................................................40-1749 H-22 PARKING BRAKE IS NOT RELEASED OR DRAGS ..........................................................40-1750 H-23 BOOM DOES NOT RISE ...................................................................................................40-1752 H-24 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE.............................................40-1754 H-25 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT .....................................................40-1756 H-26 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND ............................40-1757 H-27 HYDRAULIC DRIFT OF BOOM IS LARGE ........................................................................40-1758 H-28 BOOM MOVES UP AND DOWN DURING OPERATION....................................................40-1759 H-29 BUCKET DOES NOT TILT BACK.......................................................................................40-1760 H-30 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE.................................................40-1762 H-31 BUCKET DECELERATES DURING TILT-BACK OPERATION ...........................................40-1764 H-32 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND .....................................40-1765 H-33 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................40-1766 H-34 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) ................................................................................................................................40-1767 H-35 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE......................................................................................................................................40-1768 H-36 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (MULTI-FUNCTION MONO-LEVER TYPE)..................................................................40-1769 H-37 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ....................................................................................................................................40-1770 H-38 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS ...... ................................................................................................................................................40-1771 H-39 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES ...................................................................................................................................40-1773 H-40 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES ..... ................................................................................................................................................40-1774 H-41 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ............................40-1775 H-42 UNUSUAL NOISE IS HEARD FROM AROUND FAN .........................................................40-1776 TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1777 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1777 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION....... ................................................................................................................................................40-1778 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1779 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) ........................................................................................................40-1780 S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1781 S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1783 S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1785 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1787 S-8 ENGINE LACKS POWER.....................................................................................................40-1788 S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1790 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1792 S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1793 S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1794 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ....... ................................................................................................................................................40-1795 S-14 OIL PRESSURE DROPS ...................................................................................................40-1796 S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1798 00-18

WA500-8E0

00 INDEX AND FOREWORD

INDEX

S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1799 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1800 S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1801 S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1802 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1803 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1804 S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1806 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1808 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1809 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1811 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1812 TROUBLESHOOTING FOR AUTO-GREASING SYSTEM.................................................................40-1813 OUTLINE OF FAILURE DISPLAY ...............................................................................................40-1813 TROUBLESHOOTING FOR FCS................................................................................................40-1814 TROUBLESHOOTING FOR AUTO-GREASING PUMP ..............................................................40-1815 REPLACEMENT OF PUMP ELEMENT ......................................................................................40-1818 TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM..........................................................40-1819 REPLACEMENT OF AUTO-GREASING CONTROLLER............................................................40-1821 PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING ......40-1822 50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1 CONTENTS ............................................................................................................................................ 50-2 ABBREVIATION LIST ............................................................................................................................. 50-7 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ........................................................ 50-13 HOW TO READ THIS MANUAL..................................................................................................... 50-13 COATING MATERIALS LIST.......................................................................................................... 50-15 SPECIAL TOOLS LIST .................................................................................................................. 50-19 SKETCHES OF SPECIAL TOOLS................................................................................................. 50-45 ENGINE AND COOLING SYSTEM....................................................................................................... 50-54 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-54 REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-64 REMOVE AND INSTALL FUEL DOSER ASSEMBLY .................................................................... 50-89 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-93 REMOVE AND INSTALL EGR VALVE ASSEMBLY.......................................................................50-120 REMOVE AND INSTALL EGR COOLER ASSEMBLY...................................................................50-122 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY ..........................................................50-130 REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-133 REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-135 REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY....................................50-147 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-153 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-165 REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY...........................................50-176 REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 50-181 DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY ..................................................................................................................................................50-216 REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-218 REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-223 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-231 REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-239 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-245 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-262 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-266 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-269 REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-271 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-279 REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-289 REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-297 REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-304 REMOVE AND INSTALL VGT ASSEMBLY...................................................................................50-309 WA500-8E0

00-19

INDEX

00 INDEX AND FOREWORD

REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-316 REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-323 REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-329 REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-335 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-350 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-356 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-360 POWER TRAIN....................................................................................................................................50-363 DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY ....50-363 REMOVE AND INSTALL FRONT DIFFERENTIAL ASSEMBLY....................................................50-375 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY (SPECIFICATION WITH LSD) ..50-379 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY (SPECIFICATION WITHOUT LSD) ...... ..................................................................................................................................................50-399 DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY .....................................50-415 DISASSEMBLE AND ASSEMBLE INPUT TRANSFER ASSEMBLY .............................................50-435 DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY.................................................50-445 DISASSEMBLE AND ASSEMBLE TRANSFER AND PARKING BRAKE ASSEMBLY ..................50-488 REMOVE AND INSTALL FRONT AXLE ASSEMBLY ....................................................................50-515 REMOVE AND INSTALL REAR AXLE ASSEMBLY ......................................................................50-519 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY (FRONT, REAR)...........................50-524 STEERING SYSTEM ...........................................................................................................................50-533 REMOVE AND INSTALL STEERING VALVE ASSEMBLY ............................................................50-533 REMOVE AND INSTALL ROTARY VALVE ASSEMBLY (FOR AJSS SPEC).................................50-537 BRAKE SYSTEM .................................................................................................................................50-554 DISASSEMBLE AND ASSEMBLE SLACK ADJUSTER ASSEMBLY ............................................50-554 DISASSEMBLE AND ASSEMBLE BRAKE ACCUMULATOR CHARGE VALVE ASSEMBLY........50-555 REMOVE AND INSTALL BRAKE ASSEMBLY (FRONT, REAR) ...................................................50-557 DISASSEMBLE AND ASSEMBLE BRAKE ASSEMBLY (FRONT, REAR).....................................50-561 UNDERCARRIAGE AND FRAME........................................................................................................50-570 REMOVE AND INSTALL CENTER HINGE PIN ............................................................................50-570 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-586 REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY ..................................................50-591 HYDRAULIC SYSTEM.........................................................................................................................50-594 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-594 REMOVE AND INSTALL WORK EQUIPMENT PUMP ASSEMBLY ..............................................50-606 REMOVE AND INSTALL DIVIDER VALVE ASSEMBLY ................................................................50-614 DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY.......................................50-619 REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY ...............50-624 REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY.......................................................50-633 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-639 WORK EQUIPMENT............................................................................................................................50-645 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-645 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY........................50-653 CAB AND ITS ATTACHMENTS ...........................................................................................................50-660 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-660 REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS) .................................50-680 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-690 REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY..........................................................50-701 REMOVE AND INSTALL SWITCH ASSEMBLY OF AJSS LEVER ................................................50-705 REMOVE AND INSTALL SEAT BELT ...........................................................................................50-711 ELECTRICAL SYSTEM .......................................................................................................................50-713 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-713 REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY ................................50-719 REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY ......................................50-723 REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY ................................................50-725 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-729 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-732 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-735 00-20

WA500-8E0

00 INDEX AND FOREWORD

INDEX

REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-738 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-742 REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY.............................50-744 REMOVE AND INSTALL COMMUNICATION TERMINAL.............................................................50-746 60 MAINTENANCE STANDARD.................................................................................................................... 60-1 CONTENTS ............................................................................................................................................ 60-2 ABBREVIATION LIST ............................................................................................................................. 60-3 ENGINE AND COOLING SYSTEM......................................................................................................... 60-9 MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-9 MAINTENANCE STANDARD OF JOINT.........................................................................................60-11 MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP ......................................... 60-12 MAINTENANCE STANDARD OF COOLING FAN MOTOR............................................................ 60-15 POWER TRAIN..................................................................................................................................... 60-17 MAINTENANCE STANDARD OF DRIVE SHAFT........................................................................... 60-17 MAINTENANCE STANDARD OF TORQUE CONVERTER............................................................ 60-19 MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV ......................................................... 60-24 MAINTENANCE STANDARD OF TRANSMISSION ....................................................................... 60-25 MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE ......................................... 60-33 MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV ......................................................................................................................... 60-34 MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE ......................... 60-35 MAINTENANCE STANDARD OF MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE....................................................................................... 60-36 MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE ..................... 60-38 MAINTENANCE STANDARD OF FRONT AXLE............................................................................ 60-39 MAINTENANCE STANDARD OF REAR AXLE .............................................................................. 60-40 MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL............................... 60-41 MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL .................................... 60-45 MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-47 STEERING SYSTEM ............................................................................................................................ 60-49 MAINTENANCE STANDARD OF STEERING COLUMN................................................................ 60-49 MAINTENANCE STANDARD OF STEERING PUMP..................................................................... 60-50 MAINTENANCE STANDARD OF STEERING VALVE .................................................................... 60-54 MAINTENANCE STANDARD OF STEERING CYLINDER ............................................................. 60-55 MAINTENANCE STANDARD OF DIVERTER VALVE .................................................................... 60-57 MAINTENANCE STANDARD OF SECONDARY STEERING PUMP ............................................. 60-58 BRAKE SYSTEM .................................................................................................................................. 60-59 MAINTENANCE STANDARD OF CHARGE VALVE ....................................................................... 60-59 MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR........................................... 60-61 MAINTENANCE STANDARD OF BRAKE VALVE .......................................................................... 60-62 MAINTENANCE STANDARD OF SLACK ADJUSTER................................................................... 60-63 MAINTENANCE STANDARD OF BRAKE ...................................................................................... 60-64 MAINTENANCE STANDARD OF PARKING BRAKE ..................................................................... 60-66 MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE ...................................... 60-68 UNDERCARRIAGE AND FRAME......................................................................................................... 60-69 MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN.................. 60-69 HYDRAULIC SYSTEM.......................................................................................................................... 60-74 MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-74 MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP...................................................... 60-75 MAINTENANCE STANDARD OF POWER TRAIN CHARGE DUPLEX PUMP............................... 60-77 MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-79 MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE ....................... 60-88 WORK EQUIPMENT............................................................................................................................. 60-89 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-89 MAINTENANCE STANDARD OF BUCKET.................................................................................... 60-93 MAINTENANCE STANDARD OF LIFT CYLINDER........................................................................ 60-95 MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-96 80 APPENDIX................................................................................................................................................ 80-1 WA500-8E0

00-21

INDEX

00 INDEX AND FOREWORD

CONTENTS ............................................................................................................................................ 80-2 ABBREVIATION LIST ............................................................................................................................. 80-4 AIR CONDITIONER SYSTEM .............................................................................................................. 80-10 PRECAUTIONS FOR REFRIGERANT .......................................................................................... 80-10 AIR CONDITIONER COMPONENT ................................................................................................80-11 SPECIFICATIONS OF AIR CONDITIONER ................................................................................... 80-13 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................. 80-14 OUTLINE OF REFRIGERATION CYCLE ....................................................................................... 80-15 COMPONENT PARTS OF AIR CONDITIONER SYSTEM .................................................................... 80-17 AIR CONDITIONER UNIT.............................................................................................................. 80-17 COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-19 AIR CONDITIONER CONTROLLER .............................................................................................. 80-23 COMPRESSOR ............................................................................................................................. 80-24 CONDENSER ................................................................................................................................ 80-25 RECEIVER DRIER......................................................................................................................... 80-26 SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-27 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...... .......................................................................................................................................................... 80-28 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-30 AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-33 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-34 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .. .......................................................................................................................................................... 80-36 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................ 80-42 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR .......................................................................................................... 80-43 CHECK TEMPERATURE CONTROL FUNCTION ................................................................................ 80-45 METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION .......................................... 80-45 TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-47 METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-47 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-49 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-49 TEST EVAPORATOR TEMPERATURE SENSOR ................................................................................ 80-51 TEST RELAYS...................................................................................................................................... 80-53 METHOD FOR TESTING RELAYS ................................................................................................ 80-53 AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-55 AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-56 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-59 FAILURE CODE [879AKA].................................................................................................................... 80-61 FAILURE CODE [879AKB].................................................................................................................... 80-63 FAILURE CODE [879BKA].................................................................................................................... 80-65 FAILURE CODE [879BKB].................................................................................................................... 80-67 FAILURE CODE [879CKA].................................................................................................................... 80-69 FAILURE CODE [879CKB].................................................................................................................... 80-71 FAILURE CODE [879DKZ].................................................................................................................... 80-73 FAILURE CODE [879EMC] ................................................................................................................... 80-75 FAILURE CODE [879FMC] ................................................................................................................... 80-78 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE). .......................................................................................................................................................... 80-81 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)... .......................................................................................................................................................... 80-84 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) ..................................................................................................................................... 80-87 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-91 TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-93 CONNECTION OF SERVICE TOOL ..................................................................................................... 80-96 METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-97

00-22

WA500-8E0

00 INDEX AND FOREWORD

INDEX

PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...................................................................................................................................... 80-98 HANDLE COMPRESSOR OIL .............................................................................................................80-100 90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1 CONTENTS ............................................................................................................................................ 90-2 ABBREVIATION LIST ............................................................................................................................. 90-5 HYDRAULIC CIRCUIT DIAGRAM .........................................................................................................90-11 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................90-11 HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC)........ ................................................................................................................................................... 90-15 HYDRAULIC CIRCUIT DIAGRAM (FOR AJSS SPEC) .................................................................. 90-17 HYDRAULIC CIRCUIT DIAGRAM OF BRAKE SYSTEM ............................................................... 90-19 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM........................................................................ 90-21 HYDRAULIC AUTO-GREASING DIAGRAM .................................................................................. 90-23 ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-25 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-25 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (1/6)........ ................................................................................................................................................... 90-29 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (2/6)........ ................................................................................................................................................... 90-31 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (3/6)........ ................................................................................................................................................... 90-33 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (4/6)........ ................................................................................................................................................... 90-35 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (5/6)........ ................................................................................................................................................... 90-37 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (6/6)........ ................................................................................................................................................... 90-39 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/6) ......................................................................................................................... 90-41 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/6) ......................................................................................................................... 90-43 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/6) ......................................................................................................................... 90-45 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/6) ......................................................................................................................... 90-47 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/6) ......................................................................................................................... 90-49 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/6) ......................................................................................................................... 90-51 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/6) ............................................................. 90-53 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/6) ............................................................. 90-55 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/6) ............................................................. 90-57 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/6) ............................................................. 90-59 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/6) ............................................................. 90-61 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/6) ............................................................. 90-63 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/10) .................................................... 90-65 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/10) .................................................... 90-67 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/10) .................................................... 90-69 WA500-8E0

00-23

INDEX

00 INDEX AND FOREWORD

ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/10) .................................................... 90-71 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/10) .................................................... 90-73 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/10) .................................................... 90-75 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (7/10) .................................................... 90-77 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (8/10) .................................................... 90-79 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (9/10) .................................................... 90-81 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR STEERING WHEEL AND JOYSTICK STEERING SPEC) (MACHINE WITH KOMTRAX TERMINAL) (10/10) .................................................. 90-83 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/11)................................................................. 90-85 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/11)................................................................. 90-87 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/11)................................................................. 90-89 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/11)................................................................. 90-91 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/11)................................................................. 90-93 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/11)................................................................. 90-95 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/11)................................................................. 90-97 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/11)................................................................. 90-99 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/11)................................................................90-101 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/11)..............................................................90-103 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (11/11) ..............................................................90-105 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/9)..............................................................................................................................90-107 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/9)..............................................................................................................................90-109 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/9).............................................................................................................................. 90-111 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/9)..............................................................................................................................90-113 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/9)..............................................................................................................................90-115 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/9)..............................................................................................................................90-117 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (7/9)..............................................................................................................................90-119 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (8/9)..............................................................................................................................90-121 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH KOMTRAX TERMINAL) (9/9)..............................................................................................................................90-123 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/10) ...........................................................................................90-125 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/10) ...........................................................................................90-127 00-24

WA500-8E0

00 INDEX AND FOREWORD

INDEX

ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/10) ...........................................................................................90-129 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/10) ...........................................................................................90-131 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/10) ...........................................................................................90-133 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/10) ...........................................................................................90-135 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/10) ...........................................................................................90-137 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/10) ...........................................................................................90-139 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/10) ...........................................................................................90-141 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/10) .........................................................................................90-143 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (1/8) ........................................................................90-145 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (2/8) ........................................................................90-147 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (3/8) ........................................................................90-149 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (4/8) ........................................................................90-151 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (5/8) ........................................................................90-153 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (6/8) ........................................................................90-155 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (7/8) ........................................................................90-157 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL) (8/8) ........................................................................90-159 INDEX..................................................................................................................................................................1

WA500-8E0

00-25

ABBREVIATION LIST

00 INDEX AND FOREWORD

ABBREVIATION LIST •

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

•

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

•

Special abbreviations which appear infrequently are noted in the text.

•

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

List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)

Abbreviation

Actual word spelled out

ABS

Antilock Brake System

AISS

Automatic Idling Setting Engine System

This is a function that automatically sets the idle speed.

Steering AJSS

Advanced Joystick Steering System

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

ARAC

Automatic Retarder Accelerator Control

Travel and brake (HD, HM)

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

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

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

ARSC

Automatic Retarder Speed Control

ASR

Travel and brake Automatic Spin Regulator (HD, HM)

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

ATT

Attachment

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

BCV

BRAKE Brake cooling oil control valve (HD)

CAN

Controller Area Network

Communication and electronic control

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

CDR

Crankcase Depression Regulator

Engine

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

CLSS

Closed-center Load Sensing System

Hydraulic system

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

00-26

(HD, HM)

Work equipment

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

WA500-8E0

00 INDEX AND FOREWORD

Abbreviation

Actual word spelled out

ABBREVIATION LIST

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

Explanation

Engine

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

Electronic control system

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

CRI

Common Rail Injection

ECM

Electronic Control Module

ECMV

Electronic Control Modulation Valve

ECSS

Travel Electronically Controlled Suspension System (WA)

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

ECU

Electronic Control Unit

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

EGR

Exhaust Gas RecirculaEngine tion

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

EMMS

Equipment ManageMachine monitor ment Monitoring System

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

EPC

Electromagnetic ProporHydraulic system tional Control

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

FOPS

Falling Object Protective Cab and canopy Structure

Transmission (D, HD, WA, etc)

Electronic control system

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

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

F-N-R

Forward-Neutral-Reverse

GPS

Global Positioning System

GNSS

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

HSS

Hydrostatic Steering System

HST

Hydro Static Transmission

Operation Communication (KOMTRAX, KOMTRAX Plus)

Steering

WA500-8E0

(D Series) Transmission (D, WA)

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

This is a general term for system uses satellites such as GPS, GALILEO, etc. This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.

00-27

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ABBREVIATION LIST

00 INDEX AND FOREWORD

Abbreviation

Actual word spelled out

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

Explanation

ICT

Information and Communication Technology

Communication and electronic control

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

IMA

Inlet Metering Actuator

Engine

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

IMU

Inertial Measurement Unit

Engine

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

IMV

Inlet Metering Valve

Engine

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

KCCV

Komatsu Closed CrankEngine case Ventilation

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

KCSF

Komatsu Catalyzed Soot Filter

KDOC

Komatsu Diesel Oxidation Catalyst

KDPF

Engine

Komatsu Diesel ParticuEngine late Filter

This is a filter that captures soot in exhaust gas. It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas. It is built in to KDPF or assembled with the muffler. This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler.

Travel and brake

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

KTCS

Komatsu Traction Control System

(HM)

LCD

Liquid Crystal Display

Machine monitor

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

LED

Light Emitting Diode

Electronic parts

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

LIN

Local Interconnect Network

Communication and electronic control

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

Load Sensing

Hydraulic system

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

LVDS

Low Voltage Differential Signaling

Communication and electronic control

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

Engine

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

MAF

00-28

Mass Air Flow

WA500-8E0

00 INDEX AND FOREWORD

ABBREVIATION LIST

Abbreviation

Actual word spelled out

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

MMS

Multimedia Messaging Service

Communication

Normally Closed

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

Normally Open

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

OLSS

Open-center Load Sensing System

Hydraulic system

Pressure Compensation Hydraulic system

PCCS

Palm command control system

PCV

Pre-stroke Control Valve Engine

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

PPC

Proportional Pressure Control

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

PPM

Piston Pump and Motor

PTO

Power Take Off

PTP

Power Tilt and power Pitch dozer

Steering

ROPS

Roll-Over Protective Structure

(D Series)

Hydraulic system Hydraulic system (D, PC, etc)

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

This is a hydraulic system that can operate multiple actuators at the same time regardless of the load. This is a function that corrects the oil pressure. This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.

Piston type hydraulic pump and motor.

Power train system

Power take-off mechanism

Work equipment

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

(D Series)

Cab and canopy

ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2. This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.

SCR

Selective Catalytic Reduction

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

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

SOL

Solenoid

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

WA500-8E0

Urea SCR system

Electrical system

00-29

ABBREVIATION LIST

Abbreviation

TOPS

00 INDEX AND FOREWORD

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

Actual word spelled out

Tip-Over Protective Structure

Cab and canopy

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

TWV

2-Way Valve

Hydraulic system

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

VGT

Variable Geometry Turbocharger

Engine

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

VHPC

Variable Horse Power Control

Engine control

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

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

List of abbreviations used in the circuit diagrams Abbreviation

Actual word spelled out

A/C

Air Conditioner

A/D

Analogue-to-Digital

A/M

Air Mix Damper

ACC

Accessory

ADD

Additional

AUX

Auxiliary

Battery Relay

Clockwise

CCW

Counter Clockwise

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actuator

No Connection

00-30

WA500-8E0

00 INDEX AND FOREWORD

Abbreviation S/T STRG

Actual word spelled out Steering

SIG

Signal

SOL

Solenoid

STD

Standard

OPT OP

Option

PRESS

Pressure

SPEC

Specification

Switch

TEMP

Temperature

T/C

Torque Converter

T/M

Transmission

WA500-8E0

ABBREVIATION LIST

00-31

HOW TO READ THE SHOP MANUAL

00 INDEX AND FOREWORD

FOREWORD, SAFETY, BASIC INFORMATION HOW TO READ THE SHOP MANUAL •

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

•

The materials and specifications are subject to change without notice.

•

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

•

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

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 SPECIFICATIONS 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 THE OTHER INFORMATION 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.

00-32

WA500-8E0

00 INDEX AND FOREWORD

HOW TO READ THE SHOP MANUAL

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

Item

Remark

Danger

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

Warning

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

Caution

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

Weight

This signal indicates the weight of parts and components, and items which requires great attention to a selection of wires and working posture for slinging work.

Tightening torque

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

Coat

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

Oil and coolant

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

Draining

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

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

Item

Remark

NOTICE

Notice

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

REMARK

Remark

This signal word contains useful information to know.

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

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00-33

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION •

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

•

The symbol mark

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

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

Safety matters •

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.

00-34

WA500-8E0

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

•

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.

•

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.

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 (-).

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00-35

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

•

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 25 kg), 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.

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WA500-8E0

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

•

Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not be damaged by contact with other parts when the machine is operated.

•

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 making 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 Never stand under the load.

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. •

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 (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook.

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00-37

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

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 sys-

tem.

k Slinging

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

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

•

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

Precautions for slinging up •

Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.

•

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

•

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

•

Do not lift up the load at an angle.

Precautions for slinging down •

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

•

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

•

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

Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.

Precautions for using overhead traveling crane k When raising a heavy component (heavier than 25 kg), use a hoist or crane.

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WA500-8E0

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

REMARK Weight of component whose weight is heavier than 25 kg is shown with symbol ASSEMBLY”. •

in “DISASSEMBLY AND

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. •

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.

Selecting 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} )

8.8 {0.9}

12.7 {1.3}

17.3 {1.7}

22.6 {2.3}

28.6 {2.9}

35.3 {3.6}

55.3 {5.6}

79.6 {8.1}

141.6 {14.4}

221.6 {22.6}

318.3 {32.4}

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00-39

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

Precautions for disconnecting 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 col-

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

When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut.

Precautions for air conditioner piping •

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

•

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

•

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

•

When removing the O-rings, use a soft tool so that the piping is not damaged.

•

Check that the O-ring is not damaged or deteriorated.

•

Apply compressor oil for refrigerant (R134a) to O-ring. REMARK Do not apply oil to the threaded portion of a bolt, nut or union. Manufacturer

Part name

DENSO

ND-OIL8

VALEO THERMAL SYSTEMS

ZXL100PG (PAG46 or equivalent)

SANDEN

SP-10

When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).

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WA500-8E0

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

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 THE OTHER INFORMATION, “Precautions for disconnection and connection of air conditioner piping”.

WA500-8E0

00-41

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PRECAUTIONS TO PREVENT FIRE

00 INDEX AND FOREWORD

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 accumulation or attachment of flammable material •

Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.

•

To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.

Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always observe the following. •

Keep all the electric wiring connections clean and securely tightened.

•

Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.

Fire caused by piping Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.

Fire around the machine due to highly heated exhaust gas Some 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.

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WA500-8E0

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•

PRECAUTIONS TO PREVENT FIRE

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 lighting equipment •

When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.

•

When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual.

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00-43

ACTIONS IF FIRE OCCURS

00 INDEX AND FOREWORD

ACTIONS 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.

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WA500-8E0

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PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials. •

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

•

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

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

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

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00-45

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

00 INDEX AND FOREWORD

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS This machine complies with either regulation Tier4 Final (North America) or Stage Ⅳ (EU) (until 2018), Stage V (EU) (after 2019). This machine is equipped with the following two exhaust gas treatment systems: •

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

•

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

Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system. AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of Germany). DEF is the abbreviation for Diesel Exhaust Fluid. Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1. This solution will be represented as DEF throughout this manual.

About DEF DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine. •

In Europe, use AdBlue®.

•

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

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WA500-8E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR DEF

PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require immediate action: •

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

•

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

•

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

•

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

PRECAUTIONS FOR ADDING Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a fire. Some fluids or agents added can create and emit a toxic gas. When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from the filler port during opening or refilling.

PRECAUTIONS FOR STORING If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage. When opening the container, perform it where there is good ventilation. For storage, see “STORE AdBlue/DEF”. Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum container, toxic gas may develop and a chemical reaction may corrode the container.

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE AdBlue/DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base of “Actions if fire occurs”. If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left unattended and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical reactions.

THE OTHER PRECAUTIONS When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precautions for disposing of waste materials”. It should be treated in the same way. Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when handling the fluid waste of AdBlue/DEF. Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water. Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws.

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STORE AdBlue/DEF

00 INDEX AND FOREWORD

STORE AdBlue/DEF •

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

•

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

•

AdBlue/DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above. The relation between the upper limit of storage temperature and the storage period of AdBlue/DEF is shown in the table. Temperature of storage area

Storage period

Max.10 °C

Up to 36 months

Max.25 °C

Up to 18 months

Max.30 °C

Up to 12 months

Max.35 °C

Up to 6 months

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

Handling AdBlue/DEF in cold weather •

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

•

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

00-48

WA500-8E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

PRECAUTIONS FOR HANDLING 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 appropriate 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.

Sealing of 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.

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PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

00 INDEX AND FOREWORD

Preventing intrusion of foreign materials during refilling •

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.

Replacing 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.

Avoid reusing the hydraulic oil and lubricating oil 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.

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00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

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.

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PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF 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 disassembling work •

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

•

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

•

When draining oil, prepare a container with sufficient capacity.

•

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

•

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

•

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

•

Check the thickness and number of shims when storing shims.

•

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

•

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

•

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

•

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

•

After disconnecting the piping or removing a pipe joint, install the following plugs. NOTICE When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions. REMARK The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine.

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WA500-8E0

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

Introduction of parts for the disassembly of the face seal type hoses and tubes

Hose side

Pipe joint side

Plug (1)

Nut (2)

07376-70210

02789-00210

02896-11008

07376-70315

02789-00315

02896-11009

07376-70422

02789-00422

02896-11012

07376-70522

02789-00522

02896-11015

07376-70628

02789-00628

02896-11018

Nominal No.

O-ring (3)

Introduction of parts for the disconnection of the taper seal type hoses and tubes

Hose side

Pipe joint side

Plug (1)

Nut (2)

07376-50210

07222-00210

07376-50315

07222-00312

07376-50422

07222-00414

07376-50522

07222-00515

07376-50628

07222-00616

07376-51034

07222-01018

07376-51234

07222-01219

07376-51443

07222-01422

Nominal No.

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PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

Introduction of parts for the disconnection of the split flange type hoses and tubes

Nomi nal No.

Bolt pitch (mm) a

Flange (1)

38.1

17.5

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

42.9

19.8

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

47.6

22.2

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

52.4

26.2

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

58.7

30.2

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

66.7

31.8

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

69.9

35.8

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

79.4

36.5

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

77.8

42.8

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

96.8

44.5

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

88.9

50.8

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

106.4

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

120.6

69.8

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

130.2

77.8

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

152.4

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

Hose side

Tube side Split flange (2)

Sleeve head (3)

O-ring (4)

Bolt (5)

Washer (6)

Introduction of parts for the removal of O-ring boss type joint

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WA500-8E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

Nominal No.

Plug (1)

O-ring (2)

07040-10807

07002-10823

07040-11007

07002-11023

07040-11209

07002-11223

07040-11409

07002-11423

07040-11612

07002-11623

07040-11812

07002-11823

07040-12012

07002-12034

07040-12412

07002-12434

07041-13012

07002-13034

07040-13316

07002-13334

07041-13612

07002-13634

07040-14220

07002-14234

07040-15223

07002-15234

Introduction of parts for the removal of taper pipe thread type joint

Plug (1)

Nominal No.

Nominal thread size

Square head type (A)

Hexagonal socket head (B)

R1/8

07042-00108

07043-00108

R1/4

07042-00211

07043-00211

R3/8

07042-00312

07043-00312

R1/2

07042-00415

07043-00415

R3/4

07042-00617

07043-00617

07042-01019

07043-01019

R11/4

07042-01222

07043-01222

R11/2

07042-01422

07043-01422

07042-02026

07043-02026

Precautions for installation and assembling work •

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

•

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

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00-55

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PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

•

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

•

Bend the cotter pins and lock plates securely.

•

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

•

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

•

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

•

Apply engine oil to the rotating parts and sliding surface.

•

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

•

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

•

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

•

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

•

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

•

As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure. REMARK If the threaded portion is difficult to degrease, you may use a seal tape. When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the third thread in the advancing direction of the threads seeing from the screw end. NOTICE If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come off. If the sealed tip is pushed outside, it may cause oil leakage.

•

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

NOTICE When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed, be sure to bleed air from the hydraulic circuit before operating it for the first time according to the following procedure. 1. Start the engine, and run it at low idle. 2.

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

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

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PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

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

Precautions at the time of completion of work Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF •

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

•

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

•

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

•

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

•

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

Testing installed condition of cylinder heads and manifolds •

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

•

If there is any looseness, retighten the part. REMARK For the tightening torques, see “DISASSEMBLY AND ASSEMBLY”.

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

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

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

Check the exhaust equipment and its installation portion for looseness and damage. REMARK When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.) • KDPF • AdBlue/DEF mixing tube • SCR assembly • KDOC muffler • 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. WA500-8E0

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PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

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

Check of function of muffler in exhaust system REMARK When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.) • KDPF • AdBlue/DEF mixing tube • SCR assembly • KDOC muffler • 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 KDPF or muffler, referring to “TROUBLESHOOTING” and “DISASSEMBLY AND ASSEMBLY”.

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WA500-8E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

PRECAUTIONS FOR HANDLING 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”.

Handling wiring harnesses and connectors •

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

•

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

•

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

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

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

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PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

00 INDEX AND FOREWORD

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

Water entering the connector by high-pressure jetting The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Do not spray water directly on the connector. If the connector is waterproof, intruded water is hardly drained. Once water enters into the connector, water goes through pins to cause short-circuit. Drying the drenched connector or take appropriate actions before providing electricity.

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

Oil, mud, or dust stuck to connector If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through resulting in defective contact. If any oil, grease, dirt or dust is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air, and wash it with electrical contact restorer. NOTICE • When wiping the jointed portion of the connector, do not apply excessive force or deform the pins. • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from.

00-60

WA500-8E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING 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 appropriate workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.

Sealing 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 for replacing 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.

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PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING 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 appropriate workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.

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00 INDEX AND FOREWORD

PRACTICAL USE OF KOMTRAX

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.)

Merit of using 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.

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.

WA500-8E0

00-63

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

00 INDEX AND FOREWORD

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.

METHOD FOR DISCONNECTING AND CONNECTING 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).

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

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).

00-64

WA500-8E0

00 INDEX AND FOREWORD

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

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.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER Disconnection 1.

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

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

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.

WA500-8E0

00-65

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

00 INDEX AND FOREWORD

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

METHOD FOR DISCONNECTING AND CONNECTING 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.

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.

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.

00-66

WA500-8E0

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.

WA500-8E0

00-67

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS Disconnecting 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.

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.

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.

Connecting connectors 1.

Check the connector visually.

00-68

WA500-8E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS

•

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.

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.

Drying 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.

WA500-8E0

00-69

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PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS

00 INDEX AND FOREWORD

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.

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.

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.

Handling 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.

00-70

WA500-8E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS

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.

WA500-8E0

00-71

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR Method for disconnecting Deutsch connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2).

Method for connecting Deutsch connector 1.

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

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.

00-72

WA500-8E0

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) 1.

Slide lock (L1) to the right.

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.

Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) Insert it straight until it clicks.

Method for disconnecting slide lock type connector (FRAMATOME-24) 1.

Slide down lock (red) (L1).

WA500-8E0

00-73

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR

00 INDEX AND FOREWORD

While pressing lock (L2), pull out connector (1). REMARK Lock (L2) is located behind connector (1) in the figure.

Method for connecting slide lock type connector (FRAMATOME-24) Insert it straight until it clicks.

00-74

WA500-8E0

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL Method for disconnecting connector with lock to pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.

Method for connecting connector with lock to pull Insert the connector securely until it “clicks”.

WA500-8E0

00-75

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH Method for disconnecting connector with lock to push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow. • 114 series

•

107 series

REMARK If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

Method for connecting connector with lock to push (BOSCH-3) Insert it straight until it clicks.

00-76

WA500-8E0

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH

Method for disconnecting connector with lock to push (AMP-3) While pressing lock (E), pull out connector (5) in the direction of the arrow.

Method for connecting connector with lock to push (AMP-3) Insert it straight until it clicks.

Method for disconnecting 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.

Method for connecting connector with lock to push (SUMITOMO-3) Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-4) While pressing lock (D), pull out connector (4) in the direction of the arrow.

Method for connecting connector with lock to push (SUMITOMO-4) Insert it straight until it clicks.

WA500-8E0

00-77

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE Method for disconnecting 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.

Method for connecting connector with housing to rotate 1.

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

Turn housing (H1) clockwise until it clicks.

00-78

WA500-8E0

00 INDEX AND FOREWORD

HOW TO READ ELECTRICAL WIRE CODE

HOW TO READ ELECTRICAL WIRE CODE In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electrical wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85 Indicates type of wire by symbol. AEX

0.85 L

Type, symbol, and material of wire are shown in (Table 1). (Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on the diagram.) Indicates size of wire by nominal No. Sizes (Nominal Nos.) are shown in (Table 2). Indicates color of wire by color code. Color codes are shown in (Table 3).

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating. (Table 1) Type

Symbol

Low-voltage wire for automobile

Thin-cover low-voltage wire for automobile

Insulator material

Temperature range (°C) in use

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

General wiring

AVS Soft polyvinyl chloride

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

Conductor material

-30 to +60

Annealed copper for electric appliance

(nominal No. 3 and lower)

For mid- to small-size excavators

CAVS

(nominal No. 1.25 and lower)

(Type 2) Heat-resistant low-voltage wire for automobile

WA500-8E0

AEX

Heat-resistant crosslinked polyethylene

-50 to +110

General wiring for extremely cold weather specification Wiring at high-temperature place

00-79

HOW TO READ ELECTRICAL WIRE CODE

00 INDEX AND FOREWORD

Dimensions

(Table 2) Nominal No.

Coating D

Conductor

0.5f

(0.5)

0.75f

(0.85)

1.25f

(1.25)

Number of strands

Diameter of strand

0.18

0.32

0.18

0.32

0.18

0.32

0.26

0.32

0.26

0.32

Cross-sectional area (mm2)

0.51

0.56

0.76

0.88

1.27

1.29

1.96

2.09

3.08

3.30

5.23

d (approx.)

1.0

1.2

1.5

1.9

2.3

2.4

3.0

AVS

Standard

2.0

2.2

2.5

2.9

3.5

3.6

Standard

4.6

AEX

Standard

2.0

2.2

2.7

3.0

3.1

3.8

4.6

Nominal No.

100

Number of strands

108

127

169

217

Diameter of strand

0.45

0.80

Cross-sectional area (mm2)

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

d (approx.)

3.7

4.8

6.0

8.0

8.6

9.8

10.4

12.0

13.6

AVS

Standard

5.5

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

AEX

Standard

5.3

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

Coating D

Conductor

Nominal No.

Conductor

00-80

0.5f

0.5

0.75f

0.85

1.25f

1.25

Number of strands

Diameter of strand

round compression

Cross-sectional area (mm2)

0.56

0.88

1.29

d (approx.)

0.9

1.1

1.4

round compression

WA500-8E0

Coating D

00 INDEX AND FOREWORD

HOW TO READ ELECTRICAL WIRE CODE

Nominal No.

0.5f

0.5

0.75f

0.85

1.25f

1.25

CAVS Standard

1.6

1.8

2.1

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

Color codes table (Table 3) Color Code

Color of wire

Color Code

Color of wire

Black

LgW

Light green and White

Brown

LgY

Light green and Yellow

BrB

Brown and Black

Blue and Red

BrR

Brown and Red

Blue and White

BrW

Brown and White

Blue and Yellow

BrY

Brown and Yellow

Orange

Charcoal

Pink

Dark green

Red

Green

Red and Black

Green and Black

Red and Green

Green and Blue

Red and Blue

Gray

Red and White

Green and Red

Red and Yellow

Green and White

Sky Blue

Green and Yellow

Yellow

Blue

Yellow and Black

Blue and Black

Yellow and Green

Light green

Yellow and Blue

LgB

Light green and Black

Yellow and Red

LgR

Light green and Red

Yellow and White

REMARK In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example) GW indicates that the background is “Green” and marking is “White”.

WA500-8E0

00-81

HOW TO READ ELECTRICAL WIRE CODE

00 INDEX AND FOREWORD

Types of circuits and color codes Type of wire

AEX

Charge

Ground

Start

Light

Instrument

Signal

BrW

BrR

BrY

BrB

LgR

LgY

LgB

LgW

Type of circuit

Others

00-82

AVS, AV, CAVS

WA500-8E0

00 INDEX AND FOREWORD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD The maintenance standard section shows the judgment criteria whether the equipment or parts should be replaced or can be reused when the machine is disassembled for the maintenance. The following terms are the descriptions of the judgment criteria.

Standard dimension and tolerance •

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

•

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

•

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

•

An indication example of a standard dimension and tolerance is shown in the following table. (The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side)

Example: Standard dimension

Tolerance -0.022

120

-0.126

•

The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/ lower limit of tolerance).” Example) 120 (-0.022/ -0.126)

•

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

•

A dimension indication example of a shaft and hole is shown in the following table. (The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Standard dimension

WA500-8E0

Tolerance Shaft

Hole

-0.030

+0.046

-0.076

00-83

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EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

00 INDEX AND FOREWORD

Standard clearance and standard value •

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

•

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

•

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

•

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

Standard interference •

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

•

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

•

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

Repair limit and allowable value or allowable dimension •

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

•

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

•

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

•

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

Allowable clearance •

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

•

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

Allowable interference •

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

•

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

00-84

WA500-8E0

00 INDEX AND FOREWORD

•

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

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

WA500-8E0

00-85

STANDARD TIGHTENING TORQUE TABLE

00 INDEX AND FOREWORD

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 14 16

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

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

27 to 34 {2.8 to 3.5}

59 to 74 {6 to 7.5}

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

320 to 400 {33 to 41}

455 to 565 {46.5 to 58}

610 to 765 {62.5 to 78}

785 to 980 {80 to 100}

1150 to 1440 {118 to 147}

1520 to 1910 {155 to 195}

1960 to 2450 {200 to 250}

2450 to 3040 {250 to 310}

2890 to 3630 {295 to 370}

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

00-86

WA500-8E0

00 INDEX AND FOREWORD

Thread diameter (mm)

STANDARD TIGHTENING TORQUE TABLE

Width across flats (mm)

Tightening torque (Nm {kgfm} )

5.9 to 9.8 {0.6 to 1.0}

13.7 to 23.5 {1.4 to 2.4}

34.3 to 46.1 {3.5 to 4.7}

74.5 to 90.2 {7.6 to 9.2}

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

Type of bolt Nominal size threads per inch

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

9.8 to 14.7 {1 to 1.5}

12.7 {1.3}

2.9 to 3.9 {0.3 to 0.4}

3.43 {0.35}

16-18UNC

24.5 to 34.3 {2.5 to 3.5}

29.4 {3}

6.9 to 8.8 {0.7 to 0.9}

7.8 {0.8}

3/ -16UNC 8

44.1 to 58.8 {4.5 to 6}

52.0 {5.3}

9.8 to 14.7 {1 to 1.5}

11.8 {1.2}

16-14UNC

73.5 to 98.1 {7.5 to 10}

86.3 {8.8}

19.6 to 24.5 {2 to 2.5}

21.6 {2.2}

1/ -13UNC 2

108 to 147 {11 to 15}

127 {13}

29.4 to 39.2 {3 to 4}

34.3 {3.5}

16-12UNC

157 to 216 {16 to 22}

186 {19}

44.1 to 58.8 {4.5 to 6}

51.0 {5.2}

5/ -11UNC 8

226 to 294 {23 to 30}

265 {27}

63.7 to 83.4 {6.5 to 8.5}

68.6 {7}

3/ -10UNC 4

392 to 530 {40 to 54}

461 {47}

108 to 147 {11 to 15}

127 {13}

7/ -9UNC 8

637 to 853 {65 to 87}

745 {76}

177 to 235 {18 to 24}

206 {21}

1/ -20UNC 4

WA500-8E0

00-87

STANDARD TIGHTENING TORQUE TABLE

Type of bolt Nominal size threads per inch

00 INDEX AND FOREWORD

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

1-8UNC

883 to 1196 {90 to 122}

1040 {106}

245 to 333 {25 to 34}

284 {29}

11/8-7UNC

1187 to 1608 {121 to 164}

1393 {142}

333 to 451 {34 to 46}

392 {40}

11/4-7UNC

1598 to 2157 {163 to 220}

1873 {191}

451 to 608 {46 to 62}

530 {54}

11/2-6UNC

2354 to 3177 {240 to 324}

2765 {282}

657 to 892 {67 to 91}

775 {79}

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

Type of bolt Nominal size threads per inch

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

1/ -28UNF 4

14.7 to 19.6 {1.5 to 2}

17.7 {1.8}

3.9 to 4.9 {0.4 to 0.5}

4.41 {0.45}

16-24UNF

34.3 to 39.2 {3.5 to 4}

34.3 {3.5}

7.8 to 9.8 {0.8 to 1}

8.8 {0.9}

3/ -24UNF 8

53.9 to 68.6 {5.5 to 7}

61.8 {6.3}

14.7 to 19.6 {1.5 to 2}

16.7 {1.7}

16-20UNF

83.4 to 108 {8.5 to 11}

96.1 {9.8}

24.5 to 29.4 {2.5 to 3}

26.5 {2.7}

1/ -20UNF 2

127 to 167 {13 to 17}

147 {15}

34.3 to 49.0 {3.5 to 5}

41.2 {4.2}

16-18UNF

186 to 245 {19 to 25}

216 {22}

49.0 to 68.6 {5 to 7}

58.8 {6}

5/ -18UNF 8

255 to 343 {26 to 35}

294 {30}

73.5 to 98.1 {7.5 to 10}

83.4 {8.5}

3/ -16UNF 4

441 to 598 {45 to 61}

520 {53}

127 to 167 {13 to 17}

147 {15}

7/ -14UNF 8

716 to 961 {73 to 98}

843 {86}

196 to 265 {20 to 27}

226 {23}

1-14UNF

1020 to 1373 {104 to 140}

1196 {122}

284 to 382 {29 to 39}

333 {34}

11/8-12UNF

1353 to 1844 {138 to 188}

1598 {163}

382 to 520 {39 to 53}

451 {46}

11/4-12UNF

1804 to 2432 {184 to 248}

2118 {216}

510 to 686 {52 to 70}

598 {61}

11/2-12UNF

2707 to 3658 {276 to 373}

3177 {324}

765 to 1030 {78 to 105}

892 {91}

00-88

WA500-8E0

00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for O-ring boss piping joints REMARK Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.

Nominal No.

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

03, 04

05, 06

10, 12

Varies depending on type of connector.

Tightening torque (Nm {kgfm} ) Range

Target

35 to 63 {3.5 to 6.5}

44 {4.5}

59 to 98 {6.0 to 10.0}

78 {8.0}

84 to 132 {8.5 to 13.5}

103 {10.5}

128 to 186 {13.0 to 19.0}

157 {16.0}

363 to 480 {37.0 to 49.0}

422 {43.0}

746 to 1010 {76.0 to 103}

883 {90.0}

Table of tightening torque for O-ring boss plugs REMARK Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.

Nominal No.

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

Tightening torque (Nm {kgfm} ) Range

Target

5.88 to 8.82 {0.6 to 0.9}

7.35 {0.75}

9.8 to 12.74 {1.0 to 1.3}

11.27 {1.15}

14.7 to 19.6 {1.5 to 2.0}

17.64 {1.8}

19.6 to 24.5 {2.0 to 2.5}

22.54 {2.3}

24.5 to 34.3 {2.5 to 3.5}

29.4 {3.0}

WA500-8E0

00-89

STANDARD TIGHTENING TORQUE TABLE

Nominal No.

00 INDEX AND FOREWORD

Tightening torque (Nm {kgfm} )

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

Range

Target

34.3 to 44.1 {3.5 to 4.5}

39.2 {4.0}

44.1 to 53.9 {4.5 to 5.5}

49.0 {5.0}

58.8 to 78.4 {6.0 to 8.0}

68.6 {7.0}

93.1 to 122.5 {9.5 to 12.5}

107.8 {11.0}

107.8 to 147.0 {11.0 to 15.0}

127.4 {13.0}

127.4 to 176.4 {13.0 to 18.0}

151.9 {15.5}

181.3 to 240.1 {18.5 to 24.5}

210.7 {21.5}

274.4 to 367.5 {28.0 to 37.5}

323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type) REMARK • Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table unless otherwise specified. • The table is applied to the threaded portion coated with engine oil (wet threaded portion).

Nominal No. of hose

Width across flats (mm)

Tightening torque (Nm {kgfm} )

Taper seal

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

Range

Target

Thread size (mm)

34 to 54 {3.5 to 5.5}

44 {4.5}

34 to 63 {3.5 to 6.5}

44 {4.5}

54 to 93 {5.5 to 9.5}

16-18UN

14.3

74 {7.5}

11/ -16UN 16

17.5

59 to 98 {6.0 to 10.0}

78 {8.0}

84 to 132 {8.5 to 13.5}

103 {10.5}

13/ -16UN 16

20.6

128 to 186 {13.0 to 19.0}

157 {16.0}

1 -14UNS

25.4

177 to 245 {18.0 to 25.0}

216 {22.0}

13/16-12UN

30.2

(10)

177 to 245 {18.0 to 25.0}

216 {22.0}

(12)

197 to 294 {20.0 to 30.0}

245 {25.0}

(14)

246 to 343 {25.0 to 35.0}

294 {30.0}

00-90

WA500-8E0

00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for face seal joints REMARK • The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated low pressure piping which is used for engine. • The table is applied to the threaded portion coated with engine oil (wet threaded portion). • Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.

Outside diameter of adequate pipe (mm)

Width across flats (mm)

Tightening torque (Nm {kgfm} )

Face seal Nominal size threads per inch

Thread root diameter(mm) (reference)

Range

Target

14 to 16 {1.4 to 1.6}

15 {1.5}

16-18UN

14.3

24 to 27 {2.4 to 2.7}

25.5 {2.6}

11/ -16UN 16

17.5

24 (27)

43 to 47 {4.4 to 4.8}

45 {4.6}

13/

16-16UN

20.6

15 (16)

30 (32)

60 to 68 {6.1 to 6.8}

64 {6.5}

1 -14UNS

25.4

22 (20)

90 to 95 {9.2 to 9.7}

92.5 {9.4}

13/16-12UN

30.2

Tightening torque table for bolts and nuts on 102, 107 and 114 series engines REMARK Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table unless otherwise specified. Thread diameter (mm)

Tightening torque (Nm {kgfm} )

10±2 {1.02±0.20}

24±4 {2.45±0.41}

43±6 {4.38±0.61}

77±12 {7.85±1.22}

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.

WA500-8E0

00-91

STANDARD TIGHTENING TORQUE TABLE

00 INDEX AND FOREWORD

Thread diameter (mm)

Tightening torque (Nm {kgfm} )

8±2 {0.81±0.20}

10±2 {1.02±0.20}

12±2 {1.22±0.20}

24±4 {2.45±0.41}

36±5 {3.67±0.51}

Tightening torque table for tapered screws on 102, 107, and 114 series engines (National taper pipe thread (NPT)) REMARK Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the following table unless otherwise specified.

00-92

Material of female screw

In cast iron or steel

In aluminum

Nominal thread size

Tightening torque (Nm {kgfm} )

15±2 {1.53±0.20}

5±1 {0.51±0.10}

20±2 {2.04±0.20}

15±2 {1.53±0.20}

25±3 {2.55±0.31}

20±2 {2.04±0.20}

3/ 8

35±4 {3.57±0.41}

25±3 {2.55±0.31}

55±6 {5.61±0.61}

35±4 {3.57±0.41}

75±8 {7.65±0.82}

45±5 {4.59±0.51}

WA500-8E0

00 INDEX AND FOREWORD

CONVERSION TABLE

CONVERSION TABLE Method of using 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 of using the conversion table to convert 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).

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

When converting 550 mm to in 1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left) to get 55 mm. 2. Convert 55 mm to 2.165 in according to the preceding procedure. 3.

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

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

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.017

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.847

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

3.543

3.583

3.622

3.661

3.701

3.780

3.819

3.858

3.898

mm to in 1 mm = 0.03937 in 0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

WA500-8E0

00-93

CONVERSION TABLE

00 INDEX AND FOREWORD

1 mm = 0.03937 in 0

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.847

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

kg to lb 1 kg = 2.2046 lb 0

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

ℓ to U.S.Gal 1 ℓ = 0.2642 U.S.Gal 0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

ℓ to U.K.Gal 1 ℓ = 0.21997 U.K.Gal 0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

00-94

WA500-8E0

00 INDEX AND FOREWORD

CONVERSION TABLE

1 ℓ = 0.21997 U.K.Gal 0

6.599

6.819

7.039

7.259

7.479

7.699

7.919

8.139

8.359

8.579

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

kgfm to lbft 1 kgfm = 7.233 lbft 0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

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

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

WA500-8E0

00-95

CONVERSION TABLE

00 INDEX AND FOREWORD

1 kgf/cm2 = 14.2233 lb/in2 0

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

Temperature Conversion of Fahrenheit to Celsius •

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

•

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

•

When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right. 1 °C = 33.8 °F °C

°F

°C

°F

°C

°F

°C

°F

-40.4

-40

-40.0

-11.7

51.8

7.8

114.8

27.2

177.8

-37.2

-35

-31.0

-11.1

53.6

8.3

116.6

27.8

179.6

-34.4

-30

-22.0

-10.6

55.4

8.9

118.4

28.3

181.4

-31.7

-25

-13.0

-10.0

57.2

9.4

120.2

28.9

183.2

-28.9

-20

-4.0

-9.4

59.0

10.0

122.0

29.4

185.0

-28.3

-19

-2.2

-8.9

60.8

10.6

123.8

30.0

186.8

-27.8

-18

-0.4

-8.3

62.6

11.1

125.6

30.6

188.6

00-96

WA500-8E0

00 INDEX AND FOREWORD

CONVERSION TABLE

1 °C = 33.8 °F °C

°F

°C

°F

°C

°F

°C

°F

-27.2

-17

1.4

-7.8

64.4

11.7

127.4

31.1

190.4

-26.7

-16

3.2

-7.2

66.2

12.2

129.2

31.7

192.2

-26.1

-15

5.0

-6.7

68.0

12.8

131.0

32.2

194.0

-25.6

-14

6.8

-6.1

69.8

13.3

132.8

32.8

195.8

-25.0

-13

8.6

-5.6

71.6

13.9

134.6

33.3

197.6

-24.4

-12

10.4

-5.0

73.4

14.4

136.4

33.9

199.4

-23.9

-11

12.2

-4.4

75.2

15.0

138.2

34.4

201.2

-23.3

-10

14.0

-3.9

77.0

15.6

140.0

35.0

203.0

-22.8

-9

15.8

-3.3

78.8

16.1

141.8

35.6

204.8

-22.2

-8

17.6

-2.8

80.6

16.7

143.6

36.1

206.6

-21.7

-7

19.4

-2.2

82.4

17.2

145.4

36.7

208.4

-21.1

-6

21.2

-1.7

84.2

17.8

147.2

37.2

210.2

-20.6

-5

23.0

-1.1

86.0

18.3

149.0

37.8

100

212.0

-20.0

-4

24.8

-0.6

87.8

18.9

150.8

40.6

105

221.0

-19.4

-3

26.6

89.6

19.4

152.6

43.3

110

230.0

-18.9

-2

28.4

0.6

91.4

20.0

154.4

46.1

115

239.0

-18.3

-1

30.2

1.1

93.2

20.6

156.2

48.9

120

248.0

-17.8

32.0

1.7

95.0

21.1

158.0

51.7

125

257.0

-17.2

33.8

2.2

96.8

21.7

159.8

54.4

130

266.0

-16.7

35.6

2.8

98.6

22.2

161.6

57.2

135

275.0

-16.1

37.4

3.3

100.4

22.8

163.4

60.0

140

284.0

-15.6

39.2

3.9

102.2

23.3

165.2

62.7

145

293.0

-15.0

41.0

4.4

104.0

23.9

167.0

65.6

150

302.0

-14.4

42.8

5.0

105.8

24.4

168.8

68.3

155

311.0

-13.9

44.6

5.6

107.6

25.0

170.6

71.1

160

320.0

-13.3

46.4

6.1

109.4

25.6

172.4

73.9

165

329.0

-12.8

48.2

6.7

111.2

26.1

174.2

76.7

170

338.0

-12.2

50.0

7.2

113.0

26.7

176.0

79.4

175

347.0

WA500-8E0

00-97

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01 SPECIFICATIONS

WA500-8E0

01-1

CONTENTS

01 SPECIFICATIONS

01-2

WA500-8E0

01 SPECIFICATIONS

ABBREVIATION LIST

ABBREVIATION LIST •

•

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

•

Special abbreviations which appear infrequently are noted in the text.

•

List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)

Abbreviation

Actual word spelled out

ABS

Antilock Brake System

AISS

Automatic Idling Setting Engine System

This is a function that automatically sets the idle speed.

Steering AJSS

Advanced Joystick Steering System

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

ARAC

Automatic Retarder Accelerator Control

Travel and brake (HD, HM)

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

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

ARSC

Automatic Retarder Speed Control

ASR

Travel and brake Automatic Spin Regulator (HD, HM)

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

ATT

Attachment

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

BCV

BRAKE Brake cooling oil control valve (HD)

CAN

Controller Area Network

Communication and electronic control

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

CDR

Crankcase Depression Regulator

Engine

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

CLSS

Closed-center Load Sensing System

Hydraulic system

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

WA500-8E0

(HD, HM)

Work equipment

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

01-3

ABBREVIATION LIST

Abbreviation

Actual word spelled out

01 SPECIFICATIONS

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

Explanation

Engine

Electronic control system

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

CRI

Common Rail Injection

ECM

Electronic Control Module

ECMV

Electronic Control Modulation Valve

ECSS

Travel Electronically Controlled Suspension System (WA)

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

ECU

Electronic Control Unit

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

EGR

Exhaust Gas RecirculaEngine tion

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

EMMS

Equipment ManageMachine monitor ment Monitoring System

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

EPC

Electromagnetic ProporHydraulic system tional Control

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

FOPS

Falling Object Protective Cab and canopy Structure

Transmission (D, HD, WA, etc)

Electronic control system

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

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

F-N-R

Forward-Neutral-Reverse

GPS

Global Positioning System

GNSS

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

HSS

Hydrostatic Steering System

HST

Hydro Static Transmission

Operation Communication (KOMTRAX, KOMTRAX Plus)

Steering

01-4

(D Series) Transmission (D, WA)

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

WA500-8E0

01 SPECIFICATIONS

ABBREVIATION LIST

Abbreviation

Actual word spelled out

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

Explanation

ICT

Information and Communication Technology

Communication and electronic control

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

IMA

Inlet Metering Actuator

Engine

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

IMU

Inertial Measurement Unit

Engine

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

IMV

Inlet Metering Valve

Engine

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

KCCV

Komatsu Closed CrankEngine case Ventilation

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

KCSF

Komatsu Catalyzed Soot Filter

KDOC

Komatsu Diesel Oxidation Catalyst

KDPF

Engine

Komatsu Diesel ParticuEngine late Filter

Travel and brake

KTCS

Komatsu Traction Control System

(HM)

LCD

Liquid Crystal Display

Machine monitor

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

LED

Light Emitting Diode

Electronic parts

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

LIN

Local Interconnect Network

Communication and electronic control

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

Load Sensing

Hydraulic system

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

LVDS

Low Voltage Differential Signaling

Communication and electronic control

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

Engine

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

MAF

Mass Air Flow

WA500-8E0

01-5

ABBREVIATION LIST

01 SPECIFICATIONS

Abbreviation

Actual word spelled out

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

MMS

Multimedia Messaging Service

Communication

Normally Closed

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

Normally Open

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

OLSS

Open-center Load Sensing System

Hydraulic system

Pressure Compensation Hydraulic system

PCCS

Palm command control system

PCV

Pre-stroke Control Valve Engine

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

PPC

Proportional Pressure Control

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

PPM

Piston Pump and Motor

PTO

Power Take Off

PTP

Power Tilt and power Pitch dozer

Steering

ROPS

Roll-Over Protective Structure

(D Series)

Hydraulic system Hydraulic system (D, PC, etc)

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

Piston type hydraulic pump and motor.

Power train system

Power take-off mechanism

Work equipment

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

(D Series)

Cab and canopy

SCR

Selective Catalytic Reduction

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

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

SOL

Solenoid

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

01-6

Urea SCR system

Electrical system

WA500-8E0

01 SPECIFICATIONS

Abbreviation

TOPS

ABBREVIATION LIST

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

Actual word spelled out

Tip-Over Protective Structure

Cab and canopy

TWV

2-Way Valve

Hydraulic system

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

VGT

Variable Geometry Turbocharger

Engine

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

VHPC

Variable Horse Power Control

Engine control

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

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

List of abbreviations used in the circuit diagrams Abbreviation

Actual word spelled out

A/C

Air Conditioner

A/D

Analogue-to-Digital

A/M

Air Mix Damper

ACC

Accessory

ADD

Additional

AUX

Auxiliary

Battery Relay

Clockwise

CCW

Counter Clockwise

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actuator

No Connection

WA500-8E0

01-7

ABBREVIATION LIST

Abbreviation S/T STRG

Steering Signal

SOL

Solenoid

STD

Standard

01-8

Actual word spelled out

SIG

OPT

01 SPECIFICATIONS

Option

PRESS

Pressure

SPEC

Specification

Switch

TEMP

Temperature

T/C

Torque Converter

T/M

Transmission

WA500-8E0

01 SPECIFICATIONS

SPECIFICATION DRAWING

SPECIFICATIONS SPECIFICATION DRAWING SPECIFICATION DRAWING: WA500-8E0

I C

H B

E F

A 9 J W0 1 4 5 6

Item

Unit

WA500-8E0 (at P mode)

Machine weight (with BOC)

34090

Operating load

9580

Bucket capacity (heaped, with BOC)

5.8

Engine model

KOMATSU SAA6D140E-7 diesel engine

Engine rated horsepower •

Gross [SAE J1995] (*1)

•

ISO 14396

•

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

kW {HP} /min-1 {rpm}

266 {357}/ 1900 {1900} 266 {357}/ 1900 {1900} 264 {353}/ 1900 {1900}

Overall length (with BOC)

9945

Overall height

3785

Overall height when bucket is raised to maximum height

6470

Overall width

3190

Minimum ground clearance

450

Bucket width

3400

Dumping clearance (*3)

Bucket tip/ BOC tip

3385/3275

Dumping reach (*3)

Bucket tip/ BOC tip

1465/1525

Forward tilt angle of bucket (maximum height)

Degree

WA500-8E0

01-9

SPECIFICATION DRAWING

Item Minimum turning radius

Unit

WA500-8E0 (at P mode)

Bucket tip/ BOC tip

8185/8225

Center of outside tire

7050

kN {kg}

239{24360}

Allowable towing load

Travel speed (P mode) (*5)

01 SPECIFICATIONS

1st (Forward/ Reverse)

7.5/8.5

2nd (Forward/ Reverse)

13.1/13.0

3rd (Forward/ Reverse)

km/h

4th (Forward/ Reverse)

23.7/26.6 37.3/38.0

*1: Indicates the value of the bare engine (without cooling fan). *2: Indicates the value at the minimum cooling fan speed. REMARK • The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on a machine. •

The rated horsepower (net) at the maximum cooling fan speed is the following value. 250 kW {335 HP} /1900 min-1 {1900 rpm}

*3: Indicates the value when forward tilt angle of bucket is 45 °. *4: Indicates the value when the stop valve is operated. *5: The 2nd to 4th speed indicates the speed at lockup.

BOC Abbreviation for Bolt On Cutting edge

01-10

WA500-8E0

01 SPECIFICATIONS

SPECIFICATIONS

SPECIFICATIONS SPECIFICATIONS: WA500-8E0 Item

Unit

WA500-8E0

Machine weight (front wheels + rear wheels)

34090

Machine weight (front wheels) in SAE travel posture

16440

Machine weight (rear wheels) in SAE travel posture

17650

Bucket capacity (heaped)

5.8

Operating load

9580

Weight

Performance

E mode

P mode

Forward 1st

7.1

7.5

Forward 2nd

12.9

20.8

22.2

Forward 4th

33.6

35.5

Reverse 1st

8.0

8.5

Reverse 2nd

12.9

Reverse 3rd

23.1

24.7

Reverse 4th

35.2

38.0

13.1

22.5

23.7

37.2

37.3

Reverse 2nd

13.0

Reverse 3rd

25.0

26.6

Reverse 4th

37.5

38.0

258{26300}

264{26950}

230{23460}

235{24020}

Travel speed Travel speed when torque converter is operated

Forward 3rd

km/h

Travel speed when lockup is operated Forward 2nd Forward 3rd Forward 4th

km/h

Maximum drawbar pull Forward

kN {kg}

Reverse Gradeability

Degree

Minimum turning radius (center of outside tire) (*1)

7050

Turning radius (bucket tip/tip of BOC) in SAE travel posture

8185/8225

WA500-8E0

01-11

SPECIFICATIONS

Item

01 SPECIFICATIONS

Unit

WA500-8E0

*1: Indicates the value of when the stop valve is operated.

BOC Abbreviation for Bolt On Cutting edge Dimensions Overall length (with BOC)

9945

Overall width (body)

3190

Bucket width (with BOC)

3400

Overall height (top of cab)

3785

Overall height when bucket is raised to the maximum height

6470

Wheelbase

3780

Tread

2400

Minimum ground clearance

450

Maximum hinge pin height

4755

3385/3275

1465/1525

Steering angle (*2)

Degree

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

Degree

50/55

Forward tilt angle of bucket (maximum height)

Degree

385/440

Dumping clearance (*1) (Bucket tip/ BOC tip) Dumping reach (*1) (Bucket tip/ BOC tip)

Cutting depth (Bucket tip/ BOC tip)

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

BOC Abbreviation for Bolt On Cutting edge Engine Model

SAA6D140E-7

Type

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

No. of cylinders - bore x stroke

6-140 x 165

Total piston displacement

ℓ {cc}

15.2{15240}

Performance

P mode

Engine rated horsepower •

Gross [SAE J1995] (*1)

•

ISO14396

•

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

01-12

kW {HP} /min-1 {rpm}

266 {357}/ 1900 {1900} 266 {357}/ 1900 {1900} 264 {353}/ 1900 {1900}

WA500-8E0

01 SPECIFICATIONS

Item

SPECIFICATIONS

Unit

WA500-8E0

Maximum torque (*2)

Nm {kgfm} /min-1 {rpm}

1799 {183.48}/ 1250 {1250}

Fuel consumption ratio at rated horsepower

g/kWh {g/HPh}

216{159}

Maximum speed with no load Minimum speed with no load

2120{2120}

min-1 {rpm}

690{690}

Starting motor

24 V, 11 kW

Alternator

24 V, 90 A

Battery (*3)

12 V, 136 Ah x 2

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

REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on a machine. • The rated horsepower (net) at the maximum cooling fan speed is the following value.

250 kW {335 HP} /1900 min-1 {1900 rpm}

Power train Torque converter Type

3-element, 1-stage, 2-phase

Transmission Type

Number of speeds Reduction gear system Type Differential Type Final drive Type

Planet gear type, constant mesh type, multiple disc type, hydraulic type, and modulation type 4 forward and 4 reverse speeds

Spiral bevel gear, splash oil lubrication

Spur bevel gear type

Planetary gear, single reduction, splash lubrication type

Axle Axle type Drive wheel Front wheel

Rear wheel

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

Tires Size Rim size

WA500-8E0

29.5R25☆☆ 25.00-25WTB

01-13

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SPECIFICATIONS

Item

01 SPECIFICATIONS

Unit

WA500-8E0

kPa {kgf/cm2}

550{5.5}

Inflation pressure Front wheel Rear wheel

400{4.0}

Brake Main Braking method

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

Brake type

Sealed, wet, disc type

Operating system

Full hydraulic

Parking Braking method Brake type

Operating system

Drive shaft braking Wet, disc type Spring-control type, hydraulic release type

Steering Steering method Operating system

Articulated frame type Hydraulic operation type

Hydraulic system Power train charge duplex pump Type Discharged volume

Gear type

cm3/rev

63.1+49.8

Steering pump Type Discharged volume

Variable displacement swash plate piston type

cm3/rev

Work equipment pump Type Discharged volume

Variable displacement swash plate piston type

cm3/rev

170

Brake and cooling fan pump Type Discharged volume

Variable displacement swash plate piston type

cm3/rev

Secondary steering pump Type Discharged volume

Gear type

cm3/rev

50.8

Steering cylinder Type

Cylinder bore

100

Piston rod diameter

Stroke

486

Max. distance between pins

1337

Min. distance between pins

851

01-14

Double-acting piston type

WA500-8E0

01 SPECIFICATIONS

Item

SPECIFICATIONS

Unit

WA500-8E0

Lift cylinder Type

Double-acting piston type

Cylinder bore

160

Piston rod diameter

120

Stroke

898

Max. distance between pins

2487

Min. distance between pins

1589

Bucket cylinder Type

Double-acting piston type

Cylinder bore

185

Piston rod diameter

120

Stroke

675

Max. distance between pins

1952

Min. distance between pins

1227

Control valve Type Set pressure

2-spool type

MPa {kgf/cm2}

34.3{350}

Steering valve Type Set pressure

Spool type

MPa {kgf/cm2}

24.5{250}

Cooling fan motor Type Capacity

Fixed displacement, swash plate, piston type

cm3/rev

Work equipment Link type Shape of bucket cutting edge

Z-bar link With flat cutting edge BOC

BOC Abbreviation for Bolt On Cutting edge

WA500-8E0

01-15

WEIGHT TABLE

01 SPECIFICATIONS

WEIGHT TABLE WEIGHT TABLE: WA500-8E0

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

ing.

k This weight table shows the dry weight.

Unit: kg Item

WA500-8E0

Engine assembly

1930

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

309

•

Radiator (1 piece)

150

•

Aftercooler

•

Hydraulic oil cooler

•

Air conditioner condenser

Power train oil cooler

Brake and cooling fan pump

Cooling fan motor

Cooling fan

Transmission assembly (including torque converter)

1725

•

Torque converter

584

•

Transmission

1137

Center drive shaft

Front drive shaft

Rear drive shaft

Center support

Front axle assembly

2295

•

Front differential

379

•

Planetary carrier assembly (1 piece)

110

•

Wheel hub (1 piece)

113

Rear axle assembly

2115

•

Rear differential

401

•

Planetary carrier assembly (1 piece)

110

•

Wheel hub (1 piece)

113

Axle pivot (front)

104

Axle pivot (rear)

126

Tire and rim assembly (29.5R25☆☆ L-3) (1 piece)

845

•

Tire (29.5R25☆☆ L-3) (1 piece)

575

•

Rim (25.00-25WTB) (1 piece)

267

Power train charge duplex pump

Work equipment pump

110

Steering pump

01-16

WA500-8E0

01 SPECIFICATIONS

WEIGHT TABLE

Unit: kg Item

WA500-8E0

Control valve

152

Brake valve

Steering valve

Secondary steering pump

Steering cylinder assembly (1 piece)

Lift cylinder assembly (1 piece)

290

Bucket cylinder assembly (1 piece)

301

Front frame

2650

Rear frame

2767

Counterweight

1745

Engine hood assembly (including hood, grille assembly, and bulkhead top)

900

•

Hood

•

Side door (1 piece)

•

Grille

Hydraulic tank (including mounting bracket)

542

Fuel tank

236

Boom (including bushing)

2105

Bucket link

157

Bell crank

754

Bucket (5.8 m3 including BOC)

3186

Operator cab (including floor assembly)

1147

Operator's seat

Air conditioner unit

Battery (1 piece)

BOC Abbreviation for Bolt On Cutting edge

WA500-8E0

01-17

TABLE OF FUEL, COOLANT, AND LUBRICANTS

01 SPECIFICATIONS

TABLE OF FUEL, COOLANT, AND LUBRICANTS For details of notes (Note 1, Note 2...) in the table, see “Operation and Maintenance Manual”.

Unit: ℓ Places to supply oil, coolant, etc.

Specified capacity

Refill capacity

Engine oil pan

Transmission case

Hydraulic oil system

460

337

Axle (front wheel)

01-18

WA500-8E0

01 SPECIFICATIONS

TABLE OF FUEL, COOLANT, AND LUBRICANTS

Unit: ℓ Places to supply oil, coolant, etc.

Specified capacity

Refill capacity

Axle (rear wheel)

Cooling system

110

Fuel tank

473

AdBlue/DEF tank

WA500-8E0

01-19

10 STRUCTURE AND FUNCTION

WA500-8E0

10-1

CONTENTS

10 STRUCTURE AND FUNCTION

CONTENTS ABBREVIATION LIST .................................................................................................................................... 10-7 UREA SCR SYSTEM................................................................................................................................... 10-13 LAYOUT DRAWING OF UREA SCR SYSTEM ..................................................................................... 10-13 UREA SCR SYSTEM DIAGRAM .......................................................................................................... 10-16 FUNCTION OF UREA SCR SYSTEM................................................................................................... 10-17 FUNCTION OF AdBlue/DEF SYSTEM........................................................................................... 10-17 INDUCEMENT STRATEGY ........................................................................................................... 10-19 COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-33 AdBlue/DEF MIXING TUBE ........................................................................................................... 10-33 SCR ASSEMBLY ........................................................................................................................... 10-33 AdBlue/DEF TANK ......................................................................................................................... 10-36 AdBlue/DEF PUMP ........................................................................................................................ 10-38 AdBlue/DEF INJECTOR................................................................................................................. 10-39 AdBlue/DEF HOSE ........................................................................................................................ 10-40 AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-41 BOOT-UP SYSTEM ..................................................................................................................................... 10-42 LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL)..................... 10-42 LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...... .......................................................................................................................................................... 10-44 LAYOUT DRAWING OF BOOT-UP SYSTEM (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL)............................................................................................... 10-46 LAYOUT DRAWING OF BOOT-UP SYSTEM (FOR EMERGENCY ENGINE STOP SWITCH SPEC) (MACHINE WITH KOMTRAX TERMINAL)............................................................................................... 10-48 SYSTEM OPERATING LAMP SYSTEM ............................................................................................... 10-50 SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) .... 10-50 SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).................................................................................................................................. 10-50 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL)....... ................................................................................................................................................... 10-50 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).......................................................................................................................... 10-51 BATTERY DISCONNECT SWITCH ...................................................................................................... 10-53 LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH......................................................... 10-53 FUNCTION OF BATTERY DISCONNECT SWITCH ...................................................................... 10-53 PREHEATING SYSTEM ....................................................................................................................... 10-55 PREHEATING SYSTEM DIAGRAM ............................................................................................... 10-55 FUNCTION OF AUTOMATIC PREHEATING SYSTEM.................................................................. 10-55 OPERATION OF AUTOMATIC PREHEATING SYSTEM................................................................ 10-55 FUNCTION OF MANUAL PREHEATING SYSTEM........................................................................ 10-56 OPERATION OF MANUAL PREHEATING SYSTEM ..................................................................... 10-56 ENGINE SHUTDOWN SECONDARY SWITCH .................................................................................... 10-57 LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH ...................................... 10-57 FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH .................................................... 10-57 OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH.................................................. 10-58 ENGINE SYSTEM ....................................................................................................................................... 10-59 LAYOUT DRAWING OF ENGINE SYSTEM .......................................................................................... 10-59 FUNCTION OF ENGINE SYSTEM ................................................................................................ 10-60 ENGINE CONTROL SYSTEM .............................................................................................................. 10-61 ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) ................... 10-61 ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .... ................................................................................................................................................... 10-62 FUNCTION OF ENGINE CONTROL SYSTEM .............................................................................. 10-63 OPERATION OF ENGINE CONTROL SYSTEM ............................................................................ 10-66 ENGINE POWER MODE SELECTOR SYSTEM................................................................................... 10-68 ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM .......................................................... 10-68 FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM................................................... 10-68 10-2

WA500-8E0

10 STRUCTURE AND FUNCTION

CONTENTS

OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM ................................................ 10-68 AUTOMATIC IDLE STOP SYSTEM ...................................................................................................... 10-69 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM ...................................................................... 10-69 RPM SET.............................................................................................................................................. 10-70 FUNCTION OF RPM SET.............................................................................................................. 10-70 OPERATION OF RPM SET ........................................................................................................... 10-71 COMPONENT PARTS OF ENGINE SYSTEM ...................................................................................... 10-74 JOINT ............................................................................................................................................ 10-74 VGT ............................................................................................................................................... 10-74 EGR SYSTEM ............................................................................................................................... 10-78 EGR VALVE ................................................................................................................................... 10-80 EGR COOLER ............................................................................................................................... 10-82 KCCV SYSTEM ............................................................................................................................. 10-84 KCCV VENTILATOR ...................................................................................................................... 10-86 KDPF ............................................................................................................................................. 10-89 COOLING SYSTEM..................................................................................................................................... 10-93 LAYOUT DRAWING OF COOLING SYSTEM ....................................................................................... 10-93 SPECIFICATIONS OF COOLING SYSTEM................................................................................... 10-93 COOLING FAN CONTROL SYSTEM.................................................................................................... 10-95 COOLING FAN CONTROL SYSTEM DIAGRAM ........................................................................... 10-95 FUNCTION OF COOLING FAN CONTROL SYSTEM.................................................................... 10-95 COMPONENT PARTS OF COOLING SYSTEM...................................................................................10-100 BRAKE AND COOLING FAN PUMP.............................................................................................10-100 COOLING FAN MOTOR ...............................................................................................................10-107 CONTROL SYSTEM...................................................................................................................................10-114 LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) ..................10-114 LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .... .........................................................................................................................................................10-116 MACHINE MONITOR SYSTEM ...........................................................................................................10-118 MACHINE MONITOR SYSTEM DIAGRAM...................................................................................10-118 FUNCTION OF MACHINE MONITOR SYSTEM ...........................................................................10-118 REARVIEW MONITOR SYSTEM.........................................................................................................10-120 REARVIEW MONITOR SYSTEM DIAGRAM ................................................................................10-120 FUNCTION OF REARVIEW MONITOR SYSTEM.........................................................................10-120 KOMTRAX SYSTEM............................................................................................................................10-121 KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) ................................10-121 SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) ..........................................................................................................................................10-121 FUNCTION OF KOMTRAX SYSTEM ...........................................................................................10-122 LOAD METER SYSTEM ......................................................................................................................10-123 LOAD METER SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL)...........................10-123 LOAD METER SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)..10-124 FUNCTION OF LOAD METER SYSTEM ......................................................................................10-124 COMPONENT PARTS OF CONTROL SYSTEM..................................................................................10-130 MACHINE MONITOR....................................................................................................................10-130 SWITCH PANEL ...........................................................................................................................10-149 REARVIEW MONITOR .................................................................................................................10-150 REARVIEW CAMERA...................................................................................................................10-151 KOMTRAX TERMINAL .................................................................................................................10-152 GATEWAY FUNCTION CONTROLLER ........................................................................................10-154 COMMUNICATION TERMINAL ....................................................................................................10-157 TRANSMISSION CONTROLLER..................................................................................................10-159 WORK EQUIPMENT CONTROLLER ...........................................................................................10-163 MONITOR CONTROLLER............................................................................................................10-167 CAN TERMINATING RESISTOR ..................................................................................................10-171 ENGINE CONTROLLER ...............................................................................................................10-172 ACCELERATOR PEDAL...............................................................................................................10-178 FUEL FEED PUMP .......................................................................................................................10-180 WA500-8E0

10-3

CONTENTS

10 STRUCTURE AND FUNCTION

FUEL FEED PUMP SWITCH ........................................................................................................10-181 HYDRAULIC SYSTEM................................................................................................................................10-182 LAYOUT DRAWING OF HYDRAULIC SYSTEM ..................................................................................10-182 CLSS ...................................................................................................................................................10-183 STRUCTURE OF CLSS................................................................................................................10-183 FUNCTION OF CLSS ...................................................................................................................10-184 WORK EQUIPMENT PUMP CONTROL SYSTEM...............................................................................10-187 SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP ....................................10-187 PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW .......................10-187 COMPONENT PARTS OF HYDRAULIC SYSTEM ..............................................................................10-188 HYDRAULIC TANK .......................................................................................................................10-188 WORK EQUIPMENT PUMP .........................................................................................................10-191 STEERING PUMP ........................................................................................................................10-209 POWER TRAIN CHARGE DUPLEX PUMP ..................................................................................10-222 CONTROL VALVE ........................................................................................................................10-223 POWER TRAIN SYSTEM ...........................................................................................................................10-257 LAYOUT DRAWING OF POWER TRAIN SYSTEM..............................................................................10-257 OPERATION OF POWER TRAIN SYSTEM.........................................................................................10-261 TRANSMISSION CONTROL SYSTEM ................................................................................................10-262 TRANSMISSION CONTROL SYSTEM DIAGRAM .......................................................................10-262 TRANSMISSION GEAR SHIFT CONTROL SYSTEM..........................................................................10-264 ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM........................................................10-264 ELECTRIC MODULATION FUNCTION.........................................................................................10-265 DISPLAY FUNCTION OF GEAR SHIFT........................................................................................10-265 AUTOMATIC GEAR SHIFT FUNCTION........................................................................................10-265 SHIFT HOLD FUNCTION .............................................................................................................10-266 KICKDOWN FUNCTION ...............................................................................................................10-266 AUTOMATIC KICKDOWN FUNCTION .........................................................................................10-267 TORQUE CONVERTER LOCKUP FUNCTION.............................................................................10-267 HUNTING PREVENTION FUNCTION ..........................................................................................10-268 ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT.......10-268 SHIFT POINT CHANGING FUNCTION ........................................................................................10-268 4TH GEAR SPEED LIMITATION FUNCTION ...............................................................................10-269 TRANSMISSION PROTECTION FUNCTION ......................................................................................10-270 PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED......................................10-270 SHIFT DOWN PROTECTION FUNCTION....................................................................................10-270 ENGINE OVERRUN PREVENTION FUNCTION ..........................................................................10-271 MAXIMUM SPEED LIMITATION FUNCTION ................................................................................10-271 NEUTRALIZER FUNCTION..........................................................................................................10-272 DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION.............................................................10-273 TRANSMISSION CUT-OFF FUNCTION ..............................................................................................10-275 COMPONENT PARTS OF POWER TRAIN SYSTEM ..........................................................................10-277 DRIVE SHAFT ..............................................................................................................................10-277 TORQUE CONVERTER ...............................................................................................................10-280 LOCKUP CLUTCH ECMV.............................................................................................................10-286 TRANSMISSION...........................................................................................................................10-289 TRANSMISSION CONTROL VALVE.............................................................................................10-305 FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV ....................10-307 TRANSFER ..................................................................................................................................10-312 TORQUE CONVERTER REGULATOR VALVE .............................................................................10-314 MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE .......................................................................................................................................10-316 TRANSMISSION LUBRICATION RELIEF VALVE .........................................................................10-320 POWER TRAIN OIL COOLER ......................................................................................................10-321 AXLE ............................................................................................................................................10-322 CONVENTIONAL DIFFERENTIAL................................................................................................10-324 LIMITED SLIP DIFFERENTIAL .....................................................................................................10-326 FINAL DRIVE................................................................................................................................10-332 10-4

WA500-8E0

10 STRUCTURE AND FUNCTION

CONTENTS

AJSS KNOB..................................................................................................................................10-334 COMBINATION SWITCH ..............................................................................................................10-335 SHIFT HOLD SWITCH..................................................................................................................10-338 KICKDOWN SWITCH ...................................................................................................................10-339 WORK EQUIPMENT SYSTEM ...................................................................................................................10-340 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM .....................................................................10-340 WORK EQUIPMENT SYSTEM DIAGRAM...........................................................................................10-342 WORK EQUIPMENT CONTROL SYSTEM ..........................................................................................10-344 WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE ...................................................................................................................................10-344 WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION..............................................................................................................10-345 WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM ..............................10-346 WORK EQUIPMENT LEVER OPERATION FUNCTION ...............................................................10-347 BUCKET PRIORITY CONTROL FUNCTION ................................................................................10-347 BOOM STOP MODULATION FUNCTION.....................................................................................10-347 WORK EQUIPMENT NEUTRAL LOCK SYSTEM ................................................................................10-349 WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM........................................................10-349 FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM ................................................10-349 REMOTE POSITIONER SYSTEM .......................................................................................................10-351 REMOTE BUCKET POSITIONER SYSTEM DIAGRAM ...............................................................10-351 FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM........................................................10-351 REMOTE BOOM POSITIONER SYSTEM DIAGRAM ...................................................................10-352 FUNCTION OF REMOTE BOOM POSITIONER SYSTEM ...........................................................10-352 BUCKET POSITIONER AND BOOM POSITIONER.............................................................................10-356 STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER .........................................10-356 AUTO-DIGGING SYSTEM...................................................................................................................10-357 AUTO-DIGGING SYSTEM DIAGRAM ..........................................................................................10-357 FUNCTION OF AUTO-DIGGING SYSTEM...................................................................................10-357 ECSS ...................................................................................................................................................10-359 ECSS DIAGRAM ..........................................................................................................................10-359 FUNCTION OF ECSS...................................................................................................................10-359 OPERATION OF ECSS.................................................................................................................10-359 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ..................................................................10-361 WORK EQUIPMENT LOCK SOLENOID VALVE ...........................................................................10-361 PILOT CIRCUIT ACCUMULATOR ................................................................................................10-362 ECSS CIRCUIT ACCUMULATOR.................................................................................................10-363 WORK EQUIPMENT ELECTRIC LEVER......................................................................................10-364 ELECTRIC MONO-LEVER ...........................................................................................................10-367 MULTIFUNCTION MONO-LEVER ................................................................................................10-371 STEERING SYSTEM ..................................................................................................................................10-372 LAYOUT DRAWING OF STEERING SYSTEM ....................................................................................10-372 SECONDARY STEERING SYSTEM....................................................................................................10-374 SECONDARY STEERING SYSTEM DIAGRAM ...........................................................................10-374 FUNCTION OF SECONDARY STEERING SYSTEM....................................................................10-374 JOYSTICK STEERING SYSTEM.........................................................................................................10-375 LAYOUT DRAWING OF JOYSTICK STEERING SYSTEM ...........................................................10-375 FUNCTION OF JOYSTICK STEERING SYSTEM.........................................................................10-375 JOYSTICK CONTROL FUNCTION...............................................................................................10-376 JOYSTICK NEUTRAL SAFETY FUNCTION .................................................................................10-379 JOYSTICK NEUTRAL INTERLOCK FUNCTION ..........................................................................10-379 JOYSTICK SPEED SENSING STEERING FUNCTION ................................................................10-379 JOYSTICK Hi/Lo SELECTOR FUNCTION ....................................................................................10-380 AJSS ...................................................................................................................................................10-381 LAYOUT DRAWING OF AJSS .....................................................................................................10-381 AJSS DIAGRAM ...........................................................................................................................10-382 FUNCTION OF AJSS....................................................................................................................10-383 NEUTRALIZER FUNCTION OF AJSS ..........................................................................................10-384 WA500-8E0

10-5

CONTENTS

10 STRUCTURE AND FUNCTION

NEUTRAL INTERLOCK FUNCTION OF AJSS .............................................................................10-384 SPEED SENSING STEERING FUNCTION OF AJSS...................................................................10-385 TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS ...................................................10-386 STEERING COLUMN ..........................................................................................................................10-388 STRUCTURE OF STEERING COLUMN.......................................................................................10-388 COMPONENT PARTS OF STEERING SYSTEM.................................................................................10-389 AJSS EPC VALVE.........................................................................................................................10-389 STEERING LOCK VALVE .............................................................................................................10-390 ROTARY VALVE ...........................................................................................................................10-391 ORBITROL VALVE........................................................................................................................10-394 STOP VALVE ................................................................................................................................10-398 STEERING VALVE........................................................................................................................10-399 DIVERTER VALVE ........................................................................................................................10-410 SECONDARY STEERING RELIEF VALVE ...................................................................................10-414 SECONDARY STEERING PUMP .................................................................................................10-416 JOYSTICK KNOB .........................................................................................................................10-417 BRAKE SYSTEM ........................................................................................................................................10-418 LAYOUT DRAWING OF BRAKE SYSTEM ..........................................................................................10-418 PARKING BRAKE CONTROL SYSTEM ..............................................................................................10-421 PARKING BRAKE CONTROL SYSTEM DIAGRAM......................................................................10-421 OPERATION OF PARKING BRAKE CONTROL SYSTEM............................................................10-421 COMPONENT PARTS OF BRAKE SYSTEM.......................................................................................10-423 CHARGE VALVE...........................................................................................................................10-423 PARKING BRAKE SOLENOID VALVE ..........................................................................................10-428 PARKING BRAKE EMERGENCY RELEASE VALVE ....................................................................10-430 BRAKE CIRCUIT ACCUMULATOR ..............................................................................................10-431 BRAKE VALVE..............................................................................................................................10-432 SLACK ADJUSTER ......................................................................................................................10-436 BRAKE..........................................................................................................................................10-438 PARKING BRAKE .........................................................................................................................10-440 AUTO-GREASING SYSTEM ......................................................................................................................10-442 LAYOUT DRAWING OF AUTO-GREASING SYSTEM .........................................................................10-442 SPECIFICATIONS OF AUTO-GREASING SYSTEM ...........................................................................10-443 FUNCTION OF AUTO-GREASING SYSTEM ......................................................................................10-445 COMPONENT PARTS OF AUTO-GREASING SYSTEM .....................................................................10-446 AUTO-GREASING PUMP.............................................................................................................10-446 UNDERCARRIAGE AND FRAME...............................................................................................................10-447 FRAME, AXLE MOUNT AND CENTER HINGE PIN ............................................................................10-447 STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN.........................................10-447 FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN ............................................10-448 TIRE ....................................................................................................................................................10-449 FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE .........................................10-449 STRUCTURE OF RADIAL TIRE ...................................................................................................10-449 FUNCTION OF RADIAL TIRE.......................................................................................................10-450 STRUCTURE OF BIAS TIRE........................................................................................................10-450 FUNCTION OF BIAS TIRE ...........................................................................................................10-450 WORK EQUIPMENT...................................................................................................................................10-451 STRUCTURE OF WORK EQUIPMENT ...............................................................................................10-451 STRUCTURE OF BUCKET..................................................................................................................10-452 STRUCTURE OF WORK EQUIPMENT LUBRICATION.......................................................................10-454 CAB AND ITS ATTACHMENTS ..................................................................................................................10-456 ROPS CAB ..........................................................................................................................................10-456 STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL)....................................10-456 STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...........10-457 FUNCTION OF ROPS CAB ..........................................................................................................10-457

10-6

WA500-8E0

10 STRUCTURE AND FUNCTION

ABBREVIATION LIST

ABBREVIATION LIST •

•

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

•

Special abbreviations which appear infrequently are noted in the text.

•

List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)

Abbreviation

Actual word spelled out

ABS

Antilock Brake System

AISS

Automatic Idling Setting Engine System

This is a function that automatically sets the idle speed.

Steering AJSS

Advanced Joystick Steering System

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

ARAC

Automatic Retarder Accelerator Control

Travel and brake (HD, HM)

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

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

ARSC

Automatic Retarder Speed Control

ASR

Travel and brake Automatic Spin Regulator (HD, HM)

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

ATT

Attachment

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

BCV

BRAKE Brake cooling oil control valve (HD)

CAN

Controller Area Network

Communication and electronic control

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

CDR

Crankcase Depression Regulator

Engine

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

CLSS

Closed-center Load Sensing System

Hydraulic system

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

WA500-8E0

(HD, HM)

Work equipment

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

10-7

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ABBREVIATION LIST

Abbreviation

Actual word spelled out

10 STRUCTURE AND FUNCTION

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

Explanation

Engine

Electronic control system

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

CRI

Common Rail Injection

ECM

Electronic Control Module

ECMV

Electronic Control Modulation Valve

ECSS

Travel Electronically Controlled Suspension System (WA)

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

ECU

Electronic Control Unit

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

EGR

Exhaust Gas RecirculaEngine tion

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

EMMS

Equipment ManageMachine monitor ment Monitoring System

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

EPC

Electromagnetic ProporHydraulic system tional Control

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

FOPS

Falling Object Protective Cab and canopy Structure

Transmission (D, HD, WA, etc)

Electronic control system

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

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

F-N-R

Forward-Neutral-Reverse

GPS

Global Positioning System

GNSS

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

HSS

Hydrostatic Steering System

HST

Hydro Static Transmission

Operation Communication (KOMTRAX, KOMTRAX Plus)

Steering

10-8

(D Series) Transmission (D, WA)

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

WA500-8E0

10 STRUCTURE AND FUNCTION

ABBREVIATION LIST

Abbreviation

Actual word spelled out

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

Explanation

ICT

Information and Communication Technology

Communication and electronic control

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

IMA

Inlet Metering Actuator

Engine

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

IMU

Inertial Measurement Unit

Engine

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

IMV

Inlet Metering Valve

Engine

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

KCCV

Komatsu Closed CrankEngine case Ventilation

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

KCSF

Komatsu Catalyzed Soot Filter

KDOC

Komatsu Diesel Oxidation Catalyst

KDPF

Engine

Komatsu Diesel ParticuEngine late Filter

Travel and brake

KTCS

Komatsu Traction Control System

(HM)

LCD

Liquid Crystal Display

Machine monitor

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

LED

Light Emitting Diode

Electronic parts

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

LIN

Local Interconnect Network

Communication and electronic control

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

Load Sensing

Hydraulic system

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

LVDS

Low Voltage Differential Signaling

Communication and electronic control

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

Engine

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

MAF

Mass Air Flow

WA500-8E0

10-9

ABBREVIATION LIST

10 STRUCTURE AND FUNCTION

Abbreviation

Actual word spelled out

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

MMS

Multimedia Messaging Service

Communication

Normally Closed

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

Normally Open

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

OLSS

Open-center Load Sensing System

Hydraulic system

Pressure Compensation Hydraulic system

PCCS

Palm command control system

PCV

Pre-stroke Control Valve Engine

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

PPC

Proportional Pressure Control

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

PPM

Piston Pump and Motor

PTO

Power Take Off

PTP

Power Tilt and power Pitch dozer

Steering

ROPS

Roll-Over Protective Structure

(D Series)

Hydraulic system Hydraulic system (D, PC, etc)

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

Piston type hydraulic pump and motor.

Power train system

Power take-off mechanism

Work equipment

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

(D Series)

Cab and canopy

SCR

Selective Catalytic Reduction

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

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

SOL

Solenoid

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

10-10

Urea SCR system

Electrical system

WA500-8E0

10 STRUCTURE AND FUNCTION

Abbreviation

TOPS

ABBREVIATION LIST

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

Actual word spelled out

Tip-Over Protective Structure

Cab and canopy

TWV

2-Way Valve

Hydraulic system

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

VGT

Variable Geometry Turbocharger

Engine

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

VHPC

Variable Horse Power Control

Engine control

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

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

List of abbreviations used in the circuit diagrams Abbreviation

Actual word spelled out

A/C

Air Conditioner

A/D

Analogue-to-Digital

A/M

Air Mix Damper

ACC

Accessory

ADD

Additional

AUX

Auxiliary

Battery Relay

Clockwise

CCW

Counter Clockwise

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actuator

No Connection

WA500-8E0

10-11

ABBREVIATION LIST

Abbreviation S/T STRG

Actual word spelled out Steering

SIG

Signal

SOL

Solenoid

STD

Standard

OPT OP

Option

PRESS

Pressure

SPEC

Specification

Switch

TEMP

Temperature

T/C

Torque Converter

T/M

Transmission

10-12

10 STRUCTURE AND FUNCTION

WA500-8E0

10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF UREA SCR SYSTEM

UREA SCR SYSTEM SCR Abbreviation for Selective Catalytic Reduction

LAYOUT DRAWING OF UREA SCR SYSTEM

1. AdBlue/DEF tank

8: KDPF

2: AdBlue/DEF filler port

9: AdBlue/DEF tank coolant inlet hose

3: AdBlue/DEF pump

10: AdBlue/DEF tank coolant outlet hose

4: AdBlue/DEF pressure hose (low-temperature side)

11: AdBlue/DEF injector coolant hose

5: AdBlue/DEF pressure hose (high-temperature side)

12: AdBlue/DEF injector

6: SCR assembly

13: Engine room temperature sensor

7: AdBlue/DEF mixing tube

WA500-8E0

10-13

LAYOUT DRAWING OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

14: AdBlue/DEF tank sensor

17: AdBlue/DEF suction hose

15: AdBlue/DEF tank heating valve

18: AdBlue/DEF return hose

16: Ambient temperature sensor

10-14

WA500-8E0

10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF UREA SCR SYSTEM

19: Ammonia sensor

22: SCR outlet NOx sensor

20: SCR temperature sensor

23: Turbocharger outlet NOx sensor

21: SCR outlet temperature sensor

WA500-8E0

10-15

UREA SCR SYSTEM DIAGRAM

10 STRUCTURE AND FUNCTION

UREA SCR SYSTEM DIAGRAM 1 4

7 5

9 3

20 26

16 21

24 27

10 22

25 28 29

A B

36 39 40

31 A4P15760

A: Coolant inlet

B: Coolant outlet

1: Mass air flow and temperature sensor

21: Ammonia sensor

2: Engine

22: Ammonia sensor controller

3: Engine controller

23: SCR temperature sensor

4: KDPF

24: SCR outlet temperature sensor

5: KDOC unit

25: SCR temperature sensor controller

6: KCSF unit

26: SCR outlet NOx sensor

7: KDPF differential pressure sensor

27: SCR outlet NOx sensor controller

8: KDPF outlet pressure sensor

28: Smart sensor

9: Turbocharger outlet NOx sensor

29: Ambient temperature sensor

10: Turbocharger outlet NOx sensor controller

30: Engine room temperature sensor

11: KDOC inlet temperature sensor

31: AdBlue/DEF system

12: KDOC outlet temperature sensor

32: AdBlue/DEF tank heating valve

13: KDPF outlet temperature sensor

33: AdBlue/DEF tank

14: KDPF temperature sensor controller

34: AdBlue/DEF tank sensor

15: AdBlue/DEF mixing tube

35: AdBlue/DEF suction line

16: AdBlue/DEF injector

36: AdBlue/DEF return line

17: SCR assembly

37: AdBlue/DEF pressure line

18: Upstream SCR catalyst

38: AdBlue/DEF pump

19: Downstream SCR catalyst

39: AdBlue/DEF line heater relay

20: Ammonia oxidation catalyst

40: Machine monitor

10-16

WA500-8E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

1: Engine

5: AdBlue/DEF injector

2: Engine controller

6: KDPF

3: AdBlue/DEF pump

7: SCR catalyst

4: AdBlue/DEF tank

8: Ammonia oxidation catalyst

•

Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless nitrogen and water.

•

By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.

FUNCTION OF AdBlue/DEF SYSTEM 1: AdBlue/DEF tank

2: AdBlue/DEF suction hose

3: AdBlue/DEF pump

3A: Flow control valve 3B: Pump 3C: AdBlue/DEF filter 3D: Pressure sensor

4: AdBlue/DEF return hose 5: AdBlue/DEF pressure hose 6: AdBlue/DEF injector

1 3A

3D P

•

AdBlue/DEF system consists of AdBlue/DEF tank (1), AdBlue/DEF hoses (2), (4), (5), AdBlue/DEF pump (3), and AdBlue/DEF injector (6).

•

The AdBlue/DEF system is a part of the Komatsu Urea SCR system and its function is to provide AdBlue/DEF into the SCR Catalyst Assembly.

•

However, the comprising devices, such as the AdBlue/DEF pump, may not start functioning till certain conditions are fulfilled.

•

The AdBlue/DEF system has heating systems to thaw and prevent AdBlue/DEF from freezing because AdBlue/DEF freezes at -11 °C.

WA500-8E0

3C 3B

A4P14892

10-17

FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

Function of AdBlue/DEF injection system •

The AdBlue/DEF pump pressurizes AdBlue/DEF and delivers it into the AdBlue/DEF mixing tube through the AdBlue/DEF injector.

•

The amount of AdBlue/DEF injection is controlled by the Engine Controller.

•

The amount of AdBlue/DEF injection is calculated based on the information of the turbocharger outlet NOx sensor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the ammonia sensor, the SCR outlet NOx sensor and the exhaust gas flow rate.

•

AdBlue/DEF injection is also controlled by the system temperature because Urea SCR systems are not effective in low temperature. For the monitoring of the system temperature, the KDPF outlet temperature sensor is used in addition to the SCR temperature sensors.

•

If any abnormality is detected in any of the sensors that are used for the calculation of the amount of AdBlue/DEF injection and the monitoring of the system temperature, the Engine Controller commands termination of AdBlue/DEF injection. When this occurs, alerts will be activated and failure codes will be registered.

•

Some abnormalities may cause large amount of urea precipitation inside the AdBlue/DEF mixing tube and result in deposit of urea on the inner surfaces. If it continues and urea deposit accumulates AdBlue/DEF injection can be blocked at the AdBlue/DEF injector or the exhaust gas flow can be choked in the passages.

Function of purge system •

The AdBlue/DEF purging is incorporated to purge remaining AdBlue/DEF in the AdBlue/DEF injector, AdBlue/DEF hoses and the AdBlue/DEF pump to prevent AdBlue/DEF from solidifying inside by precipitation or freezing.

•

The AdBlue/DEF purging is activated automatically when the engine is shut down or the ambient temperature falls so low that the heating systems is not capable of maintaining fluidity of AdBlue/DEF.

•

In the case of the AdBlue/DEF purging of the engine shutdown, the purging operation continues several minutes after the engine stops. Once the purging operation completes, the Engine Controller shuts itself down automatically.

NOTICE Do not turn the battery disconnect switch to the OFF position till the System Operating Lamp in the battery box goes out. The System Operating Lamp will go out when the system shuts itself down after the purging operation completes.

Function of heating system •

The AdBlue/DEF heating system has two operation modes.

•

One operation mode is “Thaw mode”.

•

At engine start-up if the Engine Controller judges AdBlue/DEF is frozen, it automatically commands heating the AdBlue/DEF injection system.

•

The AdBlue/DEF pump and the AdBlue/DEF injector hold their operation till the Engine Controller judges the completion of AdBlue/DEF thawing operation.

The other operation mode is “Freeze Prevention mode”. •

While the machine is in operation if the Engine Controller judges AdBlue/DEF is likely to freeze, it automatically commands heating the AdBlue/DEF system.

•

While the heating is on during machine operation if the Engine Controller judges that cooling by the ambient exceeds the heating capacity of the system, it automatically starts AdBlue/DEF purging and

10-18

WA500-8E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

shuts down the operation of the AdBlue/DEF pump and the AdBlue/DEF injector. However, the heating system is kept on as long as the machine is in operation. •

“Thaw mode” and “Freeze Prevention mode” are controlled by utilizing information by temperature sensors. The temperature sensors used for the control of two modes are different and the temperature Freeze Prevention modesensors utilized by the comprising devices are different. The following table shows which comprising device uses which heating system and which temperature sensors in relation to which operation mode. Heating system

Thawing mode

Heater around hose

Ambient temperature sensor

AdBlue/DEF pressure hose (hightemperature side)

Heater around hose

Engine room temperature Engine room temperature sensor sensor

AdBlue/DEF pump

Pump built-in heater

AdBlue/DEF pump temperature sensor

AdBlue/DEF tank

Circulation of coolant

AdBlue/DEF tank temper- AdBlue/DEF tank temperature sensor ature sensor

AdBlue/DEF suction and purge hose AdBlue/DEF pressure hose (lowtemperature side)

Freeze prevention mode Ambient temperature sensor

Ambient temperature sensor

INDUCEMENT STRATEGY •

The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions control system.

•

Inducement strategy is a control action to ensure prompt 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, as well as alarms while the control actions are imposed. The warning steps of Inducement are different between for North America and for European Union.

•

The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information” screen of the machine monitor.

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BECOMES LOW (FOR NORTH AMERICA) •

When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine monitor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including engine power deration is activated.

•

The Inducement strategy progresses in 5 levels from Warning, Escalated Warning, Mild Inducement, Severe Inducement and Final Inducement.

•

Up to the start of Severe Inducement the start of each warning step is triggered by the amount of AdBlue/DEF in the AdBlue/DEF tank. Final Inducement starts at 1 hour after the start of Severe Inducement if the machine continues its operation without adding AdBlue/DEF into the tank, and reduces the engine speed to low idle and keeps it at low idle.

•

The Inducement strategy status can be checked on “SCR Information” screen of the user menu.

•

The table shows warning indications and engine power derations by each Inducement strategy status.

WA500-8E0

10-19

FUNCTION OF UREA SCR SYSTEM

Status

AdBlue/DEF level (*1) (AdBlue/DEF level gauge) 10%

Warning

(The bottom two gradations light on) 5%

Escalated Warning (Warning 2)

(Within the gradation of the second from the bottom )

10 STRUCTURE AND FUNCTION

Machine monitor AdBlue/DEF Message of level caution SCR Informa- lamp tion (Action level)

Tone of audible alert

Red 1: DEF low level warning appears.

2: Without treatment, engine power will be derated.

Activated failure code (*2)

Engine deration (*3)

CA3497 No sound

Red Triplet (*4)

(AdBlue/DEF No deration level low error 1)

CA3498

(AdBlue/DEF No deration Short intermitlevel low error tently (*5) 2) Red

Mild Inducement (Inducement 1)

2.5% 3: Engine (The gradation of the end power is unof the bottom der deration. lights on)

CA1673 Red

Long intermittently

(AdBlue/DEF Torque: over level low error 25% 3)

Red

Severe Inducement (Inducement 2)

0% (All gradations lights off)

4: Engine power is under heavy deration.

CA1673 CA3547 Red

Continuously

Torque: 50%

(AdBlue/DEF and level low error RPM: 40% 4)

Red

Final Inducement (Inducement 3)

Not remaining in the tank 5: Engine is (*6) running at low (All gradaidle. tions lights off)

CA1673 CA3547 Red

Continuously

AS00ZK (AdBlue/DEF level low error 5)

Engine speed is fixed to low idle

10-20

WA500-8E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed. *4: Construction equipment with crawler *5: Construction equipment with wheel *6: After progressed “Severe Inducement” the status advances to “Final Inducement” with in 1 hour.

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR SYSTEM DEVICES (FOR NORTH AMERICA) •

AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBlue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, inducement strategy starts so that the engine output is lowered.

•

The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Information” screen of the machine monitor.

•

The table shows warning indications and engine power derations by each Inducement strategy status. Machine monitor Status

Elapsed time (*1)

Caution Failure code Message of lamp Failure code for InduceTone of auSCR Inforfor abnormalidible alert ment strategy (Action levty (*2),(*3) mation status (*4) el)

Engine deration (*5)

Yellow

Warning

1 hour

1: Please inspect and maintain SCR system.

Yellow

No sound

CA3571 CB3571

No indication

No deration

Yellow

Escalated Warning

2 hours

(Warning 2)

2: Without treatment, engine power will be derated.

Yellow

Triplet (*6)

AS00R2

Short inter- CA3571 mittently CB3571 (*7)

(Warning 2 No deration (SCR Device Abnormality))

Red

Mild Inducement (Inducement 1)

WA500-8E0

3 hours

3: Engine power is under deration.

AS00R3 Red

Long intermittently

CA3571 CB3571

(Inducement 1(SCR Device Abnormality))

Torque: over 25%

10-21

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FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

Machine monitor Status

Elapsed time (*1)

Caution Failure code Failure code Message of lamp for InduceTone of aufor abnormaliSCR Informent strategy dible alert (Action levty (*2),(*3) mation status (*4) el)

Engine deration (*5)

Red

Severe Inducement

(Inducement 2)

4 hours

4: Engine power is under heavy deration.

AS00R4 Red

Continuously

CA3571 CB3571

(Inducement 2 (SCR Device Abnormality))

Torque: 50% and RPM: 40%

Red

Final Inducement

(Inducement 3)

AS00R5 5: Engine is Until repairrunning at ing low idle.

Red

Continuously

CA3571 CB3571

(Inducement 3 (SCR Device Abnormality))

Engine speed is fixed to low idle

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning”stage. Final Inducement is not cleared till abnormality is repaired. *2: These failure codes are displayed 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 which is displayed on the machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM”. *3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines. *4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. *5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed. *6: Construction equipment with crawler *7: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYSTEM BY THE UREA SCR SYSTEM (FOR NORTH AMERICA) •

The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. It has 5 levels totally which is the same as that, but it has different display on the machine monitor, and engine power deration (torque lowering ratio is 25% or more) and alarm starts from “Warning”.

•

The table shows warning indications and engine power derations by each Inducement strategy status.

10-22

WA500-8E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

Machine monitor Status

Elapsed time (*1)

Caution Failure code Message of lamp Tone of aufor abnormaliSCR Infor(Action lev- dible alert ty (*2),(*3) mation el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Warning

1 hour

1: Please inspect and maintain SCR system.

Red

Long intermittently

CA4151 CB4151

No indication

Torque: over 25%

Red

Escalated Warning

2 hours

(Warning 2)

2: Without treatment, engine power will be derated.

Yellow

Triplet (*6)

AS00R2

Short inter- CA4151 CB4151 mittently (*7)

Torque: over (Warning 2 (SCR Device 25% Abnormality))

Red

Mild Inducement (Inducement 1)

3 hours

3: Engine power is under deration.

Red

AS00R3 Long intermittently

CA4151 CB4151

(Inducement 1 (SCR Device Abnormality))

Torque: over 25%

Red

WA500-8E0

10-23

FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

Machine monitor Status

Elapsed time (*1)

Caution Failure code Message of lamp Tone of aufor abnormaliSCR Infor(Action lev- dible alert ty (*2),(*3) mation el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Severe Inducement (Inducement 2)

4 hours

4: Engine power is under heavy deration.

Red

AS00R4 Continuously

CA4151 CB4151

(Inducement 2 (SCR Device Abnormality))

Torque: 50% and RPM: 40%

Red

Final Inducement (Inducement 3)

Red 5: Engine Until repairis running ing at low idle.

AS00R5 Continuously

CA4151 CB4151

(Inducement 3 (SCR Device Abnormality))

Engine speed is fixed to low idle

Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning” stage. Final Inducement is not cleared till abnormality is repaired. *2: These failure codes are displayed 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 which is displayed on the machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM”. *3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines. *4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. *5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed. *6: Construction equipment with crawler *7: Construction equipment with wheel

10-24

WA500-8E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR NORTH AMERICA) •

Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or troubleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these difficulties the operator can restore engine power for a short time to the deration of “Mild Inducement” through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine power.

•

“Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 operations are allowed, but “Temporary Restoration from Inducement” is turned off whenever the system advances to “Final Inducement” even if either 30 minutes or 3 operations are not used up. All the abnormalities of the Urea SCR system need to be corrected to regain another restoration capability.

•

If all the abnormalities of the Urea SCR system are not corrected when the system is in “Severe Inducement”, the system advances to “Final Inducement” in 1 hour after “Severe Inducement” started and engine speed will be fixed to low idle to disable practical machine operation.

•

To activate Temporary Restoration, follow the procedures described below. REMARK For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCEMENT” on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40 HOURS (FOR NORTH AMERICA) •

The Urea SCR system continuously monitors its operation conditions and stores information on inappropriate operations including malfunctions.

•

The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnormality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.

•

If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were corrected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities 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 and starts from “Severe Inducement”.

•

The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not corrected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final Inducement” and engine speed will be fixed to low idle to disable practical machine operation.

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BECOMES LOW (FOR EUROPEAN UNION) •

•

The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Inducement, and Severe Inducement.

•

Up to the start of Severe Inducement the start of each warning step is triggered by the amount of AdBlue/DEF in the AdBlue/DEF tank.

•

The Inducement strategy status can be checked on “SCR Information” screen of the user menu.

•

The table shows warning indications and engine power derations by each Inducement strategy status.

WA500-8E0

10-25

FUNCTION OF UREA SCR SYSTEM

Status

AdBlue/DEF level (*1) (AdBlue/DEF level gauge) 10%

Warning

(The bottom two gradations light on) 5%

Continuous Warning

(Warning 2)

(Within the gradation of the second from the bottom )

10 STRUCTURE AND FUNCTION

Machine monitor AdBlue/DEF Message of level caution SCR Informa- lamp tion (Action level)

Tone of audible alert

Red 1: DEF low level warning appears.

2: Without treatment, engine power will be derated.

Activated failure code (*2)

Engine deration (*3)

CA3497 No sound

Red Triplet (*4)

(AdBlue/DEF No deration level low error 1)

CA3498

(AdBlue/DEF No deration Short intermitlevel low error tently (*5) 2) Red

Low-Level Inducement

(Inducement 1)

2.5% 3: Engine (The gradation of the end power is unof the bottom der deration. lights on)

Red

CA1673 Long intermit- (AdBlue/DEF Torque: over tently level low error 25% 3)

Red

Severe Inducement

(Inducement 2)

0% (All gradations lights off)

4: Engine power is under heavy deration.

CA1673 CA3547 Red

Continuously

Torque: 50%

(AdBlue/DEF and level low error RPM: 40% 4)

*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”. *2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM”. *3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed. *4: Construction equipment with crawler *5: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE AdBlue/DEF QUALITY OR IN THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION) •

10-26

WA500-8E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

•

The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Information” screen of the machine monitor.

•

The table shows warning indications and engine power derations by each Inducement strategy status. Machine monitor

Status

Elapsed time (*1)

AdBlue/DE F system Message of caution Failure code Tone of auSCR Infor- lamp for abnormalidible alert mation ty (*2),(*3) (Action level)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Yellow

Warning

5 hours

1: Please inspect and maintain SCR system.

Yellow

No sound

CA3571 CB3571

No indication

No deration

Yellow

Continuous Warning 10 hours (Warning 2)

2: Without treatment, engine power will be derated.

Yellow

Triplet (*6)

AS00R2

Short inter- CA3571 CB3571 mittently (*7)

(Warning 2 No deration (SCR Device Abnormality))

Red

Low-Level Inducement (Inducement 1)

20 hours

3: Engine power is under deration.

AS00R3 Red

Long intermittently

CA3571 CB3571

(Inducement 1 (SCR Device Abnormality))

Torque: over 25%

AS00R4

Torque: 50%

Red

Severe Inducement (Inducement 2)

WA500-8E0

4: Engine power is Until repairunder ing heavy deration.

Red

Continuously

CA3571 CB3571

(Inducement 2 (SCR Device Abnormality))

and RPM: 40%

10-27

FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning” stage. Final Inducement is not cleared till abnormality is repaired. *2: These failure codes are displayed 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 which is displayed on the machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM”. *3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines. *4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. *5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed. *6: Construction equipment with crawler *7: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYSTEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION) •

The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. It has 4 levels totally which is the same as that, but it has different display on the machine monitor, and engine power deration (torque lowering ratio is 25% or more) and alarm starts from “Warning”.

•

The table shows warning indications and engine power derations by each Inducement strategy status. Machine monitor Status

Elapsed time (*1)

Caution Failure code Message of lamp Tone of aufor abnormaliSCR Infor(Action lev- dible alert ty (*2),(*3) mation el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Warning

5 hours

1: Please inspect and maintain SCR system.

Red

Long intermittently

CA4151 CB4151

No indication

Torque: over 25%

Red

Continuous Warning 10 hours (Warning 2)

2: Without treatment, engine power will be derated.

Yellow

Triplet (*6)

AS00R2

Short inter- CA4151 mittently CB4151 (*7)

Torque: over (Warning 2 (SCR Device 25% Abnormality))

Red

10-28

WA500-8E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

Machine monitor Status

Elapsed time (*1)

Caution Failure code Message of lamp Tone of aufor abnormaliSCR Infor(Action lev- dible alert ty (*2),(*3) mation el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Low-Level Inducement (Inducement 1)

20 hours

3: Engine power is under deration.

Red

AS00R3 Long intermittently

CA4151 CB4151

(Inducement 1 (SCR Device Abnormality))

Torque: over 25%

AS00R4

Torque: 50%

Red

Severe Inducement (Inducement 2)

4: Engine power is Until repairunder ing heavy deration.

Red Continuously

CA4151 CB4151

(Inducement 2 (SCR Device Abnormality))

and RPM: 40%

Red

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FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYSTEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION) •

The Inducement strategy is different if Inducement is triggered by abnormalities in EGR. It has 4 levels totally which is the same as that, but it has different display on the machine monitor, and engine power deration (torque lowering ratio is 25% or more) and alarm starts from “Warning”.

•

The table shows warning indications and engine power derations by each Inducement strategy status. Machine monitor Status

Elapsed time (*1)

Caution Failure code Message of lamp Tone of auSCR Inforfor abnormali(Action lev- dible alert mation ty (*2),(*3) el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Warning

5 hours

1: Please inspect and maintain SCR system.

Red

Long intermittently

CA2271 CB2271

No indication

Torque: over 25%

Red

Continuous Warning 10 hours (Warning 2)

2: Without treatment, engine power will be derated.

Yellow

Triplet (*6)

AS00R2

Short inter- CA2271 CB2271 mittently (*7)

Torque: over (Warning 2 (SCR Device 25% Abnormality))

Red

Low-Level Inducement (Inducement 1)

20 hours

3: Engine power is under deration.

Red

AS00R3 Long intermittently

CA2271 CB2271

(Inducement 1 (SCR Device Abnormality))

Torque: over 25%

Red

10-30

WA500-8E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

Machine monitor Status

Elapsed time (*1)

Caution Failure code Message of lamp Tone of aufor abnormaliSCR Infor(Action lev- dible alert ty (*2),(*3) mation el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Severe Inducement (Inducement 2)

4: Engine power is Until repairunder ing heavy deration.

Red

AS00R4 Continuously

CA2271 CB2271

(Inducement 2 (SCR Device Abnormality))

Torque: 50% and RPM: 40%

Red

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EUROPEAN UNION) •

Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or troubleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these difficulties the operator can restore engine power for a short time to the deration of “Low-Level Inducement” through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine power.

•

“Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 operations are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another restoration capability.

•

To activate Temporary Restoration, follow the procedures described below.

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FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

REMARK For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCEMENT” on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40 HOURS (FOR EUROPEAN UNION) •

The Urea SCR system continuously monitors its operation conditions and stores information on inappropriate operations including malfunctions.

•

If a recurrence occurs, the Inducement strategy will be activated.

•

Inducement in the recurrence resumes counting time at the time when the previous abnormalities were corrected if the previous Inducement is in “Warning”, “Continuous Warning” or “Low-Level Inducement”. The alerts resume the previous Inducement.

•

If the time the previous abnormalities were corrected is in “Severe Inducement”, Inducement in the recurrence starts from “Low-Level Inducement” but the remaining time to “Severe Inducement” is 1 hour or 2 hours depending on abnormalities. If the 1 hour or 2 hours are used up without correcting the new abnormalities, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.

10-32

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10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM

COMPONENT PARTS OF UREA SCR SYSTEM SCR Abbreviation for Selective Catalytic Reduction

AdBlue/DEF MIXING TUBE STRUCTURE OF AdBlue/DEF MIXING TUBE REMARK The shape is subject to machine models.

A: Exhaust gas inlet (from KDPF)

B: Exhaust gas outlet (to SCR)

1: V clamp

4: AdBlue/DEF mixing tube (connector)

2: AdBlue/DEF injector

5: AdBlue/DEF mixing tube (tube)

3: Gasket for AdBlue/DEF injector

FUNCTION OF AdBlue/DEF MIXING TUBE It mixes AdBlue/DEF injected from AdBlue/DEF injector with exhaust gas, and decomposes it to ammonia which is needed to purge NOx from SCR assembly.

SCR ASSEMBLY SCR Abbreviation for Selective Catalytic Reduction

STRUCTURE OF SCR ASSEMBLY REMARK The shape is subject to machine models. WA500-8E0

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COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

19 A4P15765

A: From AdBlue/DEF mixing tube

C: Water drain

B: To exhaust pipe 1: Inlet unit

3: Downstream SCR catalyst unit

2: Upstream SCR catalyst unit

4: Ammonia sensor

10-34

WA500-8E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM

5: SCR temperature sensor

13: Hanger plate

6: Temperature sensor controller

14: Rectifying plate

7: Sensor bracket

15: Upstream SCR catalyst

8: Sensor bracket band

16: Downstream SCR catalyst

9: Outlet unit

17: Ammonia oxidation catalyst

10: SCR outlet temperature sensor

18: Catalyzer holding mat

11: SCR outlet NOx sensor

19: Water dam

12: Water drain port

20: Water baffle

•

SCR assembly consists of the following: The inlet unit (1) which introduces the exhaust gas and equalize the distribution of flow speed, the upstream SCR catalyst unit (2) which stores upstream SCR catalyst, the downstream SCR catalyst unit (3) which stores downstream SCR catalyst and ammonia oxidation catalyst, the outlet unit (9) which discharges the exhaust gas and as well as prevents rainwater from entering through outlet into downstream SCR catalyst unit (3).

•

Ammonia oxidation catalyst (17) oxidizes ammonia to water and nitrogen to prevent ammonia which is supplied to SCR assembly from being released out because SCR catalysts (15) and (16) cannot completely consume it.

•

Each 1 piece of SCR temperature sensor (5), SCR outlet temperature sensor (10), ammonia sensor (4), and SCR outlet NOx sensor (11) are installed. These sensors are usable for various troubleshooting, such as they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly functions or not.

•

Rectifying plate (14) equalizes the distribution of exhaust gas flow speed.

•

SCR catalysts (15) and (16) use the ceramic honeycomb.

•

The catalyzer holding mat (18) is made of a specific fiber and protects the ceramic catalyst against vibrations by the engine and the machine body. It also restrains the temperature of outer periphery of SCR assembly from becoming high caused by a heat transfer of the ceramics during operation.

•

Water dam (19) is located at the upstream side of the outlet and prevents rainwater from entering into downstream SCR catalyst unit (3).

•

Water baffle (20) is located at the downstream side of the outlet and prevents rainwater at outlet from splashing over the detection part of NOx sensor.

WA500-8E0

10-35

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COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

AdBlue/DEF TANK STRUCTURE OF AdBlue/DEF TANK

A: Coolant inlet

D: To AdBlue/DEF pump

B: Coolant outlet

E: To breather

C: From AdBlue/DEF pump 1: Sight gauge 10-36

2: AdBlue/DEF filler port WA500-8E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM

3: AdBlue/DEF tank sensor

6: AdBlue/DEF tank filter

4: AdBlue/DEF tank

7: Drain plug

5: Center flange assembly

AdBlue/DEF TANK SENSOR STRUCTURE OF AdBlue/DEF TANK SENSOR REMARK The shape is subject to machine models.

1: Connector

3: Temperature sensing part

2: Concentration Sensing part

4: Level sensing part

FUNCTION OF AdBlue/DEF TANK SENSOR •

This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and AdBlue/DEF temperature through CAN communication.

•

AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.

•

When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.

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COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

AdBlue/DEF PUMP STRUCTURE OF AdBlue/DEF PUMP A: Suction from AdBlue/DEF tank B: Return to AdBlue/DEF tank C: Pressurized sending to AdBlue/DEF injector 1: AdBlue/DEF pump 2: AdBlue/DEF inlet connector 3: AdBlue/DEF backflow connector 4: AdBlue/DEF outlet connector 5: Electric connector 6: AdBlue/DEF filter cap 7: AdBlue/DEF filter (built-in)

•

The followings are built-in: The filter to collect the dust in AdBlue/DEF, the valve to switch the flow direction when purging, and the heater to thaw AdBlue/DEF when it is frozen.

•

It purges AdBlue/DEF from AdBlue/DEF tank, pressurizes it to 900 kPa {9.18 kgf/cm2} , and sends it to AdBlue/DEF injector.

•

To prevent wrong connection of connectors, the backflow connectors are white and can be distinguished from others. The sizes of inlet connector and outlet connector are different and they cannot be connected each other.

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WA500-8E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF INJECTOR STRUCTURE OF AdBlue/DEF INJECTOR A: Pressurized sending from AdBlue/DEF pump B: Coolant inlet C: Coolant outlet 1: AdBlue/DEF injector 2: AdBlue/DEF inlet connector 3: Coolant inlet connector 4: Coolant outlet connector 5: Electric connector

FUNCTION OF AdBlue/DEF INJECTOR •

It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.

•

The injection amount is controlled by the valve opening or closing time while the pressure is constant.

•

It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.

OPERATION OF AdBlue/DEF INJECTOR Principle of injection of the injector is described. Following figure shows the state of injection. 1. Engine controller sends the electrical signal to control AdBlue/DEF injector. 2.

Solenoid (4) moves seal ball (2), and seal ball (2) leaves from injection port (1) to make opening state. Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.

When the electrical signal is not sent, seal ball (2) closes injection port (1) with spring force (3), so AdBlue/DEF is not injected.

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COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

AdBlue/DEF HOSE STRUCTURE OF AdBlue/DEF HOSE

1: Connector

5: Insulation tape

2: Housing

6: Heating wire

3: Coupling

7: Nylon tube

4: Corrugated tube •

It is used as AdBlue/DEF piping between AdBlue/DEF tank and AdBlue/DEF pump or between AdBlue/DEF pump and AdBlue/DEF injector.

•

The shape of the engaging portion between AdBlue/DEF tank and AdBlue/DEF pump or AdBlue/DEF injector pin is based on 3/8 inches or 5/16 inches of SAE J2044. It can be disconnected or connected with one touch.

•

There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.

•

There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one according to the model and the part to use.

FUNCTION OF AdBlue/DEF HOSE •

In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube while machine is stopped.

•

It also keeps temperature to prevent AdBlue/DEF from freezing again while machine is operated.

10-40

WA500-8E0

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