PDF DOWNLOAD - KOMATSU PC2000-11 E0 HYDRAULIC EXCAVATOR SERVICE REPAIR WORKSHOP MANUAL SEN06889-06
HYDRAULIC EXCAVATOR
PC2000 -11E0
SERIAL NUMBERS 30015 and up
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00 Index and Foreword
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow ................................................................................................................40-1315
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow
E-9
E-13
E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation
E-34 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate........................................................................................................................................40-1349 E-35 Horn Does Not Sound
Horn Does Not Stop
E-37 Alarm Does Not Sound During Travel
E-52
H-20
H-21
H-22 Travel Deviation is Large at Start of Travel Only When Travel Lever is Fully Moved...........40-1433
H-23
H-25
H-26
H-31
H-32
H-33
H-34
H-35
H-36
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H-37 Shock is Large When Upper Structure Stops Swing Operation (Right and Left).................40-1448
H-38 Shock is Large When Upper Structure Stops Swing Operation (in Only Right of Left Direction) 40-1449
H-39 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation (in Right and Left Directions)...............................................................................................................................40-1450
H-40 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation in Only One Direction 40-1451
H-41 Swing Drift on a Slope is Large
H-42 Fan Rotation is Abnormal (Such as Excessive Noise or Vibration of Fan, or Overheating).40-1453
H-43 Bottom Dump Speed is Low or Power is Low (Loading Shovel Specifications) 40-1454
H-44 Bottom Dump Cylinder Dose Not Move (Loading Shovel Specifications)
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position
S-2 Engine Cranks but No Exhaust Smoke Comes Out
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)....40-1459
S-4
Electrical
Abbreviation List
•This list of abbreviations includes the abbreviations for functions, devices, and parts which are used in the shop manual.
•Commonly used abbreviations are not included.
•Special abbreviations which are not shown frequently are included in the text as additional information. List of Abbreviations Used in the Text
AbbreviationActual word spelled out Explanation
APIAmerican Petroleum InstituteAPI is the abbreviation for American Petroleum Institute.
BMSBattery Management SystemBMS is a general term for system that controls lithium-ion battery.
BOCBolt-On Cutting edge
BTMS Battery Thermal Management System
CANController Area Network
CDR valve Crankcase Depression Regulator valve
CLSS Closed-center Load Sensing System
CRICommon Rail Injection
DEFDiesel Exhaust Fluid
ECMElectronic Control Module
ECUElectronic Control Unit
EGRExhaust Gas Recirculation
EPC Electromagnetic Proportional Control
EPCElectrical Pressure Control
FOPS Falling Object Protective Structure
GNSS Global Navigation Satellite System
BOC is a cutting edge that is attached with bolts to the bucket.
BTMS is the abbreviation for Battery Thermal Management System.
CAN is one of networks that communicate between the machine monitor and controllers.
CDR valve is a valve that is attached to the KCCV ventilator.
CLSS is a hydraulic system that provides total control over the pumps, valves, and actuators. When actuators are in neutral, pump circuits are closed.
CRI is a function that is composed of the supply pump, common rail, and injector, and that controls the fuel injection rate and injection timing.
DEF is a urea solution that is used for the SCR system.
ECM is an electronic device that controls actuators adequately with signals from sensors.
ECU is an electronic device that controls actuators adequately with signals from sensors.
EGR is a function that recirculates part of exhaust gas to the intake side to control NOx emissions.
EPC is a function that controls the pressure of the hydraulic circuit in proportion to the electric current.
EPC is a function that controls the pressure of the hydraulic circuit in proportion to the electric current.
FOPS is a structure that protects operators from falling objects.
GNSS is a general term for satellite positioning systems.
GPSGlobal Positioning SystemGPS is one of satellite positioning systems.
HVJBHigh Voltage Junction BoxHVJB is the abbreviation for High Voltage Junction Box.
IMAInlet Metering Actuator
IMUInertial Measurement Unit
IMVInlet Metering Valve
IMA is a device that controls fuel intake volume at the inlet of the supply pump.
IMU is a device that senses the angles (or angular velocity) and acceleration of the three axes.
IMV is a device that controls fuel intake volume at the inlet of the supply pump.
Abbreviation List
AbbreviationActual word spelled out
KCCV KOMATSU Closed Crankcase Ventilation
and Foreword
Explanation
KCCV is a function that isolates oil from blowby gas in the engine and returns the blowby gas to the intake side.
KCSFKOMATSU Catalyzed Soot FilterKCSF is a filter that catches soot in exhaust gas.
KDOC KOMATSU Diesel Oxidation Catalyst KDOC is a device that purifies exhaust gas.
KDPF KOMATSU Diesel Particulate Filter
KOWAKomatsu Oil and Wear Analysis
LINLocal Interconnect Network
LSLoad Sensing
MAF sensorMass Air Flow sensor
MSD Manual Service Disconnection Switch
NCNormally Closed
NONormally Open
OLSS Open-center Load Sensing System
KDPF is a device that is composed of the KCSF and KDOC, and catches soot (Particulate Matter, PM) in exhaust gas.
KOWA is a preventive maintenance service that collects and analyzes oil in the machine at the specified interval so that wear of the machine and other problems can be found at short time.
LIN is one of networks that communicate between controllers and sensors or actuators.
LS is a function that senses the load pressure of actuators and controls hydraulic pumps.
MAF sensor is a device that measures the engine intake air flow.
MSD is the abbreviation for Manual Service Disconnection Switch.
NC is an electrical circuit where contact pair is closed while the device is not in operation.
NO is an electrical circuit where contact pair is open while the device is not in operation.
OLSS is a hydraulic system that provides total control over the pumps, valves, and actuators. When actuators are in neutral, pump circuits are open.
OPGOperator Protective GuardsOPG is a structure that protects operators from falling objects.
PCPressure Compensation
PCVPressure Control Valve
PPCProportional Pressure Control
PTOPower Take Off
ROPSRoll-Over Protective Structure
SCRSelective Catalytic Reduction
SOCState Of Charge
SOHState Of Health
TOPSTip-Over Protectuive Structure
PC is a function that controls discharged volume of the hydraulic pump by use of the discharged pressure.
PCV is a device that controls fuel discharged volume at the outlet of the supply pump.
PPC is a function that controls the pressure of the hydraulic circuit in proportion to the degree of the lever operation.
PTO is a mechanism that takes out the engine power.
ROPS is a structure that protects operators from falling objects or in the event of a machine roll-over
SCR is a device that purifies nitrogen oxides (NOx) in exhaust gas from the engine.
SOC is the abbreviation for State Of Charge that is the battery charge quantity shown on the LCD panel of the battery charger
SOH is the deterioration state index of the battery.
TOPS is a protection structure that protects operators in the event of a machine tip-over
VGTVariable Geometry TurbochargerVGT is a variable type turbocharger.
List of Abbreviations Used in the Circuit Diagrams
Abbreviation Actual word spelled out
Conditioner
Abbreviation
A/DAnalogue-to-Digital
A/MAir Mix damper
ACCAccessory
ADDAdditional
AUXAuxiliary
BRBattery Relay
CWClockwise
CCWCounter Clockwise
ECUElectronic Control Unit
ECMElectronic Control Module
ENGEngine
EXGNDExternal Ground
F.G.Frame Ground
GNDGround
IMAInlet Metering Actuator
NCNo Connection
S/T
Steering STRG
SIGSignal
SOLSolenoid
STDStandard
OPT Option
OP
PRESSPressure
SPECSpecification
SWSwitch
TEMPTemperature
T/CTorque Converter
T/MTransmission
Actual word spelled out
Foreword, Safety, Basic Information
How to Read the Shop Manual
•Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
•The materials and specifications are subject to change without notice.
•Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
•Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
•The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in accordance with the machine.
•For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
•For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine Monitor”.
•For details of the switches, see the “Operation and Maintenance Manual”.
•All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.
Symbol Item Remark
Danger
Warning
Caution
Weight
Tightening torque
This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.
This symbol shows the weight of parts and components. Refer to this symbol when you handle heavy object for selection of the required equipment such as crane and lifting tools, and for what kind of working posture to take.
This signal indicates the tightening torque for portions which requires special care in assembling work.
Coat This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.
Oil and coolantThis signal indicates a place to supply oil, coolant, etc. and the quantity.
DrainingThis signal indicates a place to drain oil, coolant, etc. and the quantity.
Signal Word
Signal word for notice and remark describes the following.
Symbol Item Remark
NOTICE Notice
Unit
If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur
REMARK RemarkThis signal word contains useful information to know.
International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.
Safety Notice for Operation
•Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purposes.
•The symbol mark is indicated for such matters that require special precautions. The work indicated with this warning mark should be performed according to the instructions with special attention. Should a hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary measures.
Safety Considerations
•Well organized work place
•Correct work clothes
•Observance of work standard
•Enforcement of hand signals
•Prohibition against unlicensed persons operating and handling the machine
•Safety check before starting work
•Wear of dust glasses (for cleaning or grinding work)
•Wear of welding goggles and protectors (for welding work)
•Being in good physical condition, and good preparation
•Always be alert and careful.
General Precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the operation and maintenance manual before operation. Read and understand what is described in this manual before operation.
•Read and understand the meaning of all the safety labels stuck to the machine before performing any greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation and Maintenance Manual.
•Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on the floor. Smoke only in the designated areas. Never smoke while working.
•Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
•Always wear safety shoes and helmet when performing any operation. Do not wear loose clothes, or clothes with buttons missing.
•Always wear the protective eyeglasses when hitting parts with a hammer.
•Always wear the protective eyeglasses when grinding parts with a grinder, etc.
•When performing any operation with multiple workers, always agree on the operating procedure before starting. Be clear in verbal communication, and observe hand signals. Hang “UNDER REPAIR” warning tag in the operator's compartment Before starting work.
•Only the approved personnel can do the work in a closed environment or in a prohibited area.
•Work and operation which require license or qualification should be performed by qualified workers.
•Welding repairs should be performed by trained and experienced welders. When performing welding work, always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
•Warm up before starting the work with exercise which increases alertness and the range of motion in order to prevent injury.
•Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe area.
•When you work in high places, use a platform.
•Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
•Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
•Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
•When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).
•If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the machine has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.
Precautions for Preparatory Work
•Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving before adding oil or making any repairs.
•Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang “UNDER REPAIR” warning tag on them.
•When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
•Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.
Precautions During Work
•For the machine with the battery disconnect switch, check before starting the work that the system operating lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type. For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.
•For the machine with the quick release battery terminal (-), check before starting the work that the system operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-).
•Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.
•When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.
•The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
•Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.
•When raising a heavy component (heavier than 20kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
•When removing a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.
•When removing components, do not break or damage the electrical wiring. Damaged wiring may cause a fire.
•When removing piping, do not spill the fuel or oil. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
•Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in particular.
•Install the disassembled parts again to the original position. Replace the damaged parts or the parts that cannot be used again with new ones. Before you connect the hoses or wiring harnesses, make sure that they do not touch and give damage to other parts when you operate the machine.
REMARK
When you replace the removed or disassembled parts with new ones, refer the parts book to find out the part number.
•When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed.
•When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.
•Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
•Check that the measuring tools are correctly installed when measuring hydraulic pressure.
•Take care when removing or installing the tracks of track-type machines. Since the track shoe may separate suddenly when you remove it, never let anyone stand at either end of the track shoe.
•If the engine is operated for a long time in a closed place with poor ventilation, it may cause gas poisoning. Open the windows and doors to ventilate the place well.
Precautions for Slinging Work and When You Make Signals
•Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely.
k Do not do the work while the lifted load is in the range where it possibly falls. It is not allowed to go in the range where the lifted load possibly falls.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly.
•When you lift or fix the machine, see “Operation and Maintenance Manual” or “Field Assembly Instruction”.
k Do not lift or fix the machine by the positions where the name plate is not attached.
•When you lift the machine for the disassembly and assembly, follow the instructions on the Disassembly and Assembly.
•Check the slings before starting sling work.
•Keep putting on gloves during sling work. (Put on leather gloves, if available.)
•Measure the weight of the load by the eye and check its center of gravity.
•Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.
•Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident.
•Hanging angle must be 60 ° or smaller as a rule.
•When slinging a heavy load (20kg or heavier), the hanging angle of the rope must be narrower than that of the hook.
REMARK
When slinging a load with 2 or more ropes, the force subjected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kgf} vertically, at various hanging angles. When the 2 ropes sling a load vertically, they can sling up to 2000 kg of total weight. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 2000 kg load at a hanging angle of 150 °, each rope is subjected to a force as large as 39.2 kN {4000kgf} .
•When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.
•Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
•Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch system.
k Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.
•Never use a wire rope which has breaks in strands (A), reduced diameter (B), or kinks (C). There is a danger that the rope may break during the towing operation.
Precautions for slinging up
•Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.
•After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
•If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
•Do not lift up the load at an angle.
Precautions for slinging down
•When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
•Check that the load is stable, and then remove the sling.
•Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
Precautions When You Use Mobile Crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely
Precautions When You Use Overhead Traveling Crane
k When raising a heavy component (heavier than 20kg), use a hoist or crane.
Weight of component whose weight is heavier than 20kg is shown with symbol in “Disassembly and Assembly”.
REMARK
The symbol shows the weight of the parts with weight of 20kg or more for convenience of workers. But the weight can possibly be shown even if it is less than 20kg in accordance with the work environment. Do the work safely in response to the work environment and the physical build, preexisting condition, and physical condition of the operator. And obey the laws and regulations of each country.
•Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing caution lamp, and check the following safety items.
•Be sure not to touch the lifting tool and lifted load directly. Use push-pull sticks or tagline ropes.
•Observe the signals for sling work.
•Operate the hoist at a safe place.
•Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button.
•Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
•Do not raise or lower a load while the crane is moving longitudinally or laterally.
•Do not drag a sling.
•When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
•Consider the travel route in advance and lift up a load to a safe height.
•Place the control switch in a position where it is not an obstacle to work and passage.
•After operating the hoist, do not swing the control switch.
•Remember the position of the main switch so that you can turn off the power immediately in an emergency.
•If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition.
•If you find an obstacle around the hoist, stop the operation.
•After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
Select Wire Ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.
Wire Rope (JIS G3525 6x37-A Type) (Standard Z Twist Wire Ropes Without Galvanizing)
Nominal diameter of rope (mm) Allowable load (kN {t} )
Precautions When You Disconnect Air Conditioner Piping
NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.
REMARK
•Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a).
•Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are collecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite.
•When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut.
Precautions for Air Conditioner Piping
•When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
•Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
•Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
•When removing the O-rings, use a soft tool so that the piping is not damaged.
•Check that the O-ring is not damaged or deteriorated.
•Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
REMARK
• The figure shows an example of fitting of O-ring.
•An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see Others, “Precautions for Disconnection and Connection of Air Conditioner Piping”.
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Precautions to Prevent Fire
Fire Caused by Fuel, Oil, Coolant or Window Washer Fluid
Do not bring any open flame close to fuel, oil, coolant or window washer fluid. Always observe the following.
•Do not smoke or use any open flame near fuel or other flammable substances.
•Shut down the engine before adding fuel.
•Do not leave the machine when adding fuel or oil.
•Tighten all the fuel and oil caps securely.
•Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.
•After adding fuel or oil, wipe up any spilled fuel or oil.
•Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace.
•When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire.
•Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
•Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
•When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.
Fire Caused by Accumulated or Attached Flammable Objects
•Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
•To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.
Fire Caused by Electrical System
Short circuits in the electrical system can cause fire. Always observe the following.
•Keep all the electric wiring connections clean and securely tightened.
•Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.
Fire from Pipings
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.
Fire Caused by High Temperature Exhaust Gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (regeneration), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not bring any flammable materials close to exhaust pipe outlet.
•When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion Caused by Light
•When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.
•When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual.
Procedures If Fire Occurs
• Turn the starting switch to OFF position to stop the engine.
•Use the handrails and steps to get off the machine.
•Do not jump off the machine. You may fall and suffer serious injury.
When wearing cotton work gloves, wear rubber gloves under them. Procedures If Fire Occurs
•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).
Precautions When You Discard 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, and batteries.
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.
Precautions When You Handle Hydraulic Equipment
Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.
Select an Applicable Workplace
•In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the machine.
Disassembly and Maintenance Work in the Field
k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit and it may result in serious personal injury or death when removing and disassembling of the hydraulic equipment is performed.
k Release the remaining pressure from the hydraulic circuit always before performing the work.
•In the field, there is a risk of dust entering the component during disassembling or maintenance work, and performance check is hardly performed. Replacement of the assembly is recommended.
•Perform disassembling and maintenance work in the dust proof area.
Seal Openings (Prevention of Flowing Out of Oil)
Plug the openings of the piping and the device which have been removed to prevent foreign material from entering and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs.
Preventing Intrusion of Foreign Materials While You Refill
•During refilling with the hydraulic oil, do not let water enter the electrical components.
•Clean the oil filler port and its around, refilling pump, oil jug, or etc.
•Refilling by using an oil cleaning device is better method since it can filtrate the contaminants accumulated in the oil during storage.
Replace Hydraulic Oil While Its Temperature is High
•The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high.
•Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludges, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the circuit.
Do Not Use the Hydraulic Oil and Lubricating Oil Again
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine. If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing Operation
•Flushing is required to completely dislodge the contaminants and sludges, and existing oil containing those inside the hydraulic circuit after disassembling and assembling, and when replacing the oil with the new one.
•Normally, flushing is performed twice. Primary flushing is performed by using the flushing oil (1) and the secondary flushing is performed by using the specified hydraulic oil.
Cleaning Operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine. 00 Index and Foreword
REMARK
The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment cannot remove. So, it is very effective device. Precautions When You Handle Hydraulic Equipment
Index and Foreword
Precautions When You Disconnect and Connect Pipings
When performing “testing and adjusting” of the machine, “removal and installation” and “disassembly and assembly” of the components, observe the following precautions.
Precautions for Removal and Disassembly Work
•If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly.
•After disconnecting the hoses or tubes, plug them to prevent dust from entering.
•When draining oil, prepare a container with sufficient capacity.
•Check the matchmarks which indicate the installing position, and put matchmarks on the places where they seem necessary before removal of the components to prevent any mistake when assembling.
•To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
•Attach the tags to wires and hoses so that installation is done to the correct installing positions.
•Check the thickness and number of shims when storing shims.
•When hoisting the components, prepare the slings with sufficient strength.
•When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
•Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal.
•After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine.
Introduction of Parts for the Disassembly of the Face Seal Type Hoses and Tubes
Introduction of Parts for the Disconnection of the Taper Seal Type Hoses and Tubes
Introduction of Parts for the Disconnection of the Split Flange Type Hoses and Tubes
Introduction of Parts for the Removal of O-Ring Boss Type Joint
Introduction of Parts for the Removal of Taper Pipe Thread Type Joint
Precautions for Installation and Assembly Work
• 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.
•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.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed, be sure to bleed air from the hydraulic circuit before operating it for the first time according to the following procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximately 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke end for 3 or 4times.
NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air from the hydraulic circuit according to the same procedure.
Precautions at the End Time of Work
Refilling of coolant or water or oil, greasing, and adding
•Supply the specified amount of grease to the work equipment parts.
•When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
•When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.
•If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system. See “Testing and Adjusting”.
Testing installed condition of cylinder heads and manifolds
•Check the cylinder head and intake and exhaust manifold mountings for looseness.
•If there is any looseness, retighten the part.
REMARK
For the tightening torques, see “50 Disassembly and Assembly”.
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.)
•KDPF
•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.
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
•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”.
Precautions When You Handle Electrical Equipment
To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical equipment”.
Handle Wiring Harnesses and Connectors
•Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires.
•Compared with other electrical components fitted in boxes or cases, wiring harnesses are likely to be directly affected by rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling and maintenance of the wiring harnesses.
Main Causes of Failure in Wiring Harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.
Defective crimping or soldering of connectors
The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage.
Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the soldering, or break the wiring harness.
Water entering the connector by high-pressure jetting
The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained. 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.
Precautions When You Handle Fuel System Equipment
The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an Applicable Workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Seal the Opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.
How to Clean Parts When Dirt is Stuck
If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions When You Replace Fuel Filter Cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter other than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
Precautions When You Handle Intake System Equipment 00 Index and Foreword
Precautions When You Handle Intake System Equipment
The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an Applicable Workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Seal the Opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.
Practical Use of KOMTRAX
Various information which KOMTRAX system transmits by using the radio communication is useful for KOMTRAX operator to provide various services for the customers.
When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.
Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.
REMARK
(KOMTRAX may not be installed to the machine in some countries or areas.)
Advantage to Use KOMTRAX
•The location where the machine is working at can be checked on the map in a personal computer.
•Operation information such as service meter, operating hours, fuel consumption, and occurred caution as well as failure code can be checked.
•The operator can check the hours used and replacement interval of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
•Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be checked, and it is used to presume the machine operating condition.
•Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is utilized as an advice tool for the user and operator.
•KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the soundness of machine, in addition to KOMTRAX function described above. These data can be used on personal computer screens.
How to Make a Full Use of KOMTRAX
Making use of KOMTRAX enables the following activities.
•Quick response to a request for immediate repair
1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair request from a user.
2. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
3. To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
• Proactive maintenance
1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure code indicated by a red or yellow flag.
2. To check the condition of the machine with the customer and to make a plan to visit.
3. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
• Practice of periodic maintenance and periodic inspection service
1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits for the consumable parts indicated by red flags are over.
2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer
3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to Operate KOMTRAX
For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.
Disconnect and Connect Push-Pull Type Coupler
Disconnect and Connect Push-Pull Type Coupler
REMARK
00 Index and Foreword
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
•Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.
How to Disconnect and Connect Type 1 Push-Pull Type Coupler
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating adapter (3).
REMARK
• Push it in approximately 3.5 mm.
•Do not hold rubber cap portion (4).
2. While having adapter (3) inserted into hose side joint (2), insert rubber cap (4) to adapter (3) side until it clicks.
3. Hold hose adapter (1) or hose (5), and pull it out.
REMARK
Provide an oil container to receive a quantity of hydraulic oil which may flow out.
Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).
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00 Index and Foreword Disconnect and Connect Push-Pull Type Coupler
2. After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a problem.
How to Disconnect and Connect Type 2 Push-Pull Type Coupler
Disconnection
1. Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
2. While keeping the condition of step 1, turn lever (3) to the right (clockwise).
3. While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil which may flow out.
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.
How to Disconnect and Connect Type 3 Push-Pull Type Coupler
Disconnection
1. Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
2. While keeping the condition of step 1, push cover (3) straight until it contacts contact surface (a) of the hexagonal portion on the male side.
3. While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil which may flow out.
00 Index and Foreword
Connection
Disconnect and Connect Push-Pull Type Coupler
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.
Precautions for Disconnection and Connection of Connectors
Disconnect Connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the connecting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing the stopper (1) with your thumb.
2. When removing a connector from a clip
•Both of the connector and clip have stoppers (2), which are engaged with each other when the connector is connected.
•When removing a connector from a clip, pull the connector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the right or left, it may break the housing.
3. Action to be taken after removing connectors
After removing the connector, cover it with plastic bags to prevent entry of dust, dirt, oil, or water in the contact portion.
NOTICE
Be sure to cover the connector with plastic bags when leaving the machine disassembled for a long time, otherwise defective contact may occur.
Connect Connectors
1. Check the connector visually.
• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
•Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
•If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is any water intrusion into the connector, warm the inside of the connector and harness with a dryer. Do not overheat the connector, otherwise short circuit may occur.
•If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the wiring harness.
•If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the wiring harness cannot be fixed, remove the clamp to adjust them.
•If the connector clamp is removed, be sure to return it to its original position. Check that there is no looseness.
Dry Wiring Harness
REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.
1. Disconnect the connector and wipe off the water with a dry cloth.
NOTICE
If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow.
2. Dry the inside of the connector with a dryer. If water enters inside the connector, use a dryer to dry the connector.
NOTICE
Hot air from a dryer can be used, but limit the time of using a dryer to prevent the connector or related parts from becoming too hot, as this will cause deformation or damage to the connector.
3. Perform a continuity test on the connector.
After drying, leave the wiring harness disconnected, connect T-adapter(1), and perform a continuity test to check for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact restorer, and reassemble them.
Handle Controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
NOTICE
•Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine.
•Do not leave things on the controller.
•Cover the connector portion of the controller with a tape and a plastic bag. Do not touch the connecting portion of connector.
•Do not leave the controller in a place where it is exposed to rain.
•Do not place the controller on oil, water, soil or any places where the temperature is likely to be high even for a short period of time (Place it on a suitable dry stand).
Precautions for Troubleshooting Electrical Circuits
•Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
•Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
•Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated failure beside the actual failed part may be displayed.
•When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.
How to Disconnect and Connect Deutsch Connector
Disconnect DEUTSCH Connector
While pressing locks (a) and (b) from each side respectively, pull out female connector (2).
Connect DEUTSCH Connector
1. Push in female connector (2) horizontally, and insert it straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward you, push up portion A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.
How to Connect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2)
Insert it straight until it clicks.
How to Disconnect Slide Lock Type Connector (FRAMATOME-24)
1. Slide down lock (red) (L1).
2. While pressing lock (L2), pull out connector (1).
REMARK
Lock (L2) is located behind connector (1) in the figure.
How to Connect Slide Lock Type Connector (FRAMATOME-24)
Insert it straight until it clicks. Foreword, Safety,
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect Connector with Lock to Pull
Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
How to Connect Connector with Lock to Pull
Insert the connector securely until it “clicks”.
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect Connector with Lock to Push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow •114 series •107 series
REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
How to Connect Connector with Lock to Push (BOSCH-3)
Insert it straight until it clicks.
How to Disconnect Connector with Lock to Push (AMP-3)
While pressing lock (E), pull out connector (5) in the direction of the arrow.
How to Connect Connector with Lock to Push (AMP-3)
Insert it straight until it clicks.
How to Disconnect Connector with Lock to Push (SUMITOMO-3)
While pressing lock (E), pull out connector (5) in the direction of the arrow.
REMARK
Pull up the connector straight.
How to Connect Connector with Lock to Push (SUMITOMO-3)
Insert it straight until it clicks.
How to Disconnect Connector with Lock to Push (SUMITOMO-4)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
How to Connect Connector with Lock to Push (SUMITOMO-4)
Insert it straight until it clicks.
How to Disconnect and Connect Connector with Housing to Rotate
How to Disconnect Connector with Housing to Rotate
Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.
Connect Connector with Housing to Rotate
1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.
How to Disconnect and Connect Molex Connector
Disconnect Molex Connector
Slide the lever (a) to the direction of the arrow, and pull out the female connector (1).
Connect Molex Connector
1. Make sure that the lever (a) is protruded, and engage the pin (b) of the lever of the female connector (1) to the guide (c) of the male connector (2). Then, insert the connector.
2. Push the lever (a) in the direction of the arrow until a click sound occurs.
How to Read the Codes for Electric Cable
In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electrical wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85
Indicates type of wire by symbol. Type, symbol, and material of wire are shown in (Table 1).
AEX
0.85
(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).
L Indicates color of wire by color code. Color codes are shown in (Table 3).
Type, Symbol, and Material
AV and AVS are different in only thickness and outside diameter of the coating. The conductors of CAVS and AVSS are round compressed conductors. And the outside diameter of the conductor and the thickness of the coating are different from those of AV and AVS. As for AEX, the thickness and outside diameter of the coating are similar to those of AV, but the coating material is different from that of AV and AVS.
(Table 1)
Type Symbol
Low-voltage wire for automobile AV
Thin-cover low-voltage wire for automobile (Type 1) AVS
Thin-cover low-voltage wire for automobile (Type 2) CAVS
Conductor material Insulator material
Temperature range (°C) in use
Example of use
For large current wiring (nominal No. 5 and above)
General wiring (nominal No. 3 and lower)
-30 to +60
Soft polyvinyl chloride
Annealed copper for electric appliance
Ultra-thin-cover low-voltage power supply for automobiles AVSS -40 to +80
Heat-resistant low-voltage wire for automobile AEX
Heat-resistant ultra-thin lowvoltage electrical wire for automobiles AESS X
Heat-resistant crosslinked polyethylene -50 to +110
For mid- to small-size excavators (nominal No. 1.25 and lower)
For industrial vehicles (for forklift trucks)
Nominal No.0.5f to 2f
General wiring for extremely cold weather specification
Wiring at high-temperature place
Extremely cold area and heat resistance specifications
Thin-cover wiring
(Table 2)
Nominal No.0.5f(0.5)0.75f(0.85)1.25f(1.25)2f23f35
Conductor
Nominal No. 815203040506085100
Conductor Number
Nominal No.0.5f 0.5 0.75f0.851.25f1.25
Conductor
of strands - 7 - 11 - 16 Diameter of strandround compression -round compression round compression Cross-sectional area (mm2) - 0.56 - 0.88 -1.29 d (approx.)- 0.9 -
REMARK
“f” of nominal No. denotes “flexible”. Color Code Table
(Table 3)
BBlack
BrBrown
BrBBrown and Black
BrRBrown and Red
BrWBrown and White
LgWLight green and White
LgYLight green and Yellow
LRBlue and Red
LWBlue and White
LYBlue and Yellow
BrYBrown and Yellow OOrange
ChCharcoal PPink
DgDark green RRed
GGreen
GBGreen and Black
GLGreen and Blue
GrGray
GRGreen and Red
RBRed and Black
RGRed and Green
RLRed and Blue
RWRed and White
RYRed and Yellow
Color Code
Color of wire
GWGreen and White
Color Code
SbSky Blue
GYGreen and Yellow YYellow
LBlue
Color of wire
YBYellow and Black
LBBlue and Black YGYellow and Green
LgLight green
LgBLight green and Black
LgRLight green and Red
REMARK
YLYellow and Blue
YRYellow and Red
YWYellow and White
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example) GW indicates that the background is “Green” and marking is “White”.
Circuit Type and Color Code
Type of wire
Type of circuit
AVS, AV, CAVS, AVSS
AEX,AESSX
ChargeRWG----R-
GroundB-----B-
Start R-----R-
LightRWRBRYRGRL-O-
InstrumentYYRYBYGYL (*1)YW (*1)YGr
SignalGGWGRGYGBGL (*1)GBr
BrBrW (*2)BrR (*2)BrY (*2)BrB (*2)---
LgLgR (*2)LgY (*1)LgB (*2)LgW (*1)--O (*1)-------
Others LLWLRLYLB-L-
Dg (*1)------Ch (*1)-------
*1: This item is not set to AVSS.
*2: This item is not set to 0.75f to 2f of AVSS.
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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:
•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
Standard Clearance and Standard Value
•The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance.
•When some parts are repaired, the clearance is generally adjusted to the standard clearance.
•The values indicating performance and function of new products or equivalent are called “standard value”, which is indicated by a range or a target value.
•When some parts are repaired, the value of performance/ function is set to the standard value.
Standard Interference
•When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called “interference”.
•Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is “standard interference”.
•After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.
Allowable Limit, Allowable Value, or Allowable Dimension
•The dimension of parts changes due to the wear or deformation while they are used. When the dimension changes exceeding certain value, parts cannot be used any longer. This value is called “repair limit”.
•If a part is worn to the repair limit, it must be replaced or repaired.
•The performance and function of products lower while they are used. A value with which the product can be used without causing a problem is called “allowable value” or “allowable dimension”.
•A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgment must be made in consideration of the operating condition and customer's requirement.
Allowable Clearance
•Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called “allowable clearance”.
•If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable Interference
•The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called “allowable interference”.
•The allowable interference shows the repair limit of the part of smaller tolerance.
Explanation of Terms for Maintenance Standard 00 Index and Foreword
•The parts whose interferences are out of the allowable interference must be replaced or repaired.
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.
*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.
Thread diameter (mm)
Width across flats (mm) Tightening torque (Nm {kgfm} )
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7} 12 17 74.5 to 90.2 {7.6 to 9.2}
REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
Type of bolt
Nominal sizethreads per inch
1/4-20UNC 9.8 to 14.7 {1 to 1.5}12.7 {1.3}2.9 to 3.9 {0.3 to 0.4}3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5}29.4 {3}6.9 to 8.8 {0.7 to 0.9}7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6}52.0 {5.3}9.8 to 14.7 {1 to 1.5}11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10}86.3 {8.8}19.6 to 24.5 {2 to 2.5}21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15}127 {13}29.4 to 39.2 {3 to 4}34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22}186 {19}44.1 to 58.8 {4.5 to 6}51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30}265 {27}63.7 to 83.4 {6.5 to 8.5}68.6 {7}
3/4-10UNC 392 to 530 {40 to 54}461 {47}108 to 147 {11 to 15}127 {13}
7/8-9UNC 637 to 853 {65 to 87}745 {76}177 to 235 {18 to 24}206 {21}
Type of bolt
Nominal sizethreads per inch
torque (Nm {kgfm} )
torque (Nm {kgfm} )
1-8UNC 883 to 1196 {90 to 122}1040 {106}245 to 333 {25 to 34}284 {29}
11/8-7UNC 1187 to 1608 {121 to 164}1393 {142}333 to 451 {34 to 46}392 {40}
11/4-7UNC 1598 to 2157 {163 to 220}1873 {191}451 to 608 {46 to 62}530 {54}
11/2-6UNC 2354 to 3177 {240 to 324}2765 {282}657 to 892 {67 to 91}775 {79}
REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
Type of bolt
1/4-28UNF 14.7 to 19.6 {1.5 to 2}17.7 {1.8}3.9 to 4.9 {0.4 to 0.5}4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4}34.3 {3.5}7.8 to 9.8 {0.8 to 1}8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7}61.8 {6.3}14.7 to 19.6 {1.5 to 2}16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11}96.1 {9.8}24.5 to 29.4 {2.5 to 3}26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17}147 {15}34.3 to 49.0 {3.5 to 5}41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25}216 {22}49.0 to 68.6 {5 to 7}58.8 {6}
5/8-18UNF 255 to 343 {26 to 35}294 {30}73.5 to 98.1 {7.5 to 10}83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61}520 {53}127 to 167 {13 to 17}147 {15}
7/8-14UNF 716 to 961 {73 to 98}843 {86}196 to 265 {20 to 27}226 {23}
1-14UNF1020 to 1373 {104 to 140}1196 {122}284 to 382 {29 to 39}333 {34}
11/8-12UNF 1353 to 1844 {138 to 188}1598 {163}382 to 520 {39 to 53}451 {46}
11/4-12UNF 1804 to 2432 {184 to 248}2118 {216}510 to 686 {52 to 70}598 {61}
11/2-12UNF 2707 to 3658 {276 to 373}3177 {324}765 to 1030 {78 to 105}892 {91}
Standard Tightening Torque Table 00 Index and Foreword
Table of Tightening Torque for O-Ring Boss Piping Joints
REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.
depending on type of connector
Table of Tightening Torque for O-Ring Boss Plugs
REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.
Foreword
Table of Tightening Torque for Hose (Taper Seal Type and Face Seal Type)
REMARK
•Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table unless otherwise specified.
•The table is applied to the threaded portion coated with engine oil (wet threaded portion).
(10)41 177 to 245 {18.0 to 25.0}216 {22.0}33
240 to 300 {24.5 to 30.5}270 {27.5} - 17/16-12UN
(12)46197 to 294 {20.0 to 30.0}245 {25.0}36
(14)55246 to 343 {25.0 to 35.0}294 {30.0}42
Table of Tightening Torque for Face Seal Joints
REMARK
•The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated low pressure piping which is used for engine.
•The table is applied to the threaded portion coated with engine oil (wet threaded portion).
•Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.
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.
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. Standard Tightening Torque Table
Tightening Torque Table for Tapered Screws on 102, 107, and 114 Series Engines (National Taper Pipe Thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size
1/16
{1.53±0.20}
{0.51±0.10} 1/8
{2.04±0.20}
{1.53±0.20} 1/4
3/8
{2.55±0.31}
{3.57±0.41}
{2.04±0.20}
{2.55±0.31}
1/2 55±6 {5.61±0.61} 35±4 {3.57±0.41}
3/4
{7.65±0.82}
{4.59±0.51}
Conversion Table
How to Use the Conversion Table
The conversion table is provided to enable simple conversion of the numerical numbers between the different units. For further details of the method of using the conversion table, see the examples given below
Examples to Use the Conversion Table to Change a Unit from mm
to in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left) to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point one place to the right) to restore the target value. This gives 550 mm = 21.65 in mm to in
•A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures in the center of the following table show the temperatures in both Fahrenheit and Celsius.
•When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
•When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.
C Overall width (with the hydraulically operated stairway) mm 7685
DTrack width mm 810
ECab height mm 7030
FTail swing radius mm 5980
GTrack overall length mm 7445
H Distance between the tumbler centers mm 5780
IMinimum ground clearance mm 825
Travel
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 nearly the same as that when it is installed on a machine.
C Overall width (with the hydraulically operated stairway)
DTrack
ECab
H
794 {1080} / 1800 {1800}
794 {1080} / 1800 {1800}
780{1060} / 1800 {1800}
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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 nearly the same as that when it is installed on a machine.
Working Range Drawings
Working Range Drawings: PC2000-11E0
AMaximum digging reach mm 15780
BMaximum digging depth mm 9245
CMaximum digging height mm 13390
D Maximum vertical wall digging depth mm 2765
EMaximum dumping height mm 8640
F Maximum digging reach at ground level mm 15305
Working Range Drawings: PC2000-11E0 (Loading Shovel Specification)
Working ranges Unit
AMaximum digging height mm 14450
BMaximum dumping height mm 9665
CMaximum digging depth mm 3190
DMinimum reach at ground level mm 7090
EMaximum reach at ground levelmm 11940
FLevel crowding distance mm 4850
GMaximum digging reach mm 13170
H Minimum swing radius of work equipment mm 7500
Specifications
Specification: PC2000-11E0
Performance
Working
Dimensions
Machine model Unit
PC2000-11E0
Minimum swing radius of work equipment mm 7320
Top height at the minimum swing radius of the work equipment mm 12070
Length of track on ground mm 5780
Distance between crawler centers mm 4600
Machine cab height mm 5970
Width of standard shoe mm 810
Engine
Name
Type
Number of cylinders-bore x stroke mm
Piston displacement l {cc}
Performance
Rated horsepower
SAE J1995 (gross)
ISO 14396
ISO 9249/SAE J1349 (net)
kW {HP}/min-1 {rpm}
Komatsu SAA12V140E-7
4-cycle, water-cooled, V-shaped, direct injection, water-cooled type with turbocharger, aftercooler (water-cooled type) + EGR cooler
12 - 140 x 165
30.48 {30480}
794 {1080}/1800 {1800}
kW {HP}/min-1 {rpm} 794 {1080}/1800 {1800}
kW {HP}/min-1 {rpm}
Maximum torque Nm/rpm {kgm/rpm}
780 {1060}/1800 {1800}
4570/1350{466/1350}
Max. speed with no load rpm 1980±50
Min. speed with no load rpm 825±25
Min. fuel consumption ratio g/kWh {g/PSh} 211 {155}
Starting motor 24V, 11 kW x 2
Alternator 24V, 50A x 2
Battery 12V, 170Ah x 4
Radiator type
Undercarriage
Carrier roller
Track roller
Track shoe
Hydraulic system
Hydraulic pump
Motor oil pressure drive type
3 pieces on one side
8 pieces on one side
Assembly type double grouser shoe, 49 pieces on each side
Machine model Unit
Type, quantity
l/min
Discharged volume
Set pressure
Control valve
Type, quantity
Operating method
Hydraulic motor
Travel motor
Swing motor
Boom cylinder
Arm cylinder
Bucket cylinder
Type
PC2000-11E0
Main pump: Variable displacement tandem piston type (2 pieces (HPV375 + 375))
Fan pump: Variable displacement tandem piston type (1 piece (HPV95 + 95))
PTO lubrication pump: Gear type (1 piece (SBL020 (1))
Main pump P1: 629 + 629, P2: 518 + 518
l/min Fan pump: 160 + 160
l/min
MPa {kgf/cm2}
PTO lubrication pump: 35
Main pump: 29.4 {300}/32.9 {335}
MPa {kgf/cm2} Fan pump: 24.5 {250}
5-spool + 5-spool type port surface alignment: 2 piece
Hydraulically operated type
Piston type (equipped with the brake valve and shaft brake): 2 pieces (KMF340)
Piston type (equipped with the safety valve and shaft brake): 2 pieces (KMF230)
piston type
Double-acting piston type
Hydraulic tank
Box-shaped sealed type (equipped with the feed/exhaust valve)
Hydraulic oil filter Pump outlet side, tank return side
Hydraulic oil cooler Air cooled
Specifications:
PC2000-11E0 (Loading Shovel Specification)
Performance Working
Machine model Unit PC2000-11E0
Only for undercarriage (when standard shoe is installed, includes step) mm
Overall width of track mm 5410
Ground clearance of upper structure bottom mm 2095
Minimum ground clearance mm 825
Tail swing radius mm 5980
Minimum swing radius of work equipment mm 7500
Top height at minimum swing radius of work equipment mm 9635
Length of track on ground mm 5780
Distance between crawler centers mm 4600
Machine cab height mm 5970
Width of standard shoe mm 810
Engine
Name
Type
KOMATSU, SAA12V140E-7
4-cycle, water-cooled, V-shaped, direct injection, water-cooled type with turbocharger, aftercooler (water-cooled type) + EGR cooler
Track shoe Assembly type double grouser shoe, 49 pieces on each side
Hydraulic system
Hydraulic pump
Machine model Unit
Type, quantity
Discharged volume
Set pressure
Control valve
Type, quantity
Control method
Hydraulic motor
l/min
PC2000-11E0
Main pump: Variable displacement tandem piston type (2 pieces (HPV375 + 375))
Fan pump: Variable displacement tandem piston type (1 piece (HPV95 + 95))
PTO lubrication pump: Gear type (1 piece (SBL020 (1))
Main pump P1: 629 + 629, P2: 518 + 518
l/min Fan pump: 160 + 160
l/min PTO lubrication pump: 35
MPa{kg/cm2}
Main pump: 29.4 {300}/32.9 {335}
MPa{kg/cm2} Fan pump: 24.5 {250}
5-spool + 5-spool type port surface alignment: 2 piece
Hydraulically operated type
Travel motor Piston type (equipped with the brake valve and shaft brake): 2 pieces (KMF340)
Swing motor Piston type (equipped with the safety valve and shaft brake): 2 pieces (KMF230)
Boom cylinder Type
piston type
piston type
Bucket cylinder
Type
Inside
Diameter
Stroke
piston type
Machine
Max. distance between pins mm
Min. distance between pins mm
Bottom dump
distance between pins
Hydraulic tank
Box-shaped sealed type (equipped with the feed/exhaust valve)
Hydraulic oil filter Pump outlet side, tank return side
Hydraulic oil cooler Air cooled
Weight Table
Weight Table: PC2000-11E0
Work equipment PPC valve (R.H. and L.H.), control stand (R.H. and L.H.), L.H. instrument panel
• Travel PPC valve, travel lever, travel pedal
Weight
Table: PC2000-11E0 (Loading Shovel Specification)
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Fuel, Coolant, Lubricants (For European Union)
How to Use Fuel, Coolant and Lubricants by Ambient Temperature
Machines Without Service Center (Option)
Machines with Service Center (Option)
REMARK
Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity means the amount of oil needed to refill the system during inspection and maintenance.
Note 1: KDPF engine oil for cold district is deteriorated easily than that for normal area (replace every 500 hours), so replace oil and filter cartridge every 250 hours. For changing the maintenance time of machine monitor, ask your Komatsu distributor to perform the work.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-TE) has high performance. When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings, the use of G2-TE is recommended.
Note 4: About Non-Amine Engine Coolant (AF-NAC)
1. The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential.
Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for every 3 years or every 6000 hours whichever occurs first in the below listed conditions;
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(If other coolant than Komatsu approved non-Amine (AF-NAC) is used for refill or top off, the change interval is every 2 years or every 4000 hours whichever occurs first)
Conditions to meet every 2 years or 4000 hours to extended coolant life: Must pass "coolant test/analysis" at 4000 hours, the test interval is a precautionary procedure intended to prevent cooling and engine system damage
All maintenance top offs and refills were done with Komatsu approved non-Amine (AF-NAC) coolant
For more information (e.g. test method) on the Coolant test/ Analysis, consult an authorized Komatsu Distributor.
Non-Amine Engine Coolant (AF-NAC) is strongly recommended wherever available.
2. For the concentration of Non-Amine Engine Coolant (AF-NAC), see the Coolant density table. Non-Amine Engine Coolant (AF-NAC) is supplied in diluted state, so always fill up with it. (Never dilute it with ordinary water.)
Coolant Density Table
Min. atmospheric temperature
Note 5: If this oil is used for hydraulic system, fuel consumption increases. We strongly recommend HO56-HE for hydraulic oil.
When the machine is equipped with the auto-greasing system, see “HANDLE AUTO-GREASING SYSTEM”.
10 Structure and Function
Table of Contents
NOx Control System
Function of NOx Control System
Inducement Strategy
•The purpose of inducement is to prompt the operator to do the maintenance or repair on the emissions control system (NOx control system).
•Inducement strategy is a control function to ensure immediate correction of various failures in the engine emissions control system. It requires actions to limit engine performance and defines required indication such as warning lamps and messages, alarms while the control actions are imposed.
•The categories of abnormalities that causes Inducement are shown on the “NOx Control System Information” screen of the machine monitor.
Inducement Strategy When Abnormality is Found in the EGR System (EU Specification)
The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor display
Status Elapsed time (*1)
1Warning5 hours
Message of NOx control system Caution lamp Action level Alarm buzzer sound
Failure code for current abnormality (*2)
Failure code for Inducement strategy status (*3)
Engine deration (*4)
2 Continuous Warning (Warning 2) 10 hours
1: EGR system inspection and maintenance
Red Long intermittently CA2271No display
Torque reduction rate: 25% or more Red Red (*7)
2: EGR system inspection and maintenance
Red Triplet sound CA2271
AS00R2 (Warning 2 (NOx Control Device Abnormality))
Torque reduction rate: 25% or more
Yellow Red
Status
Elapsed time (*1)
Machine monitor display
Message of NOx control system
Caution lamp Action level
Alarm buzzer sound
3
Failure code for current abnormality (*2)
Failure code for Inducement strategy status (*3)
Engine deration (*4)
4
Low-Level Inducement (Inducement 1) 20 hours
3: EGR system inspection and maintenance
Long intermittently CA2271
Severe Inducement (Inducement 2)
Until abnormality is repaired
4: Engine power is under heavy deration.
Continuously CA2271
AS00R3 (Inducement 1 (NOx Control Device Abnormality))
Torque reduction rate: 25% or more
AS00R4 (Inducement 2 (NOx Control Device Abnormality))
Torque reduction rate: 50% or more
Engine speed reduction rate: Min. 60%
*1: Elapsed time of each stage shows an accumulated time to advance to the next stage after “Warning” stage is started.
*2: The failure code is shown on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. The failure code shown here is an example of failure code when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS (LIST OF FAILURE CODES FOR OUTPUT LIMITATION)”.
*3: The failure code is shown on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode.
*4: These percentages show a torque reduction ratio from the full torque curve, and an engine speed reduction ratio from the rated speed.
Function of Temporary Restoration from Inducement (EU Specification)
•Temporary restoration from Inducement during warning status is one of the Inducement strategies allowed to be included in the NOx control system. In case the NOx control system advances to “Severe Inducement”, engine power is derated heavily. This can cause difficulties to move the machine to a safe place for the maintenance and repair of the machine. For temporary remedies from these difficulties, the operator
Red
Red Red
Red
Red Red
can restore engine power for a short time to the deration of “Low-Level Inducement” on the machine monitor. Temporary restoration from Inducement does not regain full engine power.
•“Temporary Restoration from Inducement” can be activated only when the machine is in “Severe Inducement”. The maximum operation period is up to 30 minutes in each restoration operation, and 3 operations can be done. All the abnormalities of the system need to be corrected to regain restoration capability
•To activate Temporary Restoration, see OPERATION, “Temporary Restoration from Inducement” in the Operation & Maintenance Manual.
Inducement Strategy for Abnormality Recurrence (EU Specification)
•The NOx control system continuously monitors its operation conditions and stores information on abnormal operations and malfunctions.
•The stored information is used to monitor recurrences of abnormalities. Those information are required by the authorities. The abnormality counting spans 40 hours and it monitors the abnormalities that trigger Inducement.
•If another abnormality is sensed within 40 hours after the previous abnormalities were corrected, regardless of the level of the previous Inducement and whether the new abnormality is the same as the previous ones or not, it is judged as a recurrence.
•If a recurrence occurs, the Inducement strategy will be activated.
•If the previous corrected abnormality is “Warning”, “Continuous Warning”, or “Low-Level Inducement”, the alerts resume from the previous Inducement.
•If the previous corrected abnormality is “Severe Inducement”, the alerts resume from “Low-Level Inducement”, but the remaining time to “Severe Inducement” is 1 hour. If the 1 hour is used up without correcting the new abnormality, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.
Boot-up System
Layout Drawing of Boot-up System
1: KOMTRAX Plus controller
2: Pump controller
3: Machine monitor
4: Engine controller
5: KomVision controller
6: Battery
7: Fuse box
8: Circuit breaker
9: KOMTRAX terminal
10: System operating lamp
11: Battery isolator switch
12: Starting motor isolator switch
System Operating Lamp System
System Diagram of System Operating
Lamp System
1: Battery isolator switch
2: Battery
3: Circuit breaker
4: Fuse box
5: System operating lamp
6: Machine monitor
7: Engine controller
Function of Operation Lamp System
8: Pump controller
9: Valve controller 1
10: Valve controller 2
11: KOMTRAX terminal
12: KomVision controller
13: KOMTRAX Plus controller
The system operating lamp system is a system that lights up the system operating lamp to show the operation state of the controllers. The controllers are prevented from abnormally being terminated, and the battery power supply circuit from being shut off during the operation.
REMARK
•Before shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and check that the system operating lamp is off, and then turn the battery isolator switch to the “OFF” position.
•A controller data loss error may occur if the battery isolator switch is turned to the “OFF” position (the battery power supply circuit is shut off) while the system operating lamp is lit. Do not operate the battery isolator switch while the system operating lamp is lit.
•The system operating lamp goes out in a maximum of six minutes after the starting switch is turned to the “OFF” position.
•The system operating lamp may sometimes light up while the starting switch is in the “OFF” position, because KOMTRAX terminal may maintain its communication under this condition.
On and Off of System Operation Lamp
•Voltage of 24 V is constantly applied to one side of system operating lamp (light emitting diode).
•The output becomes low on the controller side (0 V), and a current flows through the diode and the system operating lamp is lit when any of controllers is in operation.
•The output becomes high on the controller side (24 V), and no current flows through the diode and the system operating lamp is not lit when no controller is in operation. The system operating lamp may look slightly luminous in the dark even when it is not lit. It is due to the minute leakage of current and this is not an abnormal phenomenon.
•KOMTRAX terminal repeats the start and stop to maintain the periodic communication when the starting switch is in the “OFF” position.
•The start and stop cycle (sleep cycle) of KOMTRAX terminal varies with the factors including the communication state and the time when the machine is not in operation. The lamp may stay lit approximately for the maximum of one hour.
If the system operating lamp stays lit when you want to cut off the battery circuit for maintenance, turn the starting switch to the “ON” position once, turn it to the “OFF” position, and the lamp goes out in the maximum of six minutes. After the system operating lamp goes out, operate the battery isolator switch immediately to the “OFF” position.
Battery Isolator
Layout Drawing of Battery Isolator
1: Battery isolator switch
2: Starting motor isolator switch
Function of Battery Isolator
(ON): ON position (OFF): OFF position
3: System operating lamp
•Battery isolator switch (1) is a switch that can be used to disconnect the battery as an alternative way to remove the negative terminal from the battery in the following cases.
•When the machine is stored for a long period of time
•Before performing repair or maintenance for electrical system
•Before performing electrical welding
•Before performing work for battery
•Before replacing the fuse, or etc.
•When the battery isolator switch (1) is at OFF position (the contact is opened), all the continuous power supplied for the components including the starting switch B terminal and controllers are all cut out. It is the same state as the time when the battery is not connected. Thus, all the electrical system of the machine are out of operation.
NOTICE
• Do not turn the battery isolator switch (1) to OFF position while system operating lamp is lit. If the battery isolator switch (1) is turned to OFF position while system operating lamp is lit, it may erase the data in the controller, and damage the controller seriously.
•Do not turn the battery isolator switch (1) to OFF position while the engine is running or immediately after the engine is stopped.
If the battery isolator switch (1) is turned to OFF position while the alternator generates power, the generated current has nowhere to go. It leads to over-voltage in the electrical system of the machine, which may cause serious damage to the electrical system including the electric devices and controllers.
REMARK
•The system operating lamp is lit while the controller is in operation. The system operating lamp is lit while KOMTRAX is performing communication, even when the starting switch is set in OFF position.
•If the battery was disconnected with the battery isolator switch (1) for a long period of time, machine monitor and the clock of the radio may return to the initial state. Resetting is required in this case.
Function of Starting Motor Isolator Switch
(ON): ON position
(OFF): OFF position
•Turn the starting motor isolator switch (2) to OFF position normally in the following cases.
•When the machine is going to be stored for a long period of time
•Before performing repair or maintenance for electrical system and engine room
•Before performing the work for battery
•Before replacing the battery
•When the starting motor isolator switch (2) is in OFF (contact is open) state, the power is not supplied to the starting motor, and you cannot start the engine.
Engine System
Layout Drawing of Engine System
1: Starting motor
2: Engine controller-A
3: KCCV ventilator (L.H. bank)
4: KDPF-A
5: KDPF-B
6: Air cleaner
7: EGR cooler
8: VGT
9: Alternator
10: Vibration damper
11: Engine oil filter
12: KCCV ventilator (R.H. bank)
13: Engine controller-B
REMARK
In machines with 2 systems of aftertreatment devices, the following is the relationship between the parts name for the aftertreatment devices and failure codes for engine controller to be displayed on the machine monitor
•When “-A” follows the part name
The failure code starts with “CA”. The failure code display has no symbol on its end. Example)
Part name: KDPF differential pressure sensor-A
Failure code displayed on the machine monitor: CA1881
Failure code displayed on the machine monitor: KDPF Differential Pressure Sensor Low Error
•When “-B” follows the part name
The failure code starts with “CB”. The failure code display has “_2” on its end. Example)
Part name: KDPF differential pressure sensor-B
Failure code displayed on the machine monitor: CB1881
Failure code displayed on the machine monitor: KDPF Differential Pressure Sensor Low Error_2
Function of Engine System
•VGT (8) is a turbocharger that changes the cross-sectional area of the exhaust passage.
• EGR cooler (7) is a device that cools down the exhaust gas with the coolant.
•KDPF (4) and KDPF (5) are devices that purify the exhaust gas with KDOC (catalyst) and KCSF (soot collecting filter) built-in.
•KCCV ventilators (3) and (12) are the mechanism that remove the oil from the blowby gas and return it to the intake side in order to combust it again. It mainly consists of filters.
Engine Control System
System Diagram of Engine Control
1: Battery isolator
2: Battery
3: Battery relay
4: Circuit breaker
5: Fuse box
6: Starting switch
7: Engine shutdown secondary switch
8: Engine controller
9: Lock lever
10: PPC lock switch
11: Starting motor cut-off relay (for PPC lock)
12: Starting motor cut-off relay (for personal code)
13: Fuel control dial
14: Alternator
15: Starting motor
16: Fuel supply pump
17: Various sensors
18: Machine monitor
19: KOMTRAX terminal
20: Pump controller
21: Engine shutdown secondary switch
22: Engine ACC keep/cut relay
23: Emergency stop switch
24: Starter isolator
25: Orbcomm controller
26: Starting motor cut-off relay (for pump controller)
27: Strainer proximity switch
28: Hydraulic oil tank
29: KomVision monitor
30: KomVision controller
31: Valve controller 1
31: Valve controller 2
Operation of Engine Control System
Start Engine
•When the starting switch is set at the START position, the engine controller detects that the engine stop switch is in OFF state, the lock lever is released, and the hydraulic tank strainer is installed state. Then, it transmits the start signal to the starting motor so that the starting motor starts operation to start the engine.
•When the engine starts, the engine controller checks the signal pressure transmitted from the fuel control dial, and adjust the engine speed to the set speed.
Engine Speed Control
•The fuel control dial transmits the signal voltage for the set speed, to the engine controller.
•The pump controller receives the fuel control dial position information from the engine controller via the network.
•The pump controller calculates the engine speed according to the working mode, deceleration conditions, etc., and transmits the command to the engine controller.
•The engine controller determines the fuel injection rate according to the command transmitted by the pump controller.
Stop Engine
•When the engine controller detects the starting switch and engine stop switch at the “STOP” position, stop injecting fuel, and stop running the engine.
Auto-Deceleration System
System Diagram of Auto-Deceleration System
1: Pump controller
2: Valve controller 1
3: Engine controller 2
4: Engine controller 1
5: Machine monitor
6: Fuel control dial
7: Cooling fan pump
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Function of Auto-Deceleration System
•Auto-deceleration function is a function that reduces the fuel consumption and the noise by automatically decreasing the engine speed to the medium speed when all the control levers are set to the NEUTRAL positions while waiting for a dump truck or next work.
•While the auto idle setting is enabled, when all the control levers are set to the NEUTRAL position for waiting for a dump truck or a next work, the engine speed drops down to the medium speed. When the levers are kept in the NEUTRAL positions for further 30 seconds, the engine speed automatically drops down further to the lower speed so that the fuel consumption and noise are reduced.
•When the levers are operated, the speed increases to the set speed instantaneously.
Operation of Auto-Deceleration System
When the Auto-Deceleration Switch is in “ON” Position
A: Engine speed (rpm)
B: All control levers are in NEUTRL
C: Any of control levers is operated
D: Time (sec)
E: No. 1 deceleration
E: No. 2 deceleration (1400 rpm)
G: 0.2 second
H: 4 seconds
M: 2 seconds or less
J: 1 second or less
When Control Lever is at NEUTRAL Position
•When setting the all control levers to the NEUTRAL position during traveling with the engine speed at deceleration operation speed (approximately 1400 rpm), the engine speed drops in a moment to the speed approximately 100 rpm lower than the set speed, which is the 1st deceleration.
•When all the control levers are kept in NEUTRAL for 4 seconds additionally, the engine speed drops to No. 2 deceleration speed (approximately 1400 rpm) until any control lever is operated.
When Control Lever is Operated
The engine speed increases in a moment to the speed set with the fuel control dial when any control lever is operated while the engine speed is kept at No. 2 deceleration speed.
Automatic Low Idle System
Automatic Low Idle System Diagram
1: Pump controller
2: Valve controller 1
3: Engine controller 1
4: Engine controller 2
Function of Automatic Low Idle System
5: Machine monitor
6: Fuel control dial
7: Cooling fan pump
•Automatic low idle system is a system that reduces fuel consumption and noise. It automatically decreases the engine speed to the medium when all the control levers are set to NEUTRAL position when waiting for a
dump truck or a next work. It automatically decreases the engine speed to the lower speed when the levers are kept in NEUTRAL position for further 30 seconds.
•The engine speed returns immediately to the speed set with the fuel control dial when any control lever is operated.
Operation of Automatic Low Idle System
When the Auto-Deceleration Switch and Automatic Low Idle Switch are in “ON” Position.
A: Engine speed (rpm)
B: All control levers are in NEUTRL
C: Any of control levers is operated
D: Time (sec)
E: No. 1 deceleration
E: No. 2 deceleration (1400 rpm)
G: Low idle (825 rpm)
H: 0.2 second
I: 4 seconds
J: 2 seconds or less
L: 30±1 seconds
F: 2 seconds or less
M: 1 second or less
When Control Lever is at NEUTRAL Position
•When setting the all control levers to the NEUTRAL position during traveling with the engine speed at deceleration operation speed (approximately 1400 rpm), the engine speed drops in a moment to the speed approximately 100 rpm lower than the set speed, which is the 1st deceleration.
•When all the control levers are kept in NEUTRAL for 4 seconds or more, the engine speed drops to the 2nd deceleration (approximately 1400 rpm)
•When all the control levers are kept in NEUTRAL for 30 seconds additionally, the engine speed drops to the low idle (approximately 825 rpm) until any control lever is operated.
When Control Lever is Operated
The engine speed increases in a moment to the speed set with the fuel control dial when any control lever is operated while the engine speed is kept at the 2nd deceleration speed or low idle.
Engine Automatic Warm-up System
System Diagram of Engine Automatic Warm-up System
Input and output signals
a: CAN signal
b: Hydraulic oil temperature signal
c: 1st throttle signal
1: Machine monitor
2: Engine
3: Coolant temperature sensor
4: Fuel supply pump
5: Engine speed sensor
d: Fuel supply pump control signal
e: Coolant temperature signal
f: Engine speed signal
6: Fuel control dial
7: Engine controller
8: Pump controller
9: Hydraulic oil temperature sensor
Function of Engine Automatic Warm-up System
•The engine automatic warm-up system automatically increases the engine speed to start the warm-up operation when the coolant temperature is low after the engine is started.
•The engine automatic warm-up function has 2 modes (“Heater warm-up” and “Normal warm-up”) in response to the purpose.
The heater warm-up mode increases the coolant temperature to make its heating performance better The normal warm-up mode prevents the damage of the engine caused by low temperature.
Operating condition 1
Air conditioner: Blower “ON”
Coolant temperature: Below 55 °C
Ambient temperature: Below 15 °C
Ladder switch is not pushed.
10 seconds after the engine is started.
When one of the operating conditions 1 is not satisfied
Heater warm-up is disabled (Normal warm-up)
When all the operating conditions 1 are satisfied
Heater warm-up is enabled
Operating condition 2
(Activated when all of the conditions that follow are satisfied)
Coolant temperature: Below 30 °C
Engine speed: 1200 rpm or below
Engine speed1200 rpm
Condition to cancel
(Cancelled when one of the conditions that follow is satisfied)
Automatic operation
Coolant temperature: 30 °C or more
Automatic warm-up operation time: 10 minutes or more
Manual operation Fuel control dial: Held for 3 seconds or more at 70 % or more of full speed (Max.)
Engine speed1500 rpm or more
Condition to cancel
(Cancelled when one of the conditions that follow is satisfied)
Coolant temperature: 60 °C or more
Outside air temperature: 20 °C or more
Engine speed: Desired speed
Overheat Prevention System
Overheat Prevention System
Diagram
Input and output signals
a: CAN signal
b: Hydraulic oil temperature signal
c: 1st throttle signal
1: Machine monitor
2: Engine
3: Coolant temperature sensor
4: Fuel supply pump
5: Engine speed sensor
Function of Overheat Prevention System
d: Fuel supply pump control signal
e: Coolant temperature signal
f: Engine speed signal
6: Fuel control dial
7: Engine controller
8: Pump controller
9: Hydraulic oil temperature sensor
The overheat prevention system is a system that prevents overheating by reducing the pump load and by lowering the engine speed when coolant temperature becomes too high during operation in order to protect engine and hydraulic components.
Operating condition
Coolant temperature: Min. 105 °C
Operation and remedy
Working mode: All modes
Engine speed: Low idle
Alarm monitor: Lights up
Alarm buzzer: Sounds
Condition to cancel
Coolant temperature: Less than 105 °C
Fuel control dial: Return to low idle (MIN) position.
When above conditions are satisfied, it is restored to the state before operation (manual restoration).
Operating condition
Coolant temperature: Min. 102 °C
Operating condition
Coolant temperature: Min. 100 °C or
Hydraulic oil temperature: Min. 95 °C
Operating condition
Coolant temperature: Min. 95 °C or Hydraulic oil temperature: Min. 95 °C
Operation and remedy
Working mode: All modes
Engine speed: Kept as it is
Alarm monitor: Lights up
Alarm buzzer: Does not sound
Lower the pump discharged flow rate.
Operation and remedy
Working mode: All modes
Engine speed: Kept as it is
Alarm monitor: Does not light up
Alarm buzzer: Does not sound
Lower the pump discharged flow rate.
Operation and remedy
Working mode: Travel single
Engine speed: Kept as it is
Alarm monitor: Does not light up
Alarm buzzer: Does not sound
Lower the travel speed.
Condition to cancel
Coolant temperature: Less than 102 °C
When above condition is satisfied, it is restored to the state before operation (automatic restoration).
Condition to cancel
Coolant temperature: Less than 100 °C
Hydraulic oil temperature: Max. 95 °C
When above condition is satisfied, it is restored to the state before operation (automatic restoration).
Condition to cancel
Coolant temperature: Less than 95 °C
Hydraulic oil temperature: Max. 95 °C
When above condition is satisfied, it is restored to the state before operation (automatic restoration).
Turbocharger Protection System
System Diagram of Turbocharger Protection System
Input and output signals
a: CAN signal
b: Hydraulic oil temperature signal
c: 1st throttle signal
1: Machine monitor
2: Engine
3: Coolant temperature sensor
4: Fuel supply pump
5: Engine speed sensor
d: Fuel supply pump control signal
e: Coolant temperature signal
f: Engine speed signal
6: Fuel control dial
7: Engine controller
8: Pump controller
9: Hydraulic oil temperature sensor
Function of Turbocharger Protection System
This function prevents seizure of the turbocharger when the engine speed is increased suddenly after the engine is started by limiting the engine speed.
Operating condition
ENgine oil pressure: Less than 50 kPa {0.51 kgf/cm2}
Actuated
Turbocharger protection (See the figure below)
A: Starting of engine
B: Turbocharger protection time (approximately 0 to 20 seconds)
C: Modulation time (approximately 1 seconds)
D:500 rpm
E: Approximately 1000 rpm
F: 1980 rpm (when working mode is P mode)
Fuel control dial: High idle (MAX) position with work equipment control lever operated
Multiple Injection Control System
Function of Multiple Injection Control System
Split injection control system is a system that injects slight amount of fuel prior to the main injection within the set time shown in the following table after cranking to improve the startability in cold weather. As a result, the low idle speed slightly increases within this time range.
Operating condition
Component Parts of Engine System
PTO
PTO
Abbreviation for Power Take Off
Structure of PTO
General View and Sectional View
A: Center of No. 1 pump (HPV375 + 375) shaft
B: Center of No. 2 pump (HPV375 + 375) shaft
Center of fan pump (HPV95 + 95) shaft
D: Center of input shaft
C:
1: Driven gear (number of teeth: 57)
2: Coupling
3: Main shaft
4: Joint plate
5: PTO case
6: Drive gear (number of teeth: 72, 60)
Specifications of PTO
Amount of lubricating oil: 36 ℓ
Reduction ratio
Input shaft: 1.0
No. 1 pump (HPV375 + 375): 60/57 = 1.053
No. 2 pump (HPV375 + 375): 72/57 = 1.263
Fan pump (HPV95 + 95): 56/57 = 0.982
VGT
VGT
Abbreviation for Variable Geometry Turbocharger
Structure of VGT
General View and Sectional View
7: Drive gear (number of teeth: 56)
8: Breather
A: Intake air inlet
B: Intake air outlet
C: Exhaust gas inlet
1: Blower housing
2: VGT speed sensor
3: Hydraulic actuator
4: Turbine housing
5: Plate
6: Vane
Function of VGT
D: Exhaust gas outlet
7: Nozzle ring
8: Push rod
9: Shaft
10: Blower impeller
11: Turbine impeller
12: Piston
C: Blower impeller
1: Air cleaner
2: VGT
3: KDPF
T: Turbine impeller
4: EGR cooler
5: EGR valve
*1: Some machine models or specifications may not be equipped with these.
•The exhaust gas regulations are applied to the exhaust gas from the engine running at low speed, as well as at high speed. To meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount of fresh suction air)
•To attain high EGR ratio particularly when the engine (rotation) speed is low, the turbine inlet pressure (P3) must be set higher than the boost pressure (P2) (P3 > P2). For this reason, the variable turbocharger (VGT) is employed, in which the exhaust gas pressure acting on turbine impeller (T) is adjustable. Also, since the boost pressure increases more quickly, generation of particulate caused by lack of oxygen during low-speed operation (rotation) is reduced.
•The blower impeller (C) is driven through the shaft joined to the turbine impeller (T) to send a large quantity of air to the cylinders. If more air is sent by VGT (2), more fuel can be injected, and the engine output is increased. In addition, the air cooled by the aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel injection rate is increased, and the engine output is increased.
NOTICE
Sufficient amount of quality and clean oil is required to maintain the VGT performance. Be sure to use the Komatsu-genuine high-quality oil. Replace the oil and oil filter according to the procedure in “Operation and Maintenance Manual”.
REMARK
VGT or boost piping may emit an air-bleeding sound after relief operation, but this is not an abnormality
Operation of VGT
1. The exhaust gas enters the part (C) of the turbine housing (4) and flows out through the portion (P) and the part (D). The portion (P) is surrounded by the plate (5) fixed to the turbine housing (4), nozzle ring (7), and vanes (6).
The area of its passage is changed by sliding the push rod (8) to the right or left.
2. The hydraulic actuator (3) moves the piston (12) in the actuator up and down with the hydraulic pressure controlled by the EPC valve, and slides the push rod (8) to the right and left.
3. The exhaust gas flowing through the vanes (6) rotates the blower impeller (10) through the shaft (9) joined to the turbine impeller (11). As a result, the blower impeller works as a compressor, and the intake air entering through the part (A) is compressed and discharge through the part (B).
4. When the exhaust gas pressure at the inlet (C) of the turbine housing (4) is low (engine speed is in low range), the push rod (8) slides to the right and narrows the portion (P).
5. The exhaust gas acting on the turbine impeller (11) increases, the turbocharger speed increases, and more air (oxygen) is taken in.
The VGT speed sensor (2) detects the speed of the turbocharger.
Nozzle Ring (Close) State
1. During low speed operation (rotation), the exhaust gas inlet passage (P) is narrow (L1). (It is not fully closed, however.)
2. As the turbine inlet pressure increases while the nozzle ring is closed, the turbine inflow speed increases, and the turbocharger speed increases.
Nozzle Ring (Open) State
1. During high speed operation (rotation), the exhaust gas inlet passage (P) is wide (L2).
2. As the engine speed increases and the turbine inlet pressure (exhaust gas pressure) increases, the exhaust gas inlet passage (P) is widened (L2), and the exhaust gas acts on the turbine impeller (11) efficiently.
REMARK
•The nozzle ring (7), vanes (6), and push rod (8) are all-inone unit, and the push rod (8) slides only and does not rotate.
•The hydraulic actuator (3) is equipped the VGT position sensor. The VGT position sensor is calibrated together with the variable mechanism of VGT and the result is written in the memory in the VGT position sensor. Accordingly, if any of the hydraulic actuator (3), VGT position sensor, and VGT unit fails, whole VGT must be replaced.
Operation of Hydraulic Actuator
1. The hydraulic actuator (6) is controlled by the EPC valve (3) and driven hydraulically
2. The hydraulic pressure supplied by the engine boost oil pump (12) is used for this purpose.
3. The position of the hydraulic actuator (6) is fed back to the engine controller by the signals from the VGT position sensor (5).
EGR System
EGR
Abbreviation for Exhaust Gas Recirculation
Layout Drawing of EGR System
REMARK
The drawing shows the R.H. bank.
1: Intake connector
2: EGR valve
3: VGT
4: EGR cooler
5: Exhaust manifold
6: Intake manifold
7: Mixing connector
REMARK
The drawing shows the L.H. bank.
1: Intake connector
2: EGR valve
3: VGT
4: EGR cooler
Function of EGR System
5: Exhaust manifold
6: Intake manifold
7: Mixing connector
• EGR valve (hydraulically driven) (4) controls the gas flowing from the exhaust section to the intake section. Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake section.
•EGR cooler (6) cools the exhaust gas. Engine coolant is used to cool the exhaust gas.
•Mixing connector (3) returns the air from the air-cooled aftercooler and the exhaust gas from EGR valve to the intake section.
•Exhaust gas is always clean with this system which controls EGR circuit based on information sent from sensor installed to each part to obtain EGR rate according to the operating condition. (EGR ratio means the ratio of EGR gas contained in the intake gas.)
•Monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure from occurring.
EGR System Circuit Diagram
B: Blower impeller
1: Air cleaner
2: Mass air flow and temperature sensor
3: VGT
4: Engine boost oil pump
5: Hydraulic actuator (power piston)
6: EPC valve
7: EGR valve lift sensor
8: EGR valve
9: EGR valve assembly
10: Engine controller
Operation of EGR System
T: Turbine impeller
11: Air-cooled aftercooler
12: Mixing connector
13: Intake manifold
14: Engine
15: Exhaust manifold
16: Ambient pressure sensor
17: Charge (boost) pressure and temperature sensor
18: EGR cooler
19: KDPF
1. The engine controller outputs signals in order to open EGR valve (8) most properly in accordance with the engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.
2. When EGR valve (8) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (15) into EGR cooler (18) through the EGR piping.
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3. The exhaust gas cooled by EGR cooler (18) flows through EGR valve (8), merges with the supply air in the mixing connector (12), and flows into the air intake manifold (16).
EGR Valve
EGR
Abbreviation for Exhaust Gas Recirculation
Structure of EGR Valve
Sectional View
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
1: Valve
2: Spring
3: Power piston
4: Spool
Structure
Servo drive oil inlet
D: Servo drive oil outlet
5: Spring
6: EGR valve lift sensor
7: EPC valve (for EGR)
8: EPC valve (for VGT)
• The EGR valve consists of the EGR gas flow control mechanism and EPC valve.
C:
Operation of EGR Valve
1. The oil from the engine boost oil pump flows in port (C) of EGR valve. The control pressure from EPC valve solenoid enters port (E).
2. Spool (4) is moved to the right by the reaction force of spring (5), and valve (1) is closed by the reaction for spring (2). Accordingly, the exhaust gas from EGR cooler does not flow to the intake side.
3. To open valve (1), the control pressure from EPC valve enters port (E) first. The position of spool (4) is determined by the balance of the control pressure and spring (5).
4. Since the notch of power piston (3) opens, the oil from the engine boost oil pump flows through port (C) and pushes power piston (3) to the left.
5. The oil from the engine boost oil pump acts on power piston (3) and generates force (Fp).
6. When force (Fp) increases more than reaction force (Fs) of spring (2), EGR valve (1) opens and the exhaust gas flows to the intake side.
7. Reaction force (Fs) of spring (2) and force (Fp) of power piston are balanced since the engine controller controls the control pressure with EPC valve solenoid.
8. Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which is in contact with power piston (3).
9. EGR valve lift sensor senses the displacement of spool (4).
EGR Cooler
EGR
Abbreviation for Exhaust Gas Recirculation
Structure of EGR Cooler
General View and Sectional View
A: EGR gas inlet
B: EGR gas outlet (to EGR valve)
C: Coolant inlet
1: Header plate
2: Flat tube
Operation of EGR Cooler
D: Coolant outlet
E: Air vent
F: Air vent
3: Inner fin
4: Case
• EGR gas enters through (A) and flows through flat tubes (2) (9 pieces).
•Coolant enters through (C), flows outside of flat tubes (2) in case (4), and goes out through (D).
•Flat tube (2) has inner fins (3), thus EGR gas is cooled efficiently and discharged through EGR gas outlet (B).
KCCV System
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
Layout Drawing of KCCV System
REMARK
The drawing shows the R.H. bank.
A: Blowby gas from which engine oil is removed (to VGT)
B: Blowby gas
1: Check valve 2: KCCV ventilator
C: Removed engine oil (to engine oil pan)
3: CDR valve 4: VGT
REMARK
The drawing shows the L.H. bank.
A: Blowby gas from which engine oil is removed (to VGT)
B: Blowby gas
1: Check valve
2: KCCV ventilator
Function of KCCV System
C: Removed engine oil (to engine oil pan)
3: CDR valve
4: VGT
•In the past, blowby gas (A) was allowed to be released into the atmosphere in the past, but now it is restricted by emission regulations.
•Blowby gas (A) contains ingredients of the engine oil.A filter is installed to KCCV ventilator (4) to remove the engine oil to prevent the following possible problems if it is recirculated to VGT (2) as it is.
•Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
•Abnormal combustion in engine
•Malfunction of each sensor caused by sticking engine oil
Operation of KCCV System
The left side of the figure shows the conventional blowby gas flow, and the right side shows the blowby gas flow suctioned and returned by the KCCV ventilator.
A: Blowby gas
B: Clean gas
1: Air cleaner
2: VGT
3: Aftercooler
4: Cylinder block (crankcase)
C: Engine oil
5: Breather
6: KCCV ventilator
7: Engine oil pan
8: Check valve
1. The blowby gas (A) in the cylinder block (4) passes through the breather (5), the filter in the KCCV ventilator (6) separate the engine oil (C), and the clean gas (B) is returned to the air intake side of VGT (2).
2. The separated engine oil (C) is discharged into the engine oil pan (7) through the check valve (8).
KCCV Ventilator
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
Structure of KCCV Ventilator
General View and Sectional View
A: Blowby gas inlet (from engine breather)
B: Blowby gas outlet (to VGT intake side)
C: Oil drain port (to engine oil pan)
1: Heater tube
2: Crankcase pressure sensor
3: Case
4: CDR valve
Structure
D: Coolant inlet
E: Coolant outlet
5: Filter
6: Relief valve
7: Impactor
• The filter (5) can be removed downward for replacement.
•The crankcase pressure sensor is installed to the upper part of the KCCV ventilator main unit.
Function of KCCV Ventilator
•If the blowby gas is returned to the intake side of VGT and the crank case pressure becomes negative, dust may be sucked in through the crank shaft seal.
The CDR valve (4) controls the pressure inside the crankcase to prevent this from occurring.
•If the filter (5) of the KCCV ventilator is clogged, the pressure inside the crankcase rises, and oil leakage may occur.
Therefore, the crankcase pressure sensor (2) detects clogging of the filter (5).
•Keep the KCCV ventilator warm with warmed-up engine coolant to prevent the blowby gas passage from being clogged due to freeze.
•The relief valve (6) inside the case (3) operates when the filter (5) is blocked to bypass the blowby gas and protect both the KCCV ventilator and engine.
Operation of KCCV Ventilator
1. When blowby gas enters the blowby gas inlet (A) and passes through the hole of the impactor (7) in the filter (5), large particles in the oil mist (atomized engine oil) are separated.
2. The filter (5) separates the small particles in the oil mist.
3. The separated oil oozes out from the bottom of the filter (5), and flows to the oil drain port (C), and then flows to the engine oil pan.
4. The crankcase pressure sensor (2) senses the crankcase pressure (blowby gas pressure). If the engine controller judges through detected value of the crankcase pressure sensor (2) that the filter (5) is clogged, it displays failure codes CA555 and CB555, and if the pressure increases further, it displays failure codes CA556 and CB556.
5. The relief valve (6) is installed in case (3). It is operated when filter (5) is clogged.
6. When the crankcase pressure becomes negative, the CDR valve (4) operates so that the crankcase pressure does not become excessively negative.
CDR Valve
CDR
Abbreviation for Crankcase Depression Regulator
Operation of CDR Valve
1. Normally, blowby gas flows from the crank case side (A) to the VGT air intake side (B) since the spring (2) pushes up the diaphragm (1).
2. As the intake air on the VGT air intake side (B) increases, the pressure (P1) on the crankcase side decreases.
3. The reaction force of the spring (2) is overcome by the ambient pressure (P2). The diaphragm (1) shuts the passage and temporarily blocks the flow.
4. Blowby gas accumulates in the crankcase, the pressure (P1) on the crankcase side increases, and it pushes up the diaphragm (1) again and the blowby gas starts to flow.
KDPF
KDPF
Abbreviation for KOMATSU Diesel Particulate Filter
Structure of KDPF
REMARK
The shape of the right bank and left bank is not identical.
General View
A: From VGT
B: To exhaust pipe
1: Inlet unit
2: KDOC inlet temperature sensor
3: KDOC unit
4: KCSF unit
5: KDPF differential pressure sensor
6: KDPF outlet temperature sensor
7: KDPF differential pressure sensor port
8: Outlet unit
Structure
C: Water drain
9: Temperature sensor controller
10: KDPF differential pressure sensor port
11: KDOC outlet temperature sensor
12: Hanger bracket
13: Water drain port
14: Sensor bracket
15: Sensor bracket band
•KDPF consists of the inlet unit (1) to introduce exhaust gas, the KDOC unit (3) to store oxidation catalyst, the KCSF unit (4) to store the soot collecting filter equipped with the catalyst, and the outlet unit (8) to discharge exhaust gas.
•The KDOC unit (3) consists of the ceramic honeycomb with the oxidation catalyst.
•The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics under the vibration condition of the engine and machine body.
This mat also thermally insulates the periphery of KDPF from the ceramics which becomes high temperature during operation.
•The KCSF unit (4) consists of the ceramic honeycomb with the oxidation catalyst, similarly to the KDOC unit (3).
The inside of the KCSF unit (4) consists of many cells partitioned by ceramic walls. The cells blocked on the inlet side and those blocked on the outlet side are arranged alternately
•KDPF is equipped with the KDPF temperature sensor (assembly of the KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF outlet temperature sensor) and the differential pressure sensor (assembly of KDPF differential pressure sensor and KDPF outlet pressure sensor).
•The system judges from the temperatures measured by the 3 temperature sensors that the KCSF unit (4) and KDOC unit (3) are functioning normally, and uses those temperatures for troubleshooting of various components.
•The differential pressure sensor monitors soot accumulated in the KCSF unit (4) by sensing the pressure difference between both sides of the KCSF unit (4), and uses the obtained data for troubleshooting of various components, similarly to the temperature sensor.
•The KDPF surface or the pipes around KDPF are extremely hot when the engine runs or for a while after the engine stops.
If the work close to KDPF is inevitable, take extreme care not to get burn injury.
Function of KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5:Ceramics honeycomb
•KDPF purifies the exhaust gas by catching large amount of chainlike soot or PM (Particulate Matter such as soot) which is contained in the engine exhaust gas.
•KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen monoxide) contained in the exhaust gas into NO2 (nitrogen dioxide), and regenerates (*1) the soot accumulated in KCSF (2).
•KCSF (2) captures soot.
•When the temperature of exhaust gas is relatively high during the operation, the soot accumulated in KCSF (2) is naturally oxidized and burnt away by the effect of KDOC (oxidation catalyst) (1). (This is called “passive regeneration”)
REMARK
“Passive regeneration” cannot be performed if the light load operation and low temperature state of the exhaust gas continue. Accumulated soot is gradually increased.
•The engine controller always monitors 2 soot accumulation values and compares them. One is presumed soot accumulation based on the engine operating conditions, and the other is the calculated soot accumulation based on the signal from the differential pressure sensor which is attached to KCSF (2).
•If accumulated soot and the temperature of engine exhaust gas exceed the specified level, the engine controller performs “Automatic regeneration” to burn (oxidize) the soot.
The engine controller calculates the exhaust gas temperature at the KDOC inlet and exhaust gas flow rate, and controls the engine exhaust gas temperature to increase it. (This is called “exhaust gas temperature raise control”.)
The temperature of the engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the fuel doser installed at the VGT outlet part. The exhaust gas volume is controlled by VGT
The engine controller enhances the oxidation power in KDOC (1) by raising the temperature of engine exhaust gas automatically, and improves combustion efficiency of the soot captured in KCSF (2).
REMARK
When relatively low exhaust temperature continues such as when the regeneration function on the machine monitor is disabled, outside air temperature is extremely low, light load operation is continuously carried out, the “Automatic regeneration” is not performed, and the amount of soot accumulation is increases.
•If the “Automatic regeneration” is not performed due to the excess amount of the soot accumulated in KCSF (2), perform the “Manual stationary regeneration” to burn (oxidize) the soot and reduce the amount of soot inside KCSF (2).
REMARK
If the amount of the soot exceeds the allowable level, it interferes the flow of exhaust gas to worsen fuel consumption and engine combustion state. It may lead to other failures. If the amount of the soot increases further, the “Manual stationary regeneration” cannot be performed safely, and KDPF becomes defective and replacement is inevitable. Therefore, be sure to perform the “Manual stationary regeneration” according to Operation and Maintenance Manual.
*1: Soot purification (oxidation) treatment
Types of Regeneration Function
Regeneration is a function that purifies (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF.
Passive Regeneration
Passive regeneration is a natural oxidation (burning) process of removing the soot which is accumulated in KCSF, when the soots
Active Regeneration (Engine Exhaust Temperature Rise Control + Fuel Dosing)
•Automatic regeneration
•Automatic regeneration is a function that starts the regeneration automatically by the fuel dosing (*2) when the soot accumulation exceeds the specified level and when the engine controller enters the exhaust temperature rise control (*1).
Automatic regeneration is also performed by the command from the engine controller after the elapse of a certain period of time from the previous regeneration regardless of soot accumulation in KCSF
*1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or VGT
*2: This is a fuel injection performed to accelerate the regeneration by increasing the exhaust temperature.
•Manual stationary regeneration
•“Manual Stationary Regeneration Request” is displayed on the machine monitor for the operator to perform regeneration by operating the machine monitor screen. First, when the exhaust temperature does not reach a certain level due to the operating condition of the machine. Second, additionally the operator disables regeneration, and the automatic regeneration is not performed and accumulated soot in KCSF increases.
In addition, when the engine controller or KDPF is replaced or ash in KCSF is washed, a serviceman performs regeneration by the operation on the machine monitor screen. (“Active Regeneration for Service”)
NOTICE
•For the procedure to start and stop the regeneration of KDPF, see Operation and Maintenance Manual for each machine.
•Use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, KDPF may cause a failure.
•Use the engine oil conforming to Komatsu genuine KDPF. If any oil other than the specified one is used, it may cause degradation of fuel consumption and a failure in KDPF due to early clogging of KDPF.
•Do not modify KDPF and exhaust pipe. If it is modified, KDPF cannot operate normally and may cause a failure.
•Do not give strong impacts such as standing on KDPF, dropping off, or hitting. The KDPF has a builtin ceramic that can be damaged by a strong impact.
•The white smoke may be discharged through the exhaust pipe outlet for a short time during the “Automatic Regeneration” and the “Manual Stationary Regeneration”, especially at low temperature, but this is not a failure. Be sure to perform regeneration in a well-ventilated area, since carbon monoxide may be generated.
•The temperature of the gas exhausted from the exhaust pipe may become 650 °C or higher during “Automatic Regeneration” and “Manual Stationary Regeneration”. Check that there is no combustible around the exhaust pipe in order to prevent the fire. Thoroughly ensure the safety around the machine by checking that there is no person at the place where the gas is exhausted to.
REMARK
•If diesel fuel is mixed with bio-fuel at a high ratio, KDPF regeneration is performed more frequently.
•The engine controller may start “automatic regeneration” even when the soot accumulation reaches the starting point for it. This is a treatment to maintain the function of the urea SCR system normal. It is not a failure.
•VGT is actuated automatically and the engine sounds differently during “automatic regeneration” and “manual stationary regeneration”. Also, as the flow rate of the exhaust gas in KDPF changes, the exhaust sound changes, but this is not a failure.
•The exhaust pipe may smell different from usual during the “automatic regeneration” and the “manual stationary regeneration”, but this is not a failure.
•KDPF has “KDPF dry operation” function to prevent excessive accumulation of unburnt fuel in KDPF when operation is continued at relatively low temperature for long hours. This is a function that the engine controller increases the engine exhaust temperature automatically and performs dry operation of KCSF when the set condition is satisfied. When the automatic dry operation is insufficient for the treatment, a manual stationary regeneration may be required.
•The standard temperature of KDPF is shown below.
KDOC_In (KDOC inlet temperature sensor)
KDOC_Out (KDOC outlet temperature sensor)
KDPF_Out (KDPF outlet temperature sensor)
While regeneration is not performed (idling state)
While regeneration is performed (thermal mode1000 rpm)
Vacuum valve opening pressure: 0 to 0.005 MPa {0 to 0.05 kgf/cm2}
Aftercooler
Core type: Aluminum wave 4.0/2P
Fin pitch: 4.0 mm
Fan Speed Control System of Hydraulic Fan
Fan Speed Control System Diagram of Hydraulic Fan
Input and output signals
a: Hydraulic oil temperature sensor signal
1: Engine controller
2: Coolant temperature sensor
3: Engine speed sensor
4: Hydraulic oil temperature sensor
5: Cooling fan speed sensor
6: Main pump
7: Cooling fan pump (for oil cooler and radiator)
7a: Servo
b: CAN signal (coolant temperature sensor signal, engine speed sensor signal)
c: Cooling fan speed sensor signal
7b: EPC valve
7c: Fan pump pressure sensor
8: Pump controller
9: PTO
10: Cooling fan motor (for the radiator)
11: Cooling fan motor (for the oil cooler)
12: Cooling fan (for the radiator)
13: Cooling fan (for the oil cooler)
Function of Fan Speed Control System of Hydraulic Fan
•The fan speed on the radiator side is controlled according to the engine speed and coolant temperature.
•The fan speed on the oil cooler side is controlled according to the engine speed and hydraulic oil temperature.
•When the coolant temperature and hydraulic oil temperature are low, noise or excessive fuel consumption is decreased by lowering the fan speed.
Engine Output Control System of Hydraulic Fan
Engine Output Control System Diagram of Hydraulic Fan
Input and output signals
a: Hydraulic oil temperature sensor signal
b: CAN signal (coolant temperature sensor signal, engine speed sensor signal)
1: Engine controller
2: Coolant temperature sensor
3: Engine speed sensor
4: Hydraulic oil temperature sensor
5: Cooling fan speed sensor
6: Main pump
7: Cooling fan pump (for oil cooler and radiator)
7a: Servo
c: Cooling fan speed sensor signal
d: Ambient temperature sensor signal
7b: EPC valve
7c: Fan pump pressure sensor
8: Pump controller
9: PTO
10: Cooling fan motor (for the radiator)
11: Cooling fan motor (for the oil cooler)
12: Cooling fan (for the radiator)
13: Cooling fan (for the oil cooler)
Function of Engine Output Control System of Hydraulic Fan
The pump controller calculates the horsepower the fan consumes. It controls the engine output curves (A) and (B) by the fan speed so that the excess fuel consumption is restricted.
Fan Reverse Rotation System of Hydraulic Fan
Fan Reverse Rotation System Diagram of Hydraulic Fan
Input and output signals
a: Cooling fan speed sensor signal
b: Cooling fan reverse rotation signal
1: Cooling fan (for the radiator)
2: Cooling fan speed sensor
3: Cooling fan motor (for the radiator)
4: Reversible valve
5: Solenoid valve
6: Pump controller
c: Cooling fan pump swash plate angle control signal
d: CAN signal
7: Cooling fan pump
7a: Servo
7b: EPC valve
8: Machine monitor
9: Cooling fan (for the oil cooler)
10: Cooling fan motor (for the oil cooler)
Function of Fan Reverse Rotation System of Hydraulic Fan
•The fan reverse rotation system of hydraulic fan is a function for the cooling-related devices to be cleaned easily by reversing the rotation direction of the fan.
•By reversing the fan rotation direction before starting the maintenance work, etc., heat can be discharged from the power container to the outside.
•When the pump controller receives a fan reverse signal from the machine monitor, it drives the reverse EPC valve of the fan motor and switches the fan reverse valve. As a result, the fan rotation direction is reversed. It is not possible to reverse the radiator side and the oil cooler side individually
•The rotational speed of the fan during the reverse rotation is controlled only by the engine speed. It is not affected by the cooling temperature or hydraulic oil temperature.
Component Parts of Cooling System
Cooling Fan Pump
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Structure of Cooling Fan Pump
General View
IMF: Front swash plate control current
IMR: Rear swash plate control current
PAF: Front pump discharge port
PAG: Gear pump discharge port
PAR: Rear pump discharge port
PBF: Pump pressure output port
PBR: Pump pressure output port
PD1F: Case drain port
PD1R: Air bleeder
PD2F: Drain plug
PD2R: Drain plug
PENF: Control pressure pickup port
PENR: Control pressure pickup port
1: Front pump
2: Rear pump
3: Gear pump
Overview
PEPC: EPC source pressure port
PFC: Front pump discharged pressure pickup port
PMF: Front swash plate control EPC output pressure pickup port
PMR: Rear swash plate control EPC output pressure pickup port
PPF: Front pump pressure sensor mounting port
PPR: Pump pressure sensor mounting port
PRC: Rear pump discharged pressure pickup port
PRF: Pilot pressure input port
PRR: Pilot pressure input port
PS: Pump suction port
PSG: Gear pump suction port
4: PC valve
5: EPC valve
6: Sequence valve
The cooling fan pump consists of the variable displacement swash plate type piston pump, PC valve, EPC valve, and gear pump.
Sectional Views (A-A, B-B, C-C)
13:
1: Front shaft
2: Cradle
3: Front case
4: Rocker cam
5: Shoe
6: Piston
7: Cylinder block
8: Valve plate
9: End cap
10: Rear shaft
11: Rear case
12: Servo piston
PC valve
14: Spline
15: Bearing
Sectional View
Structure
• The cylinder block (7) is supported at the shaft (1) by the spline (14).
•The shaft (1) is supported by each bearing (15) at the front and rear.
•The tip of the piston (6) is shaped as a concave sphere and crimped together with the shoe (5).
•The piston (6) and shoe (5) form a spherical bearing.
•The rocker cam (4) has the flat surface (A), and the shoe (5) is always pressed against this surface while sliding in a circular pattern.
•The rocker cam (4) rocks on the cylindrical surface (B) of the cradle (2) fixed to the case. High-pressure oil is supplied between them to form a static pressure bearing.
•The piston (6) performs relative movement in an axial direction in each cylinder chamber in the cylinder block (7).
•The cylinder block (7) rotates relatively to the valve plate (8) while sealing the pressurized oil.
•Oil pressure is balanced properly on this surface.
•The pressurized oil is sucked in and discharged from each cylinder chamber in the cylinder block (7) through the valve plate (8).
Specifications of Cooling Fan Pump
Model: HPV95+95+SBL(1)21
Model: Variable displacement swash plate type piston pump
Function of Cooling Fan Pump
•This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic energy and discharges pressurized oil corresponding to the load.
•It is possible to change the discharged volume by changing the swash plate angle.
Operation of Cooling Fan Pump
1. The cylinder block (7) rotates together with the shaft (1), and the shoe (5) slides on the plane (A).
2. The rocker cam (4) moves along the cylindrical surface (B). As a result, the tilt (a) between the center line (X) of the rocker cam (4) and the axis of the cylinder block (7) changes.
3. (A) is swash plate angle.
4. The flat surface (A) acts as a cam for the shoe (5) while the shaft angle (a) is made between the center line (X) of the rocker cam (4) and the axis of the cylinder block (7).
5. The piston (6) slides inside the cylinder block (7), and a difference is made between the volume (E) and volume (F) in the cylinder block (7).
6. The oil in amount of (F) minus (E) per each piston (6) is sucked in and discharged from.
7. As the cylinder block (7) rotates and the volume of the chamber (E) decreases, the pressurized oil is discharged on the process.
8. As the volume of the chamber (F) increases, pressurized oil is sucked in the process.
9. The difference between the volumes (E) and (F) inside the cylinder block (7) is zero when the center line (X) of the rocker cam (4) matches the axis of the cylinder block (7) (the swash plate angle is zero).
10. The suction and discharge of pressurized oil is not performed at this stage. Namely pumping action is not performed. (Angle of swash plate never becomes zero actually)
Control of Discharged Volume
1. As the swash plate angle (a) increases, the difference between the volumes (E) and (F) increases. Accordingly, the discharged volume (Q) increases.
2. The servo piston (12) changes the swash plate angle (a).
3. The servo piston (12) moves in a linear reciprocating motion corresponding to the signal pressure from the PC valve.
4. This linear movement is transmitted to the rocker cam (4) through the slider (13).
5. The rocker cam (4) supported on the cylindrical surface of the cradle (2) slides and pivots on the cylindrical surface.
6. The areas of the servo piston (12) for receiving the pressure are not identical on both sides. The hydraulic pump discharged pressure (self-pressure) (PP) is always transmitted to the pressure chamber on the small diameter piston side.
7. The output pressure (PEN) of the PC valve is supplied to the pressure chamber on the large diameter piston side.
8. Movement of the servo piston (12) is controlled by the relationship of pressure between the small diameter piston side (PP) and the large diameter side (PEN) and by the ratio of the area receiving the pressure between the small diameter piston and the large diameter piston.
Cooling Fan Pump PC Valve
Structure of Cooling Fan Pump PC Valve
PA: Pump port
PDP: Drain port
PM: EPC pressure input port
1: Plug
2: Servo piston assembly
3: Pin
4: Spool
Function of Cooling Fan Pump PC Valve
PPL: Control pressure outlet port (to servo piston large diameter side )
5: Retainer
6: Seat
7: Cover
8: Wiring
•PC valve controls the pump discharged volume (Q) corresponding to EPC valve output pressure (PM).
•PC valve reduces the pump discharged volume (Q) as EPC valve output pressure (PM) increases.
•PC valve increases the pump discharged volume (Q) as EPC valve output pressure (PM) decreases.
Operation of Cooling Fan Pump PC Valve
Procedure of EPC Valve (1)
1. The swash plate control current (IM) flows from the pump controller into the EPC valve solenoid (1).
2. The swash plate control current (IM) acts on the EPC valve and outputs signal pressure to change the force to the push piston (2).
3. The spool (3) stops at a position where the force of the spring (4) and the force which pushes the spool (2) with the signal pressure of the EPC valve are balanced.
4. The pressure output from PC valve [pressure of port (C)] varies with the position.
5. Strength of the swash plate control current (IM) is determined by engine oil temperature, hydraulic oil temperature, engine speed, and the set value of hydraulic drive fan speed.
6. As the spool (3) expands or compresses the spring (4), the spring set force changes.
When the Swash Plate Control Current Decreases (EPC Output Pressure is Decreased)
1. The port (C) of the PC valve is connected to the large diameter side of the servo piston (9).
2. The pump discharged pressure (PA) flows into the small diameter side of the servo piston (9) and the port (B).
3. The spool (3) moves to the left when the EPC output pressure (PM) is small.
4. When the port (C) and port (D) are connected, the pressure entering to the large diameter side becomes the drain pressure (PT), and the servo piston (9) moves to the left.
5. Pump discharged volume is increasing.
6. As the servo piston (9) moves, the spring (4) expands, and the spring force decreases.
7. When the spring force decreases, the spool (3) moves to the right. The port (C) and port (D) are blocked, and the pump discharged pressure port (B) is connected to the port (C).
8. Since the pressure in the port (C) and the pressure at the large diameter side of the piston increase, the servo piston (9) stops moving to the left.
9. The stop position of the servo piston (9) (= pump discharged volume) is determined by the position where the thrust caused by output pressure of EPC valve is balanced with the force of the spring (4).
10. When the stop position of the servo piston (9) (= pump discharged volume) is at the intermediate position between the maximum discharged volume and the minimum discharged volume, the pressure on the large diameter side of the piston is approximately a half pump discharged pressure (PA). When it is at the maximum discharged volume, it is drain pressure (PT). 10 Structure and Function
When the Swash Plate Control Current Rises
(EPC Output Pressure Rises)
1. The spool (3) moves to the right when the EPC output pressure (PM) is large.
2. When the port (C) and the port (B) are connected, the pressure entering into the large diameter side increases, and the servo piston (9) moves to the right.
3. The pump discharged volume goes to decrease.
4. As the servo piston (9) moves, the spring (4) is compressed and the spring force increases.
5. When the spring force increases, the spool (3) moves to the left, the port (C) and port (B) is blocked, and the drain port (D) is connected to the port (C).
6. The servo piston (9) stops moving to the right since the pressure in the port (C) decreases and the pressure on the large diameter side of the piston decreases.
7. The stop position of the servo piston (9) (= pump discharged volume) is determined by the position where the thrust caused by output pressure of the EPC valve is balanced with the force of the spring (4).
8. When the stop position of the servo piston (9) (= pump discharged volume) is at the intermediate position between the maximum discharged volume and the minimum discharged volume, the pressure on the large diameter side of the piston is approximately a half pump discharged pressure (PA). When it is at the minimum discharged volume, it is pump pressure (PA).
9. The relationship between the swash plate control current (IM) and the pump discharged volume (Q) is shown in the following figure.
Cooling Fan Pump EPC Valve
Structure of Cooling Fan Pump EPC Valve
General View and Sectional View
C: To PC valve P: From pilot relief valve
T: To tank 1: Connector 2: Coil
Body
Spring
Function of Cooling Fan Pump EPC Valve
•EPC valve consists of proportional solenoid part and hydraulic valve part.
•When EPC valve receives the signal current (i) from the controller, it generates an EPC output pressure proportional to the amperage of current and outputs to the PC valve.
Operation of Cooling Fan Pump EPC Valve
When Signal Current is Zero (Coil is De-energized)
1. When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
2. The spool (5) is pushed to the left by the spring (4).
3. The port (P) is closed and the pressurized oil from the pilot relief valve does not flow to PC valve.
4. The pressurized oil from PC valve is drained to the tank through the port (C) and port (T).
5: Spool
6: Rod
7: Plunger
When Signal Current is Very Small (Coil is Energized)
1. When low signal current flows through the coil (2), the coil (2) is energized, and the thrust force to the right is generated in the plunger (7).
2. The rod (6) pushes the spool (5) to the right, and the pressurized oil from the port (P) flows to the port (C).
3. The pressure at the port (C) increases and the total of the force applied to surface of the spool (5) and the force of the spring (4) becomes larger than thrust of the plunger (7).
4. The spool (5) is pushed to the left, and the port (P) and port (C) are disconnected.
5. The port (C) is connected to the port (T).
6. The spool (5) moves to a position where the thrust of the plunger (7) becomes equal to the total of the pressure at the port (C) and the force of the spring (4).
7. The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the amperage of the signal current.
When Signal Current is Maximum (Coil is Energized)
1. When signal current flows through the coil (2), the coil (2) is energized.
2. Since the signal current is the maximum at this time, the thrust force of the plunger (7) also becomes the maximum.
3. The spool (5) is pushed to the right by the spring (6).
4. The pressurized oil flows from the port (P) to port (C) at the maximum rate, and the circuit pressure between the EPC valve and PC valve is maximized.
5. The pressurized oil does not flow to the tank since the port (T) is closed.
Cooling Fan Motor
Structure of Cooling Fan Motor
General View
P: From fan pump
T: To hydraulic tank from oil cooler
TC: To hydraulic tank
Sectional View
1: Output shaft
2: Case
3: Thrust plate
4: Shoe
5: Piston assembly
6: Cylinder block
7: Valve plate
8: End cover
9: Center spring
Specifications of Cooling Fan Motor
Model: LMF110
Capacity: 110.7 cc/rev
Rated speed: 1100 rpm
Rated flow rate: 121.8 ℓ/min
Cracking pressure of check valve: 78.5 kPa {0.8 kgf/cm2}
10: Speed sensor
11: Spring
12: Suction valve
13: Solenoid valve
14: Block
15: Reversivle spool
16: Safety valve
17: Spring
Cracking pressure of safety valve: 24.5 kPa {250 kgf/cm2}
Function of Cooling Fan Motor
It is a swash plate type axial piston motor. It converts the energy of the pressurized oil sent from the cooling fan pump into rotary motion.
Operation of Cooling Fan Motor
1. Pressurized oil flows from the pump through valve plate (7) to cylinder block (5).
2. Pressurized oil flows to only either side of (Y-Y) which is connecting the top dead center and bottom dead center during the stroke of piston (4).
3. Pressurized oil which flows in either side of cylinder block (5) pushes pistons (4) (4 pieces or 5 pieces). Each piston generates force F1 “F1 kg = P kgf/cm2 x πD2/4 cm2”. This force acts on thrust plate (2).
4. Since thrust plate (2) is fixed at angle (a) to output shaft (1), the force is divided into components (F2) and (F3).
5. Radial component (F3) of these components generates torque (T = F3 x ri) against (Y-Y) which is connecting the top dead center and bottom dead center.
6. Combined force “T = ∑ (F3 x ri)” of these torques rotates cylinder block (5) through pistons (4).
7. This cylinder block (5) is coupled with output shaft (1) by spline.
8. Output shaft (1) rotates and transmits the torque.
Suction Valve of Cooling Fan Motor
Function of Suction Valve of Cooling Fan Motor
When the pump stops turning, no pressurized oil flows into the motor. Since the motor is turned by the inertial force, the pressure on the motor outlet side increases. When inflow of the pressurized oil from inlet port (P) stops, suction valve (1) draws in the pressurized oil on the outlet side and supplies it to port (MA) to compensate for insufficiency in pressurized oil and prevent cavitation.
Operation of Cooling Fan Motor Suction Valve
When Engine is Started
1. The pressurized oil is supplied from the cooling fan pump to port (P), and the pressure on port (MA) side increases.
2. When the starting torque is generated in the motor, the motor starts rotation.
3. The pressurized oil on the motor outlet (MB) side returns through port (T) to the tank.
When Engine is Stopped
1. When the engine is stopped, the input speed of the cooling fan pump becomes 0 rpm.
2. No pressurized oil is supplied from the cooling fan pump to port (P).
3. As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to stop.
4. The suction safety valve (1) sends the oil in port (T) on the outlet side to the (MA) side in order to prevent cavitation when the motor shaft is rotated by the force of inertia while the oil flow in port (P) is decreasing.
Reversible Valve of Cooling Fan Motor
Operation of Reversible Valve of Cooling
Fan Motor
When Cooling Fan Reverse Solenoid Valve is “De-energized”
1. When coil (1) is “de-energized”, the pressurized oil from the pump is stopped by spool (2).
2. Port (C) is connected to the tank circuit.
3. Spool (3) is pushed to the right by spring (4).
4. Port (MA) opens, the pressurized oil flows in, and the motor rotates forward (clockwise).
When Cooling Fan Reverse Solenoid Valve is “Energized”
1. When coil (1) is “energized”, spool (2) is switched.
2. The pressurized oil from the pump flows into port (C), and then into spool chamber (D).
3. The pressurized oil in chamber (D) compresses spring (4).
4. Spool (3) moves to the left.
5. Port (MB) opens, the pressurized oil flows in, and the motor rotates in reverse (counterclockwise).
Safety Valve of Cooling Fan Motor
Function of Safety Valve of Cooling Fan Motor
The pressure in motor port (P) may increase when the engine is started, etc. Safety valve (1) is installed to protect the fan system circuit in this case.
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