DOWNLOAD PDF : Komatsu HYDRAULIC EXCAVATOR PC210LCi-11 Service Repair Workshop ManualSEN06616-16

HYDRAULIC EXCAVATOR

PC210LCi -11

SERIAL NUMBERS 500470 and up

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00 Index and Foreword

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E-5

E-8

E-9

E-14

E-15 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation ....................40-1388

E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 40-1389

E-17 Fuel Gauge Does Not Move from Minimum or Maximum 40-1390

E-18 Display of Fuel Gauge is Different from Actual Fuel Level 40-1392

E-19 Engine Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum.40-1393

E-20 Display of Engine Coolant Temperature Gauge is Different from Actual Coolant Temperature 40-1394

E-21 Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum 40-1395

E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature........40-1397

E-23 Some Areas of Machine Monitor Screen are Not Shown 40-1398

E-24 Function Switch Does Not Operate 40-1399

E-25 Automatic Warm-up System Does Not Operate (in Cold Weather) 40-1400

E-26 Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated 40-1401

E-27 Auto-Decelerator is Not Operated or Canceled with Lever 40-1402

E-28 Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated 40-1403

E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed40-1404

E-30 Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated 40-1405

E-31 Travel Speed Does Not Change Even When You Change Travel Speed

E-32 Alarm Buzzer Does Not Stop

E-33 Service Meter is Not Shown While Starting Switch is in OFF Position

E-34 Service Mode Cannot be Selected

E-35 All Work Equipment, Swing, Travel Do Not Operate

E-38 Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position 40-1417

E-39 While

E-62

E-63

E-66

E-67

E-79 When You Examine and Adjust the Bucket Edge Position, the Value is Different from Actual

E-80

E-81 Auto Grade Assist Control Does Not Operate While "Semi-auto limited digging mode" is

E-82 Auto Stop Control Does Not Operate While "Semi-Auto Mode" is Shown...........................40-1484

E-83 Blade Edge Position on Design Surface is Not Accurate When Auto Grade Assist

E-84 Blade Edge Stop Position is Not Accurate for Design Surface When Auto Stop Control Function is on

H-32

H-33

H-34

Abbreviation List

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

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

•Special abbreviations which appear infrequently are noted in the text.

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

List of Abbreviations Used in the Text

Abbreviation Actual word spelled out

ABSAntilock Brake System

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

Travel and brake

Explanation

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

AISS Automatic Idling Setting System Engine

AJSS Advanced Joystick Steering System

ARAC Automatic Retarder Accelerator Control

ARSC Automatic Retarder Speed Control

ASR Automatic Spin Regulator

ATTAttachment

BCV Brake cooling oil control valve

CANController Area Network

Steering

This is a function that automatically sets the idle speed.

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

Travel and brake

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

Travel and brake

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

Travel and brake

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

Work equipment

BRAKE

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

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

Communication and electronic control

CDR Crankcase Depression Regulator Engine

CLSS Closed-center Load Sensing System

Hydraulic system

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

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

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

Abbreviation List 00 Index and Foreword

Abbreviation

Actual word spelled out

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

CRICommon Rail InjectionEngine

ECM Electronic Control Module Electronic control system

Transmission

ECMV Electronic Control Modulation Valve

Explanation

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

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

This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch. (D, HD, WA, etc)

ECSS Electronically Controlled Suspension System Travel

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

ECUElectronic Control UnitElectronic control system

EGR Exhaust Gas Recirculation Engine

EMMS Equipment Management Monitoring System Machine monitor

EPC Electromagnetic Proportional Control Hydraulic system

FOPS Falling Object Protective Structure Cab and canopy

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

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

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

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

This structure protects the operator's head from falling objects. (Falling object protective structure)

This performance is standardized as ISO 3449.

F-N-R Forward-Neutral-Reverse Operation Forward - Neutral - Reverse

GPS Global Positioning System

GNSS Global Navigation Satellite System

Communication

(KOMTRAX, KOMTRAX Plus)

Communication

(KOMTRAX, KOMTRAX Plus)

Steering

HSS Hydrostatic Steering System

HST Hydro Static Transmission

This system uses satellites to determine the current location on the earth.

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

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

Transmission

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

Abbreviation Actual word spelled out

ICT Information and Communication Technology

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

Communication and electronic control

IMAInlet Metering ActuatorEngine

IMU Inertial Measurement Unit Engine

IMVInlet Metering ValveEngine

KCCV Komatsu Closed Crankcase Ventilation Engine

KCSF Komatsu Catalyzed Soot Filter Engine

KDOC Komatsu Diesel Oxidation Catalyst Engine

KDPF Komatsu Diesel Particulate Filter Engine

Travel and brake

KTCS Komatsu Traction Control System

(HM)

LCDLiquid Crystal DisplayMachine monitor

LEDLight Emitting DiodeElectronic parts

LIN Local Interconnect Network

Communication and electronic control

LSLoad Sensing Hydraulic system

LVDS Low Voltage Differential Signaling

Communication and electronic control

MAFMass Air Flow Engine

Explanation

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

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

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

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

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

This is a filter that captures soot in exhaust gas. It is built in to KDPF.

This is a catalyst that is used for purifying exhaust gas.

It is built in to KDPF or assembled with the muffler

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

It is installed instead of the conventional muffler.

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

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

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

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

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

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

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

Abbreviation List 00 Index and Foreword

Abbreviation Actual word spelled out

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

MMS Multimedia Messaging Service Communication

NCNormally Closed

NONormally Open

OLSS Open-center Load Sensing System

Electrical system, hydraulic system

Electrical system, hydraulic system

Hydraulic system

PCPressure CompensationHydraulic system

Steering

PCCS Palm command control system

Explanation

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

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

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

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

This is a function that corrects the oil pressure.

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

PCVPre-stroke Control ValveEngine

PPC Proportional Pressure Control

PPMPiston Pump and Motor

Hydraulic system

Hydraulic system

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

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

Piston type hydraulic pump and motor. (D, PC, etc)

PTOPower Take OffPower train systemPower take-off mechanism

PTP Power Tilt and power Pitch dozer

Work equipment

This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer (D Series)

ROPS Roll-Over Protective Structure Cab and canopy

SCR Selective Catalytic Reduction Urea SCR system

SI

Le Systeme International d' Unites (International unit system) Unit

SOLSolenoid

Electrical system

ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure)

This performance is standardized as ISO 3471 or ISO 12117-2.

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

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

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

Abbreviation Actual word spelled out

TOPS Tip-Over Protective Structure

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

Cab and canopy

TWV2-Way Valve

Hydraulic system

VGT Variable Geometry Turbocharger Engine

VHPC Variable Horse Power Control Engine control

*1: Code for applicable machine model

D: Bulldozer

HD: Dump truck

HM: Articulate dump truck

PC: Hydraulic excavator

WA: Wheel loader

Explanation

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

This performance is standardized as ISO 12117.

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

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

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

List of Abbreviations Used in the Circuit Diagrams

Abbreviation Actual word spelled out

A/CAir Conditioner

A/DAnalogue-to-Digital

A/MAir Mix Damper

ACCAccessory

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

Abbreviation List 00 Index and Foreword

Abbreviation

S/T Steering

STRG

SIGSignal

SOLSolenoid

STDStandard

OPT Option

OP

PRESSPressure

SPECSpecification

SWSwitch

TEMPTemperature

T/CTorque Converter

T/MTransmission

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 SPECIFICATIONS

This section describes the specifications of the machine.

10 STRUCTURE AND FUNCTION

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

20 STANDARD VALUE TABLE

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

30 TESTING AND ADJUSTING

This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.

40 TROUBLESHOOTING

This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.

50 DISASSEMBLY AND ASSEMBLY

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

60 MAINTENANCE STANDARD

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

80 THE OTHER INFORMATION

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

90 Circuit diagrams

This section describes hydraulic circuit diagrams and electrical circuit diagrams.

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

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.

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

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

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

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

Precautions for Preparatory Work

•Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving before adding oil or making any repairs.

•Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang “UNDER REPAIR” warning tag on them.

•When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.

•Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.

Precautions During Work

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

REMARK

Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type. For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.

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

REMARK

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

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

•When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.

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

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

•When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

•When removing a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.

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

•When removing piping, do not spill the fuel or oil. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.

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

•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 Never stand under the load.

k Do not move a load over a person.

k Never step on the load.

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

k The sling workers and assistant workers other than the guide must move to a place where they are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly.

•Check the slings before starting sling work.

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

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

•Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.

•Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.

k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident.

•Hanging angle must be 60 ° or smaller as a rule.

•When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook.

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 25 kg), use a hoist or crane.

REMARK

Weight of component whose weight is heavier than 25 kg is shown with symbol in “DISASSEMBLY AND ASSEMBLY”.

•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} )

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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

VALEO THERMAL SYSTEMS

ND-OIL8

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

Precautions to Prevent Fire

Fire Caused by Fuel, Oil, Coolant or Window Washer Fluid

Do not bring any open flame close to fuel, oil, coolant or window washer fluid. Always observe the following.

•Do not smoke or use any open flame near fuel or other flammable substances.

•Shut down the engine before adding fuel.

•Do not leave the machine when adding fuel or oil.

•Tighten all the fuel and oil caps securely.

•Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.

•After adding fuel or oil, wipe up any spilled fuel or oil.

•Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace.

•When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire.

•Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.

•Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.

•When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.

Fire Caused by Accumulated or Attached Flammable Objects

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

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

Fire Caused by Electrical System

Short circuits in the electrical system can cause fire. Always observe the following.

•Keep all the electric wiring connections clean and securely tightened.

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

Fire from Pipings

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

Fire Caused by High Temperature Exhaust Gas

Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).

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

•When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused by KDPF regeneration.

See the Operation and Maintenance Manual for the setting procedure.

Explosion Caused by Light

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

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

Procedures If Fire Occurs

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

•Use the handrails and steps to get off the machine.

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

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

Do not breathe the fumes.

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

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

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

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

Precautions When You Discard Waste Materials

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, batteries, and DEF.

Index and Foreword

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.

Procedures for Exhaust Gas Regulations

This machine conforms to either regulation of Tier4 Final (North America) or Stage IV (Europe).

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

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

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

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

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

DEF is the abbreviation for Diesel Exhaust Fluid.

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

About DEF

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

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

•In Europe, use AdBlue®

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

API Diesel Exhaust Fluid Certification Mark is the trade mark of API (American Petroleum Institute).

Precautions for DEF

General Character and Precautions for Handling

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

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

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

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

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

Precautions When You Add

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

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

Precautions for Storage

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

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

Precautions for Fire Hazard and Leakage

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

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

Other Precautions

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

Never use an iron or aluminum container when disposing DEF fluid, because toxic gas may develop and a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when handling the fluid waste of DEF.

Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.

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

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. Precautions When You Handle

00 Index and Foreword

REMARK

Precautions When You Handle Hydraulic Equipment

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 Disconnect and Connect Pipings

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

Precautions for Removal and Disassembly Work

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

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

•When draining oil, prepare a container with sufficient capacity.

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

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

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

•Check the thickness and number of shims when storing shims.

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

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

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

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

NOTICE

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

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

NOTICE

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

REMARK

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

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

Nomi nal No.

Bolt pitch (mm)Hose side Tube side O-ring (4)Bolt (5)Washer (6)

abFlange (1) Split flange (2) Sleeve head (3)

0438.117.507379-0040007371-3040007378-1040007000-1202101010-8082501643-50823

0542.919.807379-0050007371-3050007378-1050007000-1302201010-8083001643-50823

0647.622.207379-0064007371-3064007378-1060007000-1302507372-5103501643-51032

1052.426.207379-0104407371-3104907378-1100007000-1303207372-5103501643-51032

12

14

20

58.730.207379-0125007371-3125507378-1120007000-1303807372-5103501643-51032

66.731.807379-0126007371-5126007378-1121007000-1303801010-8124501643-51232

69.935.807379-0146007371-3146507378-1140007000-1304807372-5124001643-51232

79.436.507379-0147007371-5147007378-1141007000-1304801010-8145501643-31445

77.842.807379-0207107371-3207607378-1200007000-1206007372-5124001643-51232

96.844.507379-0208007371-5208007378-1201007000-1206001010-8186501643-31845

2488.950.807379-0248407371-1248407378-1240007000-1207007372-5124001643-51232

30106.46207379-0301007371-1301007378-1300007000-1208507372-5165001643-51645

34120.669.807379-0341107371-1341107378-1340007000-1210007372-5165001643-51645

40130.277.807379-0401207371-1401207378-1400007000-1211007372-5165001643-51645

50152.49207379-0501107371-1501107378-1500007000-1213507372-5165501643-51645

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

Index and Foreword Precautions When You Disconnect and Connect Pipings

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.

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

NOTICE

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

NOTICE

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

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

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

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

NOTICE

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

Precautions at the End Time of Work

Refilling of coolant or water or oil, greasing, and adding of DEF

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

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

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

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

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

Testing installed condition of cylinder heads and manifolds

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

•If there is any looseness, retighten the part.

REMARK

For the tightening torques, see “DISASSEMBLY AND ASSEMBLY”.

Test engine piping for damage and looseness

Intake and exhaust system

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

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

Cooling system

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

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

Fuel system

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

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

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

REMARK

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

•KDPF

•DEF mixing tube

•SCR assembly

•KDOC muffler

•Muffler

•Exhaust pipe

•KDPF & SCR Ass'y

•Parts which connects the above, or etc.

Precautions When You Disconnect and Connect Pipings

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

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

If there is any looseness, retighten the part.

Check of function of muffler in exhaust system

REMARK

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

•KDPF

•DEF mixing tube

•SCR assembly

•KDOC muffler

•Muffler

•Exhaust pipe

•KDPF & SCR Ass'y

•Parts which connects the above, or etc.

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

If there is any unusual noise, repair KDPF or muffler, referring to “TROUBLESHOOTING” and “DISASSEMBLY AND ASSEMBLY”.

Precautions When You Handle Electrical Equipment

To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical equipment”.

Handle Wiring Harnesses and Connectors

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

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

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

Main Causes of Failure in Wiring Harness

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

Defective crimping or soldering of connectors

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

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.

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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).

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

Connection

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

00 Index and Foreword

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.

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. Foreword,

How to Disconnect and Connect Slide Lock Type Connector

How to Disconnect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2)

1. Slide lock (L1) to the right.

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

REMARK

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

How to Connect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2)

Insert it straight until it clicks.

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

1. Slide down lock (red) (L1).

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

REMARK

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

How to Connect Slide Lock Type Connector (FRAMATOME-24)

Insert it straight until it clicks. Foreword, Safety,

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”.

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.

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 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

Dimensions

(Table 2)

Nominal No. 815203040506085100

Conductor

Conductor

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

GGreen

GBGreen and Black

GLGreen and Blue

GrGray

RRed

RBRed and Black

RGRed and Green

RLRed and Blue

RWRed and White

RYRed and Yellow 00 Index and Foreword

GRGreen and Red

Color Code

Color of wire

GWGreen and White

GYGreen and Yellow

LBlue

LBBlue and Black

LgLight green

LgBLight green and Black

LgRLight green and Red

REMARK

Color Code

SbSky Blue

YYellow

Color of wire

YBYellow and Black

YGYellow and Green

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-----RLightRWRBRYRGRL-O-

InstrumentYYRYBYGYL (*1)YW (*1)YGr

SignalGGWGRGYGBGL (*1)GBr

Others LLWLRLYLB-L-

BrBrW (*2)BrR (*2)BrY (*2)BrB (*2)---

LgLgR (*2)LgY (*1)LgB (*2)LgW (*1)--O (*1)------Gr------P------Sb------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.

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 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.

00 Index and Foreword

Explanation of Terms for Maintenance Standard

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

Standard Tightening Torque Table

Table of Tightening Torque for Bolts and Nuts

REMARK

Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.

Thread diameter (mm) Width across flats (mm)

6 10 11.8 to 14.7 {1.2 to 1.5} (*2) 10

to 34 {2.8 to 3.5} (*2) 12

{6 to 7.5} (*1, *2) 14

to 190 {15.5 to 19.5}

24

to 285 {23.5 to 29.5} (*1) 22 18 27 320 to 400 {33 to 41} 20 30 455 to 565 {46.5 to 58}

610 to 765 {62.5 to 78}

*1: Split flange bolt

*2: Flanged bolt

REMARK

Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in the table below. Standard Tightening Torque Table 00

2890 to 3630 {295 to 370}

Thread diameter (mm)

Width across flats (mm) Tightening torque (Nm {kgfm} ) 6 10 5.9 to 9.8 {0.6 to 1.0} 8 12 13.7 to 23.5 {1.4 to 2.4}

14 34.3 to 46.1 {3.5 to 4.7} 12 17 74.5 to 90.2 {7.6 to 9.2}

REMARK

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

Type of bolt

1/4-20UNC 9.8 to 14.7 {1 to 1.5}12.7 {1.3}2.9 to 3.9 {0.3 to 0.4}3.43 {0.35}

5/16-18UNC 24.5 to 34.3 {2.5 to 3.5}29.4 {3}6.9 to 8.8 {0.7 to 0.9}7.8 {0.8}

3/8-16UNC 44.1 to 58.8 {4.5 to 6}52.0 {5.3}9.8 to 14.7 {1 to 1.5}11.8 {1.2}

7/16-14UNC 73.5 to 98.1 {7.5 to 10}86.3 {8.8}19.6 to 24.5 {2 to 2.5}21.6 {2.2}

1/2-13UNC 108 to 147 {11 to 15}127 {13}29.4 to 39.2 {3 to 4}34.3 {3.5}

9/16-12UNC 157 to 216 {16 to 22}186 {19}44.1 to 58.8 {4.5 to 6}51.0 {5.2}

5/8-11UNC 226 to 294 {23 to 30}265 {27}63.7 to 83.4 {6.5 to 8.5}68.6 {7}

3/4-10UNC 392 to 530 {40 to 54}461 {47}108 to 147 {11 to 15}127 {13}

7/8-9UNC 637 to 853 {65 to 87}745 {76}177 to 235 {18 to 24}206 {21}

Type of bolt

Nominal sizethreads per inch Tightening torque (Nm {kgfm} ) Tightening torque (Nm {kgfm} )

1-8UNC 883 to 1196 {90 to 122}1040 {106}245 to 333 {25 to 34}284 {29}

11/8-7UNC 1187 to 1608 {121 to 164}1393 {142}333 to 451 {34 to 46}392 {40}

11/4-7UNC 1598 to 2157 {163 to 220}1873 {191}451 to 608 {46 to 62}530 {54}

11/2-6UNC 2354 to 3177 {240 to 324}2765 {282}657 to 892 {67 to 91}775 {79}

REMARK

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

Type of bolt

1/4-28UNF 14.7 to 19.6 {1.5 to 2}17.7 {1.8}3.9 to 4.9 {0.4 to 0.5}4.41 {0.45}

5/16-24UNF 34.3 to 39.2 {3.5 to 4}34.3 {3.5}7.8 to 9.8 {0.8 to 1}8.8 {0.9}

3/8-24UNF 53.9 to 68.6 {5.5 to 7}61.8 {6.3}14.7 to 19.6 {1.5 to 2}16.7 {1.7}

7/16-20UNF 83.4 to 108 {8.5 to 11}96.1 {9.8}24.5 to 29.4 {2.5 to 3}26.5 {2.7}

1/2-20UNF 127 to 167 {13 to 17}147 {15}34.3 to 49.0 {3.5 to 5}41.2 {4.2}

9/16-18UNF 186 to 245 {19 to 25}216 {22}49.0 to 68.6 {5 to 7}58.8 {6}

5/8-18UNF 255 to 343 {26 to 35}294 {30}73.5 to 98.1 {7.5 to 10}83.4 {8.5}

3/4-16UNF 441 to 598 {45 to 61}520 {53}127 to 167 {13 to 17}147 {15}

7/8-14UNF 716 to 961 {73 to 98}843 {86}196 to 265 {20 to 27}226 {23}

1-14UNF1020 to 1373 {104 to 140}1196 {122}284 to 382 {29 to 39}333 {34}

11/8-12UNF 1353 to 1844 {138 to 188}1598 {163}382 to 520 {39 to 53}451 {46}

11/4-12UNF 1804 to 2432 {184 to 248}2118 {216}510 to 686 {52 to 70}598 {61}

11/2-12UNF 2707 to 3658 {276 to 373}3177 {324}765 to 1030 {78 to 105}892 {91}

Table of Tightening Torque for O-Ring Boss Piping Joints

REMARK

Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.

0420

0624

1233

depending on type of connector

Table of Tightening Torque for O-Ring Boss Plugs

REMARK

Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.

Standard Tightening Torque Table

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).

to 63 {3.5 to 6.5}44 {4.5}14

0532128 to 186 {13.0 to 19.0}157 {16.0}241 -14UNS25.4 0636177 to 245 {18.0 to 25.0}216 {22.0}30

(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 36.5 (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.

diameter of adequate pipe (mm)

Tightening Torque Table for Bolts and Nuts on 102, 107 and 114 Series Engines

REMARK

Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table unless otherwise specified.

{1.02±0.20}

{2.45±0.41}

{4.38±0.61}

{7.85±1.22}

Tightening Torque Table for 102, 107, and 114 Series Engines (Joint Bolts)

REMARK

Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following table unless otherwise specified.

Thread diameter (mm) Tightening torque (Nm {kgfm} )

6 8±2 {0.81±0.20} 8 10±2 {1.02±0.20} 10 12±2 {1.22±0.20}

24±4 {2.45±0.41} 14 36±5 {3.67±0.51}

Tightening Torque Table for Tapered Screws on 102, 107, and 114 Series Engines (National Taper Pipe Thread (NPT))

REMARK

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

Material of female screw In cast iron or steel In aluminum

Nominal thread size Tightening torque (Nm {kgfm} )Tightening torque (Nm {kgfm} )

1/16 15±2 {1.53±0.20}

{0.51±0.10} 1/8

{2.04±0.20}

{4.59±0.51} Standard Tightening Torque Table 00 Index and Foreword

{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}

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Conversion Table

How to Use the Conversion Table

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

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

in.

When converting 55 mm to in

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

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

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

When converting 550 mm to in

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

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

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

1 mm = 0.03937 in

401.5751.6141.6541.6931.7321.7721.8111.8501.8901.929

501.9692.0082.0172.0872.126

702.7562.7952.8352.8472.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.701

000.0390.0790.1180.1570.1970.2360.2760.3150.354

1 mm = 0.03937 in 0123456789

602.3622.4022.4412.4802.5202.5592.5982.6382.6772.717 702.7562.7952.8352.8472.9132.9532.9923.0323.0713.110 803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898

kg to lb

1 kg = 2.2046 lb 0123456789 002.204.416.618.8211.0213.2315.4317.6419.84 1022.0524.2526.4628.6630.8633.0735.2737.4839.6841.89 2044.0946.3048.5050.7151.9155.1257.3259.5361.7363.93 3066.1468.3470.5572.7574.9677.1679.3781.5783.7885.98 4088.1890.3992.5994.8097.0099.21101.41103.62105.82108.03 50110.23112.44114.64116.85119.05121.25123.46125.66127.87130.07 60132.28134.48136.69138.89141.10143.30145.51147.71149.91152.12 70154.32156.53158.73160.94163.14165.35167.55169.76171.96174.17 80176.37178.57180.78182.98185.19187.39189.60191.80194.01196.21 90198.42200.62202.83205.03207.24209.44211.64213.85216.05218.26 ℓ to U.S.Gal

0123456789

000.2640.5280.7931.0571.3211.5851.8492.1132.378 102.6422.9063.1703.4343.6983.9634.2274.4914.7555.019 205.2835.5485.8126.0766.3406.6046.8697.1337.3977.661 307.9258.1898.4548.7188.9829.2469.5109.77410.03910.303 4010.56710.83111.09511.35911.62411.88812.15212.41612.68012.944 5013.20913.47313.73714.00114.26514.52914.79515.05815.32215.586 6015.85016.11516.37916.64316.90717.17117.43517.70017.96418.228 7018.49218.75619.02019.28519.54919.81320.07720.34120.60520.870 8021.13421.39821.66221.92622.19022.45522.71922.98323.24723.511 9023.77524.04024.30424.56824.83225.09625.36125.62525.88926.153

to U.K.Gal

1 ℓ = 0.21997 U.K.Gal 0123456789

000.2200.4400.6600.8801.1001.3201.5401.7601.980 102.2002.4202.6402.8603.0803.3003.5203.7403.9504.179 204.3994.6194.8395.0595.2795.4995.7195.9396.1596.379

306.5996.8197.0397.2597.4797.6997.9198.1398.3598.579 408.7999.0199.2399.4599.6799.89910.11910.33910.55910.778 5010.99811.28111.43811.65811.87812.09812.31812.52812.75812.978 6013.19813.41813.63813.85814.07814.29814.51814.73814.95815.178 7015.39815.61815.83816.05816.27816.49816.71816.93817.15817.378 8017.59817.81818.03718.25718.47718.69718.91719.13719.35719.577 9019.79720.01720.23720.45720.67720.89721.11721.33721.55721.777 kgfm to

007.214.521.728.936.243.450.657.965.1 1072.379.686.894.0101.3108.5115.7123.0130.2137.4 20144.7151.9159.1166.4173.6180.8188.1195.3202.5209.8 30217.0224.2231.5238.7245.9253.2260.4267.6274.9282.1 40289.3296.6303.8311.0318.3325.5332.7340.0347.2354.4 50361.7368.9376.1383.4390.6397.8405.1412.3419.5426.8 60434.0441.2448.5455.7462.9470.2477.4484.6491.8499.1 70506.3513.5520.8528.0535.2542.5549.7556.9564.2571.4 80578.6585.9593.1600.3607.6614.8622.0629.3636.5643.7 90651.0658.2665.4672.7679.9687.1694.4701.6708.8716.1 100723.3730.5737.8745.0752.2759.5766.7773.9781.2788.4 110795.6802.9810.1817.3824.6831.8839.0846.3853.5860.7 120868.0875.2882.4889.7896.9904.1911.4918.6925.8933.1 130940.3947.5954.8962.0969.2976.5983.7990.9998.21005.4 1401012.61019.91027.11034.31041.51048.81056.01063.21070.51077.7 1501084.91092.21099.41106.61113.91121.11128.31135.61142.81150.0 1601157.31164.51171.71179.01186.21193.41200.71207.91215.11222.4 1701129.61236.81244.11251.31258.51265.81273.01280.11287.51294.7 1801301.91309.21316.41323.61330.91338.11345.31352.61359.81367.0 1901374.31381.51388.71396.01403.21410.41417.71424.91432.11439.4

0014.228.442.756.971.185.399.6113.8128.0 10142.2156.5170.7184.9199.1213.4227.6241.8256.0270.2 20284.5298.7312.9327.1341.4355.6369.8384.0398.3412.5

1 kgf/cm2 = 14.2233 lb/in2 0123456789

30426.7440.9455.1469.4483.6497.8512.0526.3540.5554.7 40568.9583.2597.4611.6625.8640.1654.3668.5682.7696.9 50711.2725.4739.6753.8768.1782.3796.5810.7825.0839.2 60853.4867.6881.8896.1910.3924.5938.7953.0967.2981.4 70995.6101010241038105310671081109511091124 801138115211661181119512091223123712521266 901280129413091323133713511365138013941408 1001422143714511465147914931508152215361550 1101565157915931607162116361650166416781693 1201707172117351749176417781792180618211835 1301849186318771892190619201934194919631977 1401991200520202034204820622077209121052119 1502134214821622176219022052219223322472262 1602276229023042318233323472361237523892404 1702418243224462460247524892503251825322546

Temperature

Conversion of Fahrenheit to Celsius

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

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

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

-37.2-35-31.0-11.11253.68.347116.627.882179.6 -34.4-30-22.0-10.61355.48.948118.428.383181.4 -31.7-25-13.0-10.01457.29.449120.228.984183.2 -28.9-20-4.0-9.41559.010.050122.029.485185.0 -28.3-19-2.2-8.91660.810.651123.830.086186.8

-27.8-18-0.4-8.31762.611.152125.630.687188.6 -27.2-171.4-7.81864.411.753127.431.188190.4 -26.7-163.2-7.21966.212.254129.231.789192.2 -26.1-155.0-6.72068.012.855131.032.290194.0 -25.6-146.8-6.12169.813.356132.832.891195.8 -25.0-138.6-5.62271.613.957134.633.392197.6 -24.4-1210.4-5.02373.414.458136.433.993199.4 -23.9-1112.2-4.42475.215.059138.234.494201.2 -23.3-1014.0-3.92577.015.660140.035.095203.0 -22.8-915.8-3.32678.816.161141.835.696204.8 -22.2-817.6-2.82780.616.762143.636.197206.6 -21.7-719.4-2.22882.417.263145.436.798208.4 -21.1-621.2-1.72984.217.864147.237.299210.2 -20.6-523.0-1.13086.018.365149.037.8100212.0 -20.0-424.8-0.63187.818.966150.840.6105221.0 -19.4-326.603289.619.467152.643.3110230.0 -18.9-228.40.63391.420.068154.446.1115239.0 -18.3-130.21.13493.220.669156.248.9120248.0 -17.8032.01.73595.021.170158.051.7125257.0 -17.2133.82.23696.821.771159.854.4130266.0 -16.7235.62.83798.622.272161.657.2135275.0 -16.1337.43.338100.422.873163.460.0140284.0 -15.6439.23.939102.223.374165.262.7145293.0 -15.0541.04.440104.023.975167.065.6150302.0 -14.4642.85.041105.824.476168.868.3155311.0 -13.9744.65.642107.625.077170.671.1160320.0 -13.3846.46.143109.425.678172.473.9165329.0 -12.8948.26.744111.226.179174.276.7170338.0 -12.21050.07.245113.026.780176.079.4175347.0

01 Specification

Abbreviation List

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

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

•Special abbreviations which appear infrequently are noted in the text.

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

List of Abbreviations Used in the Text

Abbreviation Actual word spelled out

ABSAntilock Brake System

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

Travel and brake

Explanation

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

AISS Automatic Idling Setting System Engine

AJSS Advanced Joystick Steering System

ARAC Automatic Retarder Accelerator Control

ARSC Automatic Retarder Speed Control

ASR Automatic Spin Regulator

ATTAttachment

BCV Brake cooling oil control valve

CANController Area Network

Steering

This is a function that automatically sets the idle speed.

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

Travel and brake

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

Travel and brake

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

Travel and brake

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

Work equipment

BRAKE

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

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

Communication and electronic control

CDR Crankcase Depression Regulator Engine

CLSS Closed-center Load Sensing System

Hydraulic system

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

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

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

Abbreviation

Actual word spelled out

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

CRICommon Rail InjectionEngine

ECM Electronic Control Module Electronic control system

Transmission

ECMV Electronic Control Modulation Valve

Explanation

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

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

This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch. (D, HD, WA, etc)

ECSS Electronically Controlled Suspension System Travel

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

ECUElectronic Control UnitElectronic control system

EGR Exhaust Gas Recirculation Engine

EMMS Equipment Management Monitoring System Machine monitor

EPC Electromagnetic Proportional Control Hydraulic system

FOPS Falling Object Protective Structure Cab and canopy

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

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

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

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

This structure protects the operator's head from falling objects. (Falling object protective structure)

This performance is standardized as ISO 3449.

F-N-R Forward-Neutral-Reverse Operation Forward - Neutral - Reverse

GPS Global Positioning System

GNSS Global Navigation Satellite System

Communication

(KOMTRAX, KOMTRAX Plus)

Communication

(KOMTRAX, KOMTRAX Plus)

Steering

HSS Hydrostatic Steering System

HST Hydro Static Transmission

This system uses satellites to determine the current location on the earth.

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

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

Transmission

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

Abbreviation Actual word spelled out

ICT Information and Communication Technology

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

Communication and electronic control

IMAInlet Metering ActuatorEngine

IMU Inertial Measurement Unit Engine

IMVInlet Metering ValveEngine

KCCV Komatsu Closed Crankcase Ventilation Engine

KCSF Komatsu Catalyzed Soot Filter Engine

KDOC Komatsu Diesel Oxidation Catalyst Engine

KDPF Komatsu Diesel Particulate Filter Engine

Travel and brake

KTCS Komatsu Traction Control System

(HM)

LCDLiquid Crystal DisplayMachine monitor

LEDLight Emitting DiodeElectronic parts

LIN Local Interconnect Network

Communication and electronic control

LSLoad Sensing Hydraulic system

LVDS Low Voltage Differential Signaling

Communication and electronic control

MAFMass Air Flow Engine

Explanation

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

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

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

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

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

This is a filter that captures soot in exhaust gas. It is built in to KDPF.

This is a catalyst that is used for purifying exhaust gas.

It is built in to KDPF or assembled with the muffler

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

It is installed instead of the conventional muffler.

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

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

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

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

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

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

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

Abbreviation Actual word spelled out

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

MMS Multimedia Messaging Service Communication

NCNormally Closed

NONormally Open

OLSS Open-center Load Sensing System

Electrical system, hydraulic system

Electrical system, hydraulic system

Hydraulic system

PCPressure CompensationHydraulic system

Steering

PCCS Palm command control system

Explanation

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

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

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

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

This is a function that corrects the oil pressure.

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

PCVPre-stroke Control ValveEngine

PPC Proportional Pressure Control

PPMPiston Pump and Motor

Hydraulic system

Hydraulic system

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

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

Piston type hydraulic pump and motor. (D, PC, etc)

PTOPower Take OffPower train systemPower take-off mechanism

PTP Power Tilt and power Pitch dozer

Work equipment

This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer (D Series)

ROPS Roll-Over Protective Structure Cab and canopy

SCR Selective Catalytic Reduction Urea SCR system

SI

Le Systeme International d' Unites (International unit system) Unit

SOLSolenoid

Electrical system

ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure)

This performance is standardized as ISO 3471 or ISO 12117-2.

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

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

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

Abbreviation Actual word spelled out

TOPS Tip-Over Protective Structure

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

Cab and canopy

TWV2-Way Valve

Hydraulic system

VGT Variable Geometry Turbocharger Engine

VHPC Variable Horse Power Control Engine control

*1: Code for applicable machine model

D: Bulldozer

HD: Dump truck

HM: Articulate dump truck

PC: Hydraulic excavator

WA: Wheel loader

Explanation

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

This performance is standardized as ISO 12117.

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

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

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

List of Abbreviations Used in the Circuit Diagrams

Abbreviation Actual word spelled out

A/CAir Conditioner

A/DAnalogue-to-Digital

A/MAir Mix Damper

ACCAccessory

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

Abbreviation

S/T Steering

STRG

SIGSignal

SOLSolenoid

STDStandard

OPT Option

OP

PRESSPressure

SPECSpecification

SWSwitch

TEMPTemperature

T/CTorque Converter

T/MTransmission

Specifications

Specification Drawing

Specification Drawing: PC210LCI-11

Engine model - Komatsu SAA6D107E-3 diesel engine

Rated horsepower

• SAE J1995 (gross)

• ISO 14396

• ISO 9249/SAE J1349 (net) kW{HP}/ min-1{rpm}

123 {165} /2000 {2000}

123 {165} /2000 {2000}

123 {165} /2000 {2000}

AOverall length mm 9700

BOverall height (including head guard) mm 2970

C Overall width mm For north america 3080 For european union 2980

D Shoe width mm For north america 700 For european union 600

E Cab

REMARK

The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on a machine.

Working Range Drawings

Working Range Drawings: PC210LCI-11

Specifications

Specification: PC210LCI-11

Performance

Working ranges

Max. digging depth

Max. vertical wall digging depth

Max. digging reach

Max. digging reach at ground level

Max. digging height

Max. dumping height

Max. digging force (When one-touch power maximizing function operates)

Continuous swing speed

Swing operation max. slope angle

(Lo/Mi/Hi)

Gradeability

Ground pressure (standard shoe)

Dimensions

(for transport) (*1)

Min. ground clearance

Min. swing radius of work equipment

Max. height of work equipment in min. swing radius posture

Overall width of track

Overall length of the track

Distance between tumbler centers

Machine cab height

Width of standard shoe

Engine

Model - SAA6D107E–3

Type4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and air-cooled aftercooler

No. of cylinders - bore x stroke mm

6-107 x 124

Total piston displacement ℓ{cc} 6.69 {6690}

Performance

Rated horsepower

• SAE J1995 (gross)

• ISO 14396

• ISO 9249/SAE J1349 (net)

Max. torque

Max. speed with no load

kW{HP}/ min-1{rpm}

123 {165}/ 2000 {2000}

123 {165}/ 2000 {2000}

123 {165}/ 2000 {2000}

Nm{kgfm}/ min-1{rpm} 729 to 74.3 {1500 to 1500}

• (when mounted on machine) min-1{rpm} 1850±50{1850±50}

• At basic engine 2060±50{2060±50}

Min. speed with no load min-1{rpm} 1050±25{1050±25}

Min. fuel consumption ratio g/kWh{g/HPh} 217.5{160}

Starting motor - 24 V, 5.5 kW

Alternator - 24 V, 90 A

Battery (*2) - 12 V, 140Ah x 2 pcs.

Radiator type - CF90-4

*1: Including grouser height (26 mm)

*2: The battery capacity (Ah) is indicated in the 5-hour rate.

REMARK

The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on a machine.

Undercarriage

Carrier roller -2 on one side

Track roller -9 on one side

Track shoeAssembly type triple grouser shoe, 49 pieces on each side

Hydraulic system

Hydraulic pump

Type x quantityVariable displacement piston type (HPV125 + 125) x 2 pcs.

Discharged volume ℓ/min

Set pressure

Control valve

2}

x 2

{380}

Machine

Type x quantity -7-spool type x 1 pc.

Operating method -Hydraulic

Travel motorVariable displacement piston type (HMV120-2) x 2 pcs. (with brake valve and parking brake)

Swing motorfixed displacement piston type (KMF125ABE-6) x 1 piece (with safety valve and parking brake)

Boom cylinder (*3)

Type -Double-acting piston type

Cylinder bore mm 130

Piston rod diameter mm 90

Stroke mm 1335

Max. distance between pins mm 3205

Min. distance between pins mm 1870

Arm cylinder (*4)

Type -Double-acting piston type

Cylinder bore mm 135

Piston rod diameter mm 95

Stroke mm 1490

Max. distance between pins mm 3565

Min. distance between pins mm 2075

Bucket cylinder

Type -Double-acting piston type

Cylinder bore mm 115

Piston rod diameter mm 80

Stroke mm 1105

Max. distance between pins mm 2800

Min. distance between pins mm 1695

Hydraulic tank: -Box-shaped sealed type

Hydraulic oil filter -Tank return side

Hydraulic oil cooler -Air-cooled type (thickness : 62)

*3: With cushion on head side.

Weight Table

Weight Table: PC210LCI-11

k This weight table is provided for your reference for when handling the components or when transporting.

k This weight table shows the dry weight.

Track shoe assembly For north america

Triple grouser shoe (700 mm)

Triple grouser shoe (800 mm)

Triple grouser shoe (900 mm)

For european union Triple grouser shoe (600 mm)

Table of Fuel, Coolant, and Lubricants

For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual.

10 Structure and Function

Table of Contents

Abbreviation List

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

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

•Special abbreviations which appear infrequently are noted in the text.

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

List of Abbreviations Used in the Text

Abbreviation

Actual word spelled out

ABSAntilock Brake System

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

Travel and brake

Explanation

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

AISS Automatic Idling Setting System Engine

AJSS Advanced Joystick Steering System

ARAC Automatic Retarder Accelerator Control

ARSC Automatic Retarder Speed Control

ASR Automatic Spin Regulator

ATTAttachment

BCV Brake cooling oil control valve

CANController Area Network

Steering

This is a function that automatically sets the idle speed.

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

Travel and brake

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

Travel and brake

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

Travel and brake

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

Work equipment

BRAKE

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

Communication and electronic control

CDR Crankcase Depression Regulator Engine

CLSS Closed-center Load Sensing System Hydraulic system

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

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

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

This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS). Abbreviation List 10 Structure and Function

Abbreviation Actual word spelled out

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

CRICommon Rail InjectionEngine

ECM Electronic Control Module

ECMV Electronic Control Modulation Valve

ECSS Electronically Controlled Suspension System

Electronic control system

Transmission

Explanation

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

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

This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch. (D, HD, WA, etc)

Travel

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

ECUElectronic Control UnitElectronic control system

EGR Exhaust Gas Recirculation Engine

EMMS Equipment Management Monitoring System Machine monitor

EPC Electromagnetic Proportional Control Hydraulic system

FOPS Falling Object Protective Structure Cab and canopy

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

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

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

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

This structure protects the operator's head from falling objects. (Falling object protective structure)

This performance is standardized as ISO 3449.

F-N-R Forward-Neutral-Reverse Operation Forward - Neutral - Reverse

GPS Global Positioning System

GNSS Global Navigation Satellite System

Communication

(KOMTRAX, KOMTRAX Plus)

Communication

(KOMTRAX, KOMTRAX Plus)

Steering

HSS Hydrostatic Steering System

HST Hydro Static Transmission

This system uses satellites to determine the current location on the earth.

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

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

Transmission

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

Abbreviation Actual word spelled out

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

ICT Information and Communication Technology Communication and electronic control

IMAInlet Metering ActuatorEngine

IMU Inertial Measurement Unit Engine

IMVInlet Metering ValveEngine

KCCV Komatsu Closed Crankcase Ventilation Engine

KCSF Komatsu Catalyzed Soot Filter Engine

KDOC Komatsu Diesel Oxidation Catalyst Engine

KDPF Komatsu Diesel Particulate Filter Engine

Travel and brake

KTCS Komatsu Traction Control System

Explanation

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

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

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

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

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

This is a filter that captures soot in exhaust gas. It is built in to KDPF.

This is a catalyst that is used for purifying exhaust gas.

It is built in to KDPF or assembled with the muffler

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

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

LCDLiquid Crystal DisplayMachine monitor

LEDLight Emitting DiodeElectronic parts

LIN Local Interconnect Network Communication and electronic control

LSLoad Sensing Hydraulic system

LVDS Low Voltage Differential Signaling Communication and electronic control

MAFMass Air Flow Engine

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

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

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

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

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

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

Abbreviation Actual word spelled out

MMS Multimedia Messaging Service

NCNormally Closed

NONormally Open

OLSS Open-center Load Sensing System

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

Communication

Electrical system, hydraulic system

Electrical system, hydraulic system

Hydraulic system

PCPressure CompensationHydraulic system

Steering

PCCS Palm command control system

Explanation

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

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

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

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

This is a function that corrects the oil pressure.

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

PCVPre-stroke Control ValveEngine

PPC Proportional Pressure Control

PPMPiston Pump and Motor

Hydraulic system

Hydraulic system

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

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

Piston type hydraulic pump and motor. (D, PC, etc)

PTOPower Take OffPower train systemPower take-off mechanism

PTP Power Tilt and power Pitch dozer

ROPS Roll-Over Protective Structure

Work equipment

This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer (D Series)

SCR Selective Catalytic Reduction

Cab and canopy

Urea SCR system

SI Le Systeme International d' Unites (International unit system) Unit

SOLSolenoid

Electrical system

ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure)

This performance is standardized as ISO 3471 or ISO 12117-2.

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

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

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

Abbreviation List 10 Structure and Function

Abbreviation Actual word spelled out

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

TOPS Tip-Over Protective Structure Cab and canopy

TWV2-Way Valve Hydraulic system

VGT Variable Geometry Turbocharger Engine

VHPC Variable Horse Power Control Engine control

*1: Code for applicable machine model

D: Bulldozer

HD: Dump truck

HM: Articulate dump truck

PC: Hydraulic excavator

WA: Wheel loader

Explanation

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

This performance is standardized as ISO 12117.

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

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

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

List of Abbreviations Used in the Circuit Diagrams

Abbreviation Actual word spelled out

A/CAir Conditioner

A/DAnalogue-to-Digital

A/MAir Mix Damper

ACCAccessory

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

Abbreviation

S/T Steering

STRG

SIGSignal

SOLSolenoid

STDStandard

OPT Option

OP

PRESSPressure

SPECSpecification

SWSwitch

TEMPTemperature

T/CTorque Converter

T/MTransmission

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Urea SCR System

SCR

Abbreviation for Selective Catalytic Reduction Urea

Layout Drawing of Urea SCR System

1: DEF filler port

2: DEF tank coolant outlet hose

3: DEF return hose

4: DEF tank

5: DEF tank pressure hose (low temperature side)

6: DEF pump

7: DEF suction hose

8: DEF tank coolant inlet hose

9: DEF pressure hose (high-temperature side)

10: DEF tank heating valve

11: KDPF

12: DEF mixing tube

Layout Drawing of Urea SCR System

Structure and Function Layout Drawing of

13: SCR assembly

14: DEF injector coolant hose

15: DEF injector

16: Ambient temperature sensor

17: Engine room temperature sensor

Detailed Drawing of SCR Assembly

1: SCR outlet NOx sensor

2. SCR outlet temperature sensor

3: Turbocharger outlet NOx sensor

4: Ammonia sensor

5: SCR temperature sensor

Detailed Drawing of DEF Tank

1: DEF tank sensor

Urea SCR System Diagram

A: Coolant inlet

1: Mass air flow and temperature sensor

2: Engine

3: Engine controller

4: KDPF assembly

5: KDOC unit

6: KCSF unit

7: KDPF differential pressure sensor

8: KDPF outlet pressure sensor

9: Turbocharger outlet NOx sensor

10: Turbocharger outlet NOx sensor controller

11: KDOC inlet temperature sensor

12: KDOC outlet temperature sensor

13: KDPF outlet temperature sensor

14: KDPF temperature sensor controller

15: DEF mixing tube

16: DEF injector

17: SCR assembly

18: Upstream SCR catalyst

19: Downstream SCR catalyst and ammonia oxidation catalyst (integrated type)

20: Ammonia sensor

B: Coolant outlet

21: Ammonia sensor controller

22: SCR temperature sensor

23: SCR outlet temperature sensor

24: SCR temperature sensor controller

25: SCR outlet NOx sensor

26: SCR outlet NOx sensor controller

27: Smart sensor

28: Ambient temperature sensor

29: Engine room temperature sensor

30: DEF system

31: DEF tank heating valve

32: DEF tank

33: DEF tank sensor

34: DEF suction line

35: DEF return line

36: DEF pressure line

37: DEF pump

38: DEF line heater relay

39: Machine monitor

Function of Urea SCR System

1: Engine

2: Engine controller

3: DEF pump

4: DEF tank

5: DEF injector

6: KDPF

7: SCR catalyst

8: Ammonia oxidation catalyst

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

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

Function of DEF System

1: DEF tank

2: DEF suction hose

3: DEF pump

3A: Flow control valve

3B: Pump

3C: DEF filter

3D: Pressure sensor

4: DEF return hose

5: DEF pressure hose

6: DEF injector

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

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

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

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

Function of DEF injection system

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

Function

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

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

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

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

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

Function of purge system

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

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

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

NOTICE

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

Function of heating system

•The DEF heating system has two operation modes.

•One operation mode is “Thaw mode”.

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

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

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

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

•While the heating is on during machine operation if the Engine Controller judges that cooling by the ambient exceeds the heating capacity of the system, it automatically starts DEF purging and shuts down the operation of the DEF pump and the DEF injector. However, the heating system is kept on as long as the machine is in operation.

•“Thaw mode” and “Freeze Prevention mode” are controlled by utilizing information by temperature sensors. The temperature sensors used for the control of two modes are different and the temperature Freeze Prevention modesensors utilized by the comprising devices are different. The following table shows which

comprising device uses which heating system and which temperature sensors in relation to which operation mode.

Heating system Thawing modeFreeze prevention mode

DEF suction and purge hose

DEF pressure hose (low-temperature side)

DEF pressure hose (high-temperature side)

DEF pump

DEF tank

Inducement Strategy

Heater around hose

Ambient temperature sensor

Ambient temperature sensor

Heater around hose Engine room temperature sensor Engine room temperature sensor

Pump built-in heater

Circulation of coolant

pump temperature sensor

tank temperature sensor

temperature sensor

tank temperature sensor

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

•Inducement strategy is a control action to ensure prompt correction of various failures in the engine emissions control system. It requires actions to limit engine performance and defines required indication such as warning lamps and messages, as well as alarms while the control actions are imposed. The warning steps of Inducement are different for North America and for European Union.

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

Inducement Strategy When the DEF Level in the Tank Becomes Low (For North America)

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

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

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

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

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

DEF level (*1)

Status

(DEF level gauge)

1Warning 10% (The bottom two gradations light on)

Message of SCR Information

1: DEF low level warning appears.

Machine monitor

DEF level caution lamp (Action level)

Red

Tone of audible alert Activated failure code (*2)

No sound CA3497 (DEF level low error 1)

Engine deration (*3)

No deration

Function of Urea SCR System

Status

2 Escalated Warning (Warning 2)

DEF level (*1) (DEF level gauge)

5%

(Within the gradation of the second from the bottom )

3 Mild Inducement (Inducement 1) 2.5%

(The gradation of the end of the bottom lights on)

Message of SCR Information

2: Without treatment, engine power will be derated.

Machine monitor

DEF level caution lamp (Action level)

Red

Red

3: Engine power is under deration.

Tone of audible alert

Activated failure code (*2)

Triplet (*4)

Short intermittently (*5)

CA3498 (DEF level low error 2)

Engine deration (*3)

4

5

Severe Inducement (Inducement 2)

0% (All gradations lights off)

4: Engine power is under heavy deration.

Final Inducement (Inducement 3)

Not remaining in the tank (*6) (All gradations lights off)

5: Engine is running at low idle.

No deration

Long intermittently

Red

Red

Red

Continuously

CA1673 (DEF level low error 3)

Torque: over 25% Red

CA1673

CA3547 (DEF level low error 4)

Torque: 50% and RPM: 40%

CA1673

Continuously

Engine speed is fixed to low idle Red

*1: It is shown the value of Monitoring ID 19111: “DEF Level Corrected”.

CA3547 AS00ZK (DEF level low error 5)

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. For the failure codes, see TROUBLESHOOTING, “Troubleshooting Points for Urea SCR System”.

*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed.

*4: Construction equipment with crawler

*5: Construction equipment with wheel

*6: After progressed “Severe Inducement” the status advances to “Final Inducement” with in 1 hour.

Inducement Strategy When Abnormality is Found in the Urea SCR System Devices (For North America)

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

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

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

Machine monitor

Status

Elapsed time (*1)

1Warning1 hour

Message of SCR Information

Caution lamp (Action level)

Tone of audible alert

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

2 Escalated Warning (Warning 2) 2 hours

1: Please inspect and maintain SCR system. Yellow No sound

CA3571

CB3571 No indicationNo deration Yellow

2: Without treatment, engine power will be derated. Yellow

Triplet (*6)

AS00R2 (Warning 2 (SCR Device Abnormality)) No deration Yellow

Short intermittently (*7)

CA3571 CB3571

3 Mild Inducement (Inducement 1) 3 hours

3: Engine power is under deration. Red

Long intermittently

CA3571 CB3571

AS00R3 (Inducement 1(SCR Device Abnormality))

Torque: over 25% Red

Status

Elapsed time (*1)

4 Severe Inducement (Inducement 2) 4 hours

Message of SCR Information

Caution lamp (Action level)

Red

4: Engine power is under heavy deration.

Red

Red

Machine monitor

Tone of audible alert

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

Continuously

CA3571 CB3571

AS00R4 (Inducement 2 (SCR Device Abnormality))

Torque: 50% and RPM: 40%

5 Final Inducement (Inducement 3)

Until repairing 5: Engine is running at low idle.

Continuously

CA3571 CB3571

Engine speed is fixed to low idle Red

AS00R5 (Inducement 3 (SCR Device Abnormality))

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning”stage. Final Inducement is not cleared till abnormality is repaired.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. The failure code shown here is an example of failure code which is displayed on the machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “Troubleshooting Points for Urea SCR System”.

*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines.

*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode.

*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed.

*6: Construction equipment with crawler

*7: Construction equipment with wheel

Inducement Strategy When Abnormality is Found in the KDPF System by the Urea SCR System (For North America)

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

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

Status Elapsed time (*1)

1Warning1 hour

Message of SCR Information

Caution lamp (Action level)

1: Please inspect and maintain SCR system. Red

Machine monitor

Tone of audible alert

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

2 Escalated Warning (Warning 2) 2 hours

2: Without treatment, engine power will be derated.

3 Mild Inducement (Inducement 1) 3 hours

3: Engine power is under deration.

Long intermittently

CA4151 CB4151 No indication

Torque: over 25% Red

Triplet (*6)

Short intermittently (*7)

Long intermittently

CA4151 CB4151

CA4151 CB4151

AS00R2 (Warning 2 (SCR Device Abnormality))

Torque: over 25%

AS00R3 (Inducement 1 (SCR Device Abnormality))

Torque: over 25%

Red

Yellow Red

Red

Red Red

4

Status

Elapsed time (*1)

Severe Inducement (Inducement 2) 4 hours

Message of SCR Information

Caution lamp (Action level)

Machine monitor

Tone of audible alert

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

4: Engine power is under heavy deration.

Continuously

CA4151 CB4151

AS00R4 (Inducement 2 (SCR Device Abnormality))

Torque: 50% and RPM: 40%

5 Final Inducement (Inducement 3)

Until repairing 5: Engine is running at low idle.

Continuously

CA4151 CB4151

AS00R5 (Inducement 3 (SCR Device Abnormality))

Engine speed is fixed to low idle

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning” stage. Final Inducement is not cleared till abnormality is repaired.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. The failure code shown here is an example of failure code which is displayed on the machine monitor when an abnormality occurs. For the failure codes,see TROUBLESHOOTING, “Troubleshooting Points for Urea SCR System”.

*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines.

*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode.

*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed.

*6: Construction equipment with crawler

*7: Construction equipment with wheel

Red

Red Red

Red

Red

Red

Function of Temporary Restoration from Inducement (For North America)

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

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

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

•To activate Temporary Restoration, follow the procedures described below.

REMARK

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

Inducement Strategy for Abnormality Recurrence in 40 Hours (For North America)

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

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

•If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were corrected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities is the same as the previous ones or not, it is judged as a recurrence.

•If a recurrence occurs, the Inducement strategy will be activated and starts from “Severe Inducement”.

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

Inducement Strategy When the DEF Level in the Tank Becomes Low (For European Union)

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

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

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

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

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

Function

Status

DEF level (*1) (DEF level gauge)

1Warning 10% (The bottom two gradations light on)

2 Continuous Warning (Warning 2) 5%

(Within the gradation of the second from the bottom )

Message of SCR Information

1: DEF low level warning appears.

2: Without treatment, engine power will be derated.

Machine monitor

DEF level caution lamp (Action level)

Red

Red

Red

Tone of audible alert

Activated failure code (*2)

No sound

CA3497 (DEF level low error 1)

Triplet (*4)

Short intermittently (*5)

CA3498 (DEF level low error 2)

Engine deration (*3)

No deration

3 Low-Level Inducement (Inducement 1)

4

2.5% (The gradation of the end of the bottom lights on)

Severe Inducement (Inducement 2) 0% (All gradations lights off)

3: Engine power is under deration.

Red

Red

4: Engine power is under heavy deration.

Red

Long intermittently

CA1673 (DEF level low error 3)

No deration

Torque: over 25%

CA1673

Continuously

*1: It is shown the value of Monitoring ID 19111: “DEF Level Corrected”.

CA3547 (DEF level low error 4)

Torque: 50% and RPM: 40%

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. For the failure codes, see TROUBLESHOOTING, “Troubleshooting Points for Urea SCR System”.

*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed.

*4: Construction equipment with crawler

*5: Construction equipment with wheel

Inducement Strategy When Abnormality is Found in the DEF Quality or in the Urea SCR System Devices (For European Union)

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

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

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

Machine monitor

Status Elapsed time (*1)

1Warning5 hours

Message of SCR Information

DEF system caution lamp (Action level)

Tone of audible alert

1: Please inspect and maintain SCR system. Yellow No sound

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

2 Continuous Warning (Warning 2) 10 hours

3 Low-Level Inducement (Inducement 1) 20 hours

4 Severe Inducement (Inducement 2) Until repairing

CA3571 CB3571 No indicationNo deration Yellow

2: Without treatment, engine power will be derated. Yellow Triplet (*6) Short intermittently (*7)

AS00R2 (Warning 2 (SCR Device Abnormality)) No deration Yellow

CA3571 CB3571

3: Engine power is under deration. Red Long intermittently

4: Engine power is under heavy deration. Red Continuously

CA3571 CB3571

AS00R3 (Inducement 1 (SCR Device Abnormality))

Torque: over 25% Red

CA3571 CB3571

Torque: 50% and RPM: 40% Red

AS00R4 (Inducement 2 (SCR Device Abnormality))

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning” stage. Final Inducement is not cleared till abnormality is repaired.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. The failure code shown here is an example of failure code which is displayed on the machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “Troubleshooting Points for Urea SCR System”.

*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines.

*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode.

*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed.

*6: Construction equipment with crawler

*7: Construction equipment with wheel

Inducement Strategy When Abnormality is Found in the KDPF System by the Urea SCR System Devices (For European Union)

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

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

Machine monitor

Status Elapsed time (*1)

1Warning5 hours

Message of SCR Information

Caution lamp (Action level)

1: Please inspect and maintain SCR system. Red

Tone of audible alert

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

2 Continuous Warning (Warning 2) 10 hours

2: Without treatment, engine power will be derated.

Red

Long intermittently

CA4151 CB4151 No indication

Torque: over 25% Red

Triplet (*6)

Short intermittently (*7)

CA4151 CB4151

AS00R2 (Warning 2 (SCR Device Abnormality))

Torque: over 25%

Yellow Red

3

Status

Elapsed time (*1)

Message of SCR Information

Caution lamp (Action level)

Machine monitor

Tone of audible alert

Low-Level Inducement (Inducement 1) 20 hours

3: Engine power is under deration.

Long intermittently

4

Severe Inducement (Inducement 2) Until repairing

4: Engine power is under heavy deration.

Continuously

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

CA4151 CB4151

CA4151 CB4151

AS00R3 (Inducement 1 (SCR Device Abnormality))

Torque: over 25%

AS00R4 (Inducement 2 (SCR Device Abnormality))

Torque: 50% and RPM: 40%

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning”stage. Final Inducement is not cleared till abnormality is repaired.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. The failure code shown here is an example of failure code which is displayed on the machine monitor when an abnormality occurs. For the failure codes,see TROUBLESHOOTING, “Troubleshooting Points for Urea SCR System”.

*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines.

*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode.

*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed.

*6: Construction equipment with crawler

*7: Construction equipment with wheel

Red

Red Red

Red

Red Red

Inducement Strategy When Abnormality is Found in the EGR System by the Urea SCR System Devices (For European Union)

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

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

Machine monitor

Status

Elapsed time (*1)

1Warning5 hours

Message of SCR Information

Caution lamp (Action level)

Tone of audible alert

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

2 Continuous Warning (Warning 2) 10 hours

1: Please inspect and maintain SCR system.

2: Without treatment, engine power will be derated.

3 Low-Level Inducement (Inducement 1) 20 hours

3: Engine power is under deration.

Red Long intermittently

Triplet (*6)

Short intermittently (*7)

CA2271 CB2271 No indication

Torque: over 25% Red

CA2271 CB2271

AS00R2 (Warning 2 (SCR Device Abnormality))

Long intermittently

CA2271 CB2271

AS00R3 (Inducement 1 (SCR Device Abnormality))

Torque: over 25%

Torque: over 25%

Red

Yellow

Red

Red

Red Red

4

Status

Severe Inducement (Inducement 2)

Elapsed time (*1)

Message of SCR Information

Caution lamp (Action level)

Machine monitor

Tone of audible alert

Until repairing

4: Engine power is under heavy deration.

Continuously

Failure code for abnormality (*2),(*3)

Failure code for Inducement strategy status (*4)

Engine deration (*5)

CA2271 CB2271

AS00R4 (Inducement 2 (SCR Device Abnormality))

Torque: 50% and RPM: 40%

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning”stage. Final Inducement is not cleared till abnormality is repaired.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. The failure code shown here is an example of failure code which is displayed on the machine monitor when an abnormality occurs. For the failure codes,see TROUBLESHOOTING, “Troubleshooting Points for Urea SCR System”.

*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines.

*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode.

*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed.

*6: Construction equipment with crawler

*7: Construction equipment with wheel

Function of Temporary Restoration from Inducement (EU Specification)

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

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

•To activate Temporary Restoration, follow the procedures described below.

REMARK

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

Red

Red Red

Inducement Strategy for Abnormality Recurrence (EU Specification)

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

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

•If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were corrected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities is the same as the previous ones or not, it is judged as a recurrence.

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

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

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

Component Parts of Urea SCR System

SCR

Abbreviation for Selective Catalytic Reduction

DEF Mixing Tube

Structure of DEF Mixing Tube

REMARK

The shape is subject to machine models.

A: Exhaust gas inlet (from KDPF)

1: Clamp

2: DEF injector

3: Gasket for DEF injector

Function of DEF Mixing Tube

B: Exhaust gas outlet (to SCR)

4: DEF mixing tube (connector)

5: DEF mixing tube (tube)

It mixes DEF injected from DEF injector with exhaust gas, and decomposes it to ammonia which is needed to purge NOx from SCR assembly.

SCR Assembly

SCR

Abbreviation for Selective Catalytic Reduction

Structure of SCR Assembly

REMARK

The shape is subject to machine models.

A: From DEF mixing tube

B: To exhaust pipe

1: SCR body

2: SCR temperature sensor

3: SCR outlet NOx sensor

4: SCR outlet temperature sensor

5: Temperature sensor controller

6: Ammonia sensor

7: Hanger plate

8: water baffle

9: Water drain port

10: Sensor table

11: Sensor table band

12: Catalyzer hold mat

13: Water dam

14: Downstream SCR catalyst and ammonia oxidation catalyst (integrated type)

15: Upstream SCR catalyst

16: Rectifier tube

•SCR assembly consists of rectifier tube (16) equalizing the distribution of flow speed by leading exhaust gas, upstream SCR catalyst (15), downstream SCR catalyst, ammonia oxidation catalyst (14), and water dam which prevents rain water from entering into downstream SCR catalyst and ammonia oxidation catalyst (14) while exhausting gas.

•Ammonia oxidation catalyst (a part of 14) oxidizes ammonia to water and nitrogen with ammonia oxidation catalyst (a part of 14) to prevent ammonia which is supplied to SCR assembly from being released out because SCR catalyst (a part of 14, 15)cannot completely consume it.

•Each 1 piece of SCR temperature sensor (2), SCR outlet temperature sensor (4), ammonia sensor (6), and SCR outlet NOx sensor (3) are installed. These sensors are usable for various troubleshooting, such as they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly functions or not.

•Rectifying tube (16) equalizes the distribution of exhaust gas flow speed.

•SCR catalyst (15, a part of 14) uses the ceramic honeycomb.

•The catalyzer holding mat (12) is made of a specific fiber and protects the ceramic catalyst against vibrations by the engine and the machine body. It also protects the outer periphery of SCR assembly against a heat transfer of the ceramics during operation.

•Water dam (13) is located at the upstream side of the outlet and prevents rainwater from entering into downstream SCR catalyst unit and ammonia oxidation catalyst (14).

•Water baffle (8) is located at the downstream side of the outlet and prevents rainwater at outlet from splashing over the detection part of NOx sensor.

DEF Tank

Structure of DEF Tank

A: Coolant outlet

B: Coolant inlet

C: From DEF pump

D: To DEF pump

E: To breather

1: Sensor flange assembly

2: DEF filler cap

3: Sight gauge

4: DEF tank

5: DEF tank sensor

DEF Tank Sensor

Structure of DEF Tank Sensor

REMARK

The shape is subject to machine models.

6: DEF tank filter

7: Drain plug

1: Connector

2: Concentration Sensing part

Function of DEF Tank Sensor

3: Temperature sensing part

4: Level sensing part

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

•DEF level and DEF concentration are measured by using ultrasonic wave.

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

DEF Pump

Structure of DEF Pump

A: Suction from DEF tank

B: Return to DEF tank

C: Pressurized sending to DEF injector

1: DEF pump

2: DEF inlet connector

3: DEF backflow connector

4: DEF outlet connector

5: Electric connector

6: DEF filter cap

7: DEF filter (built-in)

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

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

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

DEF Injector

Structure of DEF Injector

A: Pressurized sending from DEF pump

B: Coolant inlet

C: Coolant outlet

1: DEF injector

2: DEF inlet connector

3: Coolant inlet connector

4: Coolant outlet connector

5: Electric connector

Function of DEF Injector

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

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

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

Operation of DEF Injector

Principle of injection of the injector is described. Following figure shows the state of injection.

1. Engine controller sends the electrical signal to control DEF injector.

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

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

DEF Hose

Structure of DEF Hose

1: Connector

2: Housing

3: Coupling

4: Corrugated tube

5: Insulation tape

6: Heating wire

7: Nylon tube

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

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

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

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

Function of DEF Hose

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

•It also keeps temperature constant to prevent DEF from freezing again while machine is operated.

DEF Tank Heating Valve

Structure of DEF Tank Heating Valve

A: Engine coolant inlet

1: Solenoid

2: Solenoid core

3: Solenoid coil

4: Spring

Function of DEF Tank Heating Valve

B: Engine coolant outlet

5: Plunger

6: Diaphragm

7: Valve

• DEF tank heating valve thaws DEF tank, and opening/closing of the valve (7) is done by solenoid (1).

•The opening position of valve is fixed and the control is only for opening/closing. When the solenoid (1) is de-energized, the valve is closed.

•Diaphragm (6) prevents entering of engine coolant into solenoid (1).

Operation of DEF Tank Heating Valve

1. When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (7) which is directly connected to plunger (5).

2. When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down by spring (4) and valve (7) is closed.

Boot-up System

Layout Drawing of Boot-up System

1: Fuse box

2: Pump controller

3: Engine controller

4: Battery

5: KOMTRAX terminal

6: Machine monitor

7: Fusible link

8: System operating lamp

9: Battery disconnect switch

System Operating Lamp System

System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal)

1: Battery disconnect switch

2: Battery

3: Fusible link

4: Fuse box

5: System operating lamp

6: Machine monitor

7: Engine controller

*1: Machine with KomVision.

Function of Operation Lamp System

8: Pump controller

9: KOMTRAX terminal

10: ICT sensor controller

11: Work equipment controller

12:ID key controller

13:KomVision controller(*1)

System operating lamp is lit while any of controllers are in operation. To prevent the abnormal end of the disconnection of the battery power supply circuit while the controllers are in operation, check the operation state with this lamp.

REMARK

•Before shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and check that the system operating lamp goes off, then turn the battery disconnect switch to “OFF” position.

•If the battery disconnect switch is turned to “OFF” position (the battery power supply circuit is OFF) while the system operating lamp is lit, data loss error of controller may occur. Never operate the battery disconnect switch while the system operating lamp is lit.

•The system operating lamp goes off in 5 minutes after the starting switch is turned to “OFF” position.

•The system operating lamp may sometimes light up while the starting switch is in “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 (LED (Light Emitting Diode)).

•When any controller is in operation, the controller side outputs Low (0 V), and a current flows through the diode and the system operating lamp lights up.

•When all controllers are stopped, the controller side outputs High (24 V), and no current flows through the diode and the system operating lamp goes off.

The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the minute leakage of current and not an abnormal phenomenon.

•When the starting switch is in “OFF” position, KOMTRAX terminal repeats the start and stop to maintain the periodic communication.

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•The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the communication state and machine stop time. So the lamp can be lit as long as approximately 1 hour When you want to cut off the battery circuit for maintenance but the system operating lamp is kept lit, turn the starting switch to “ON” position once and then turn it to “OFF” position. Lamp goes off in a maximum of. 5 minutes. After system operating lamp goes off, turn the battery disconnect switch immediately to “OFF” position.

Battery Disconnect Switch

Function of Battery Disconnect Switch

(O): OFF position

(I): ON position

•Usually, battery disconnect switch (1) is used instead of disconnecting the cable from the negative terminal of the battery in the following cases.

•When storing the machine for a long period (1 month or longer)

•When servicing or repairing the electrical system

•When performing electric welding

•When handling the battery

•When replacing the fuse, etc.

•When battery disconnect switch (1) is turned to OFF position (the contact is opened), all the continuous power supplies for the components, including the starting switch B terminal and controllers, are all cut out, and the condition is the same as the condition when the battery is not connected. Accordingly, all of the electrical system of the machine does not operate.

NOTICE

•Do not turn battery disconnect switch (1) to OFF position while the system operating lamp is lit. If battery disconnect switch (1) is turned to OFF position while the system operating lamp is lit, the data in the controller may be lost and the controller may be damaged seriously.

•Do not turn battery disconnect switch (1) to OFF position while the engine is running or immediately after the engine is stopped.

If battery disconnect switch (1) is turned to OFF position while the alternator is generating power, the generated current has nowhere to go, leading to overvoltage 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 lights up while the controller is in operation or DEF pump is in operation. It lights up when KOMTRAX is performing communication, even if the starting switch is set to OFF position.

•If battery disconnect switch (1) has been at OFF position for a long period, the machine monitor and the clock of the radio may be initialized. In this case, re-setting is required.

Engine System

Layout Drawing of Engine System

1: EGR cooler

2: VGT

3: Engine oil filter

4: SCR assembly

5: KDPF

6: KCCV ventilator

7: Vibration damper

8: Auto-tensioner

9: Air cleaner

10: Alternator

11: Starting motor

Specifications of Engine System

Type of damper: Wet type

Damper oil: TO30

Quantity of damper oil: 0.65 ℓ

Function of Engine System

12: Damper

13: Rear engine mount

14: Front engine mount

15: Engine controller

• VGT (2) is a turbocharger which can change the cross-sectional area of the exhaust passage.

•EGR cooler (1) cools the exhaust gas with the coolant.

•KDPF (5) has KDOC (catalyst) and KCSF (soot collecting filter) in it and purifies the exhaust gas.

•KCCV ventilator (6) separates and returns oil to the intake side to burn the blowby gas again. It mainly consists of filters.

Engine Control System

System Diagram of Engine Control

1: Battery disconnect switch

2: Battery

3: Battery relay

4: Fusible link

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: Safety relay

15: Starting motor

16: Fuel supply pump

17: Various sensors

18: Machine monitor

19: KOMTRAX terminal

20: Pump controller

Function of Engine Control System

Mechanism and Function to Start Engine

•When starting switch (6) is turned to ON position, engine controller (8) sends a command current to fuel supply pump (16).

Accordingly, a fail-safe mechanism is provided, that is, the engine stops when the electrical system has trouble.

•When starting switch (6) is turned to START position while lock lever (9) is in LOCK position, the starting current is supplied to starting motor (15) and the engine starts.

If lock lever (9) is in FREE position, starting motor cut-off relay (11) operates to cut off the starting current to starting motor (15) and the engine does not start, that is, a neutral safety mechanism.

•Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the signal to machine monitor (18).

Machine monitor (18) operates starting motor cut-off relay (12) to cut off the starting current to starting motor (15), thus the engine does not start.

Mechanism and Function of Engine Speed Control

Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8) selects the lower throttle signal and sends the command current to fuel supply pump (16). Fuel supply pump (16) adjust the fuel injection rate to control the engine speed.

Mechanism and Function to Stop Engine

When starting switch (6) is turned to OFF position, the current from terminal ACC of starting switch (6) to engine controller (8) is cut off, and the command current to fuel supply pump (16) is also cut off. Fuel supply pump (16) stops supplying fuel, the engine speed decreases, and the engine stops.

Mechanism and Function of Engine Stopping System with Engine Shutdown Secondary Switch

When engine shutdown secondary switch (7) is set to the engine stop position, the current from terminal ACC of starting switch (6) to engine controller (8) is cut off forcibly. The condition becomes the same as when starting switch (6) is turned to OFF position, and the engine stops.

Auto-Deceleration System

System Diagram of Auto-Deceleration System

a: CAN signal

b: Oil pressure sensor signal

c: Oil pressure switch signal

1: Pump controller

2: Engine controller

3: Machine monitor

4: Fuel control dial

5: Fuel supply pump

6: Various sensors

7: Oil pressure switch

Function of Auto-Deceleration System

d: 1st throttle signal

e: Fuel supply pump control signal

f: Various sensor signals

8: Oil pressure sensor

9: Main pump

10: Control valve

10a: Self-pressure reducing valve

10b: Merge-divider valve

10c: Travel junction valve

11: PPC lock solenoid valve

•When all the control levers are set to NEUTRAL positions while waiting for a dump truck or next work, the engine speed decreases to the control speed automatically to improve the fuel economy and reduce the noise.

•If any control lever is operated, the engine speed returns immediately to the speed set with the fuel control dial.

Operation of Auto-Deceleration System

A: All work equipment control levers in NEUTRAL

B: Work equipment control lever operated

C: Fuel control dial at set speed

D: Engine control speed (approximately 1050 rpm)

E: 4 sec.

F: Max. 2 sec.

G: Max. 1 sec.

When Control Lever is at NEUTRAL Position

While the engine is running at approximately 1050 rpm or higher speed, when all the control levers are kept in NEUTRAL for 4 seconds or more, engine speed is decreased to approximately 1050 rpm and kept to the engine control speed (approximately 1050 rpm) until any control lever is operated.

When Control Lever is Operated

While the engine speed is kept at the engine control speed (approximately 1050 rpm), when any control lever is operated, the engine speed increases immediately to the fuel control dial set speed.

Engine Automatic Warm-up System

System Diagram of Engine Automatic Warm-up System

a: Front pump PC-EPC valve drive signal

b: Rear pump PC-EPC valve drive signal

c: Solenoid valve GND

d: CAN signal

1: Battery disconnect switch

2: Battery

3: Battery relay

4: Fusible link

5: Fuse box

6: Resistor for PC-EPC valve

7: Pump controller

8: Engine controller

9: Machine monitor

10: Air conditioner unit

11: Pump drive secondary switch

12: Fuel control dial

13: Fuel supply pump

14: Various sensors

15: Hydraulic oil temperature sensor

e: Hydraulic oil temperature signal

f: 1st throttle signal

g: Fuel supply pump control signal

h: Various sensor signals

16: Front pump

16a: Servo

16b: LS valve

16c: PC valve

17: Rear pump

17a: Servo

17b: LS valve

17c: PC valve

18: Control valve

18a: Self-pressure reducing valve

18b: Merge-divider valve

18c: Travel junction valve

19: Front pump PC-EPC valve

20: Rear pump PC-EPC valve

Function of Engine Automatic Warm-up System

•When the coolant temperature is low after the engine is started, the engine speed is increased automatically to warm up the engine.

•The engine automatic warm-up function has 2 kinds; “Heater warm-up” and “Normal warm-up”, either of which is used according to the purpose. The purpose of the heater warm-up is to increase the coolant temperature to improve the effect of the heat. The purpose of the normal warm-up is to heat the engine to prevent damage on the engine caused by low temperature.

Operating conditions 1

Machine specification: Air conditioner specification

Air conditioner: Blower “ON”

Coolant temperature: Below 55 °C

Ambient temperature: Below 5 °C

Manual stationary regeneration: OFF

Soot accumulation: Max. 2 g/ℓ

When any of operating conditions 1 is not satisfied

Heater warm-up disabled (normal warm-up)

Operating conditions 2

(Operates when all of the following conditions are satisfied)

Coolant temperature: Below 30 °C

Engine speed: Max. 1200 rpm

Operation

Engine speed1200 rpm

Condition to cancel

(Canceled when any of the following conditions is satisfied)

Automatic Coolant temperature: Min. 30 °C

Warm-up operation time: Min. 10 minutes

Manual Fuel control dial: Held at 70 % or more of High idle (MAX) for 3 seconds and longer

Engine speed: Any

When all of operating conditions 1 are satisfied

Heater warm-up enabled

Operation

Engine speedMin. 1300 rpm

Condition to cancel

(Canceled when any of the following conditions is satisfied)

Coolant temperature: Min. 60 °C

Ambient temperature: Min. 10 °C

Cancellation

Overheat Prevention System

Overheat

Prevention System Diagram

a: Front pump PC-EPC valve drive signal

b: Rear pump PC-EPC valve drive signal

c: Solenoid valve GND

d: CAN signal

1: Battery disconnect switch

2: Battery

3: Battery relay

4: Fusible link

5: Fuse box

6: Resistor for PC-EPC valve

7: Pump controller

8: Engine controller

9: Machine monitor

10: Air conditioner unit

11: Pump drive secondary switch

12: Fuel control dial

13: Fuel supply pump

14: Various sensors

15: Hydraulic oil temperature sensor

e: Hydraulic oil temperature signal

f: 1st throttle signal

g: Fuel supply pump control signal

h: Various sensor signals

16: Front pump

16a: Servo

16b: LS valve

16c: PC valve

17: Rear pump

17a: Servo

17b: LS valve

17c: PC valve

18: Control valve

18a: Self-pressure reducing valve

18b: Merge-divider valve

18c: Travel junction valve

19: Front pump PC-EPC valve

20: Rear pump PC-EPC valve

Function of Overheat Prevention System

When the coolant temperature or the hydraulic oil temperature increases too high during operation, the pump load is reduced and the engine speed is lowered to prevent overheat and protect the engine and hydraulic components.

Operating condition

Working mode: Travel

Hydraulic oil temperatureMin.

95 °C

Operating condition

Working mode: P, E, ATT-P, or ATT-E mode

Coolant temperatureMin.

100 °C or Hydraulic oil temperatureMin.

100 °C

Operating condition

Working mode: P, E, ATT-P, or ATT-E mode

Coolant temperatureMin.

102 °C or Hydraulic oil temperatureMin.

102 °C

Operating condition

Working mode: B mode

Coolant temperatureMin.

102 °C or

Hydraulic oil temperatureMin.

102 °C

Operation and remedy

Engine speed: Kept as it is

Pump discharged volume: Throttled

Operation and remedy

Engine speed: Kept as it is

Pump discharged volume: Throttled

• Pump absorption torque is lowered and engine load is reduced according to the torque control signal.

Operation and remedy

Engine speed: Kept as it is

Pump discharged volume: Throttled

• Pump absorption torque is lowered and engine load is reduced according to the torque control signal.

Operation and remedy

Engine speed: Kept as it is Pump discharged volume: Throttled

Alarm monitor: Lights up

Condition to cancel

Hydraulic oil temperatureBelow 93 °C

• When above condition is satisfied, state before operation is restored (automatic restoration).

Condition to cancel

Coolant temperatureBelow 100 °C

Hydraulic oil temperatureBelow 100 °C

• When above condition is satisfied, state before operation is restored (automatic restoration).

Condition to cancel

Coolant temperatureBelow 102 °C

Hydraulic oil temperatureBelow 102 °C

• When above condition is satisfied, state before operation is restored (automatic restoration).

Condition to cancel

Coolant temperatureBelow 102 °C

Hydraulic oil temperatureBelow 102 °C

• When above condition is satisfied, state before operation is restored (automatic restoration).

Operating condition

Working mode: All modes

Coolant temperatureMin. 105 °C or

Hydraulic oil temperatureMin. 105 °C

Engine speed: Low idle

Alarm monitor: Lights up

Alarm buzzer: Sounds

Coolant temperatureBelow 105 °C

Hydraulic oil temperatureBelow 105 °C

Fuel control dial: Return to Low idle (MIN) position.

• When above condition is satisfied, state before operation is restored (manual restoration).

Turbocharger Protection System

System Diagram of Turbocharger Protection System

a: Front pump PC-EPC valve drive signal

b: Rear pump PC-EPC valve drive signal

c: Solenoid valve GND

d: CAN signal

1: Battery disconnect switch

2: Battery

3: Battery relay

4: Fusible link

5: Fuse box

6: Resistor for PC-EPC valve

7: Pump controller

8: Engine controller

9: Machine monitor

10: Air conditioner unit

11: Pump drive secondary switch

12: Fuel control dial

13: Fuel supply pump

14: Various sensors

15: Hydraulic oil temperature sensor

e: Hydraulic oil temperature signal

f: 1st throttle signal

g: Fuel supply pump control signal

h: Various sensor signals

16: Front pump

16a: Servo

16b: LS valve

16c: PC valve

17: Rear pump

17a: Servo

17b: LS valve

17c: PC valve

18: Control valve

18a: Self-pressure reducing valve

18b: Merge-divider valve

18c: Travel junction valve

19: Front pump PC-EPC valve

20: Rear pump PC-EPC valve

Function of Turbocharger Protection System

This function limits the engine speed to prevent seizure of the turbocharger when the engine speed is increased suddenly just after the engine is started.

Operating condition

Engine oil pressure: Below 50 kPa {0.51 kgf/cm2}

A: Starting of engine

B: Turbocharger protection time (approximately 0 to 20 seconds)

C: Modulation time (approximately 1 second)

D: 500 rpm

E: Approximately 1050 rpm

F: 1650 rpm (*1)

(*1) Working mode: P mode

Fuel control dial: High idle (MAX) position

Travel lever: Fine control

Operation

Protection of turbocharger (see following figure)

Automatic Idle Stop System

System Diagram of Automatic Idle Stop System

a: CAN signal

b: BR signal

1: Battery disconnect switch

2: Battery

3: Battery relay

4: Fusible link

5: Fuse box

6: Starting switch

7: Relay

8: Lock lever

Function of Automatic Idle Stop System

c: Lock lever signal

d: Various sensor signals

9: PPC lock switch

10: Pump controller

11: Machine monitor

12: Engine controller

13: KOMTRAX terminal

14: Engine

15: Hydraulic oil temperature sensor

16: Coolant temperature sensor

•When the auto idle stop function is enabled and the conditions for operation are satisfied, the engine is stopped after the set time.

•Engine stops by auto idle stop function when engine controller judges the applicable condition and stops the engine.

•When the engine is stopped by the auto idle stop function while it is running at high speed, a message to turn ON the auto-deceleration function is displayed on the machine monitor, and the auto-deceleration function is set to ON.

•The operating time of the auto idle stop function can be set by user menu or service menu on the machine monitor.

Condition of Automatic Idle Stop System Operation

The auto idle stop function starts when all of the following conditions are satisfied at the same time.

•Engine is running.

•Lock lever is in LOCK position.

•Working mode is “P”, “E”, “ATT/P”, “ATT/E”, or “B”. (Disabled when working mode is “L” or “Arm crane”).

•Engine automatic warm-up function of “Normal warm-up” mode is not being operated.

•Engine coolant is not overheating (below 102 °C).

•Hydraulic oil is not overheating (below 102 °C)

• Auto idle stop time on machine monitor has not been reset.

•Machine monitor is not set in service mode. (*1)

•None of following failure codes is occurring.

*1: See “Setting time”.

Corresponding failure codes are as follows.

Failure code

B@BCNSEng Water Overheat

B@HANSHydraulic Oil Overheat

Failure (displayed on screen)

CA144Coolant Temperature Sensor High Error

CA145Coolant Temperature Sensor Low Error

D8AQKRCAN 2 Defective Communication (KOMTRAX)

DA2RKRController Area Network 1 Defective Communication (Pump Controller)

DA2QKRController Area Network 2 Defective Communication (Pump Controller)

DAFQKRCAN 2 Defective Communication (Monitor)

DB2RKRCAN 1 Defective Communication (Engine Controller)

DB2QKRCAN 2 Defective Communication (Engine Controller)

DGH2KAHydraulic Oil Temperature Sensor Open Circuit

DGH2KBHydraulic Oil Temperature Sensor Ground Fault

Setting Time

The set time for the auto idle stop function is set in the following menus. For setting of each menu, see “30 Testing and Adjusting”.

Fixing Auto Idle Stop Time (Service Menu)

Setting Contents of setting

Variable In auto idle stop time setting menu, operator can select OFF or minimum set time in auto idle stop setting to maximum time of 60 minutes. (Default)

OFF The auto idle stop function does not operate, and the auto idle stop time setting menu is not displayed.

Fix to X min. In auto idle stop time setting menu, operator can select set time in auto idle stop setting to X minutes (set time at left). (Cannot select OFF)

Fixing Auto Idle Stop Time (User Menu)

Setting Contents of setting

OFFAuto idle stop function does not operate. (Default)

Y min.Stop the engine at Y minutes (set time at left) after setting the lock lever to LOCK position.

NOTICE

When “Fix X min.” is selected in the Auto idle stop time fixing menu, the screen changes to the operator screen automatically and the auto idle stop function operates 60 minutes after the lock lever is set to LOCK position, even if the Service menu is being used. Before performing work with the Service menu, check the set value of the auto idle stop function.

Abrupt Engine Stop is Found

•When the engine is stopped by the auto idle stop function, if the auto-deceleration function is OFF and the fuel control dial is at a position above MIN., abrupt engine stop is sensed and the failure code is sent.

•The failure code is recorded in the mechanical system abnormality record.

•If abrupt engine stop is sensed, the auto-deceleration function is turned ON automatically.

•The failure code displayed at abrupt engine stop varies with the number of occurrence, and the message displayed on the machine monitor varies according to the failure code.

Action levelFailure code

L00

L01

L03

Failure (displayed on screen)

A900N6Abrupt Engine Stop by Auto Idle Stop 1

A900NYAbrupt Engine Stop by Auto Idle Stop 2

A900FRAbrupt Engine Stop by Auto Idle Stop 3

•When failure code “A900FR” of action level “L03” is sent, the turbocharger assembly must be replaced since the durability of the engine may decrease.

•After replacing the turbocharger assembly, reset the number of occurrence by using “Reset number of abrupt stops by auto idle stop” in “Inspection” on the service menu.

REMARK

If the number of occurrence is not reset by using “Reset number of abrupt stops by auto idle stop”, failure code “A900FR” is sent again next time and after. Accordingly, be sure to reset after replacing the turbocharger assembly.

Component Parts of Engine System

VGT

VGT

Abbreviation for Variable Geometry Turbocharger

Structure of VGT

REMARK

The shape is subject to machine models.

General View and Sectional View

A: Intake air inlet

B: Intake air outlet

1: Blower housing

2: VGT speed sensor

3: Hydraulic actuator

4: Turbine housing

5: Plate

6: Vane

Function of VGT

C: Exhaust inlet

D: Exhaust 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

4: DEF mixing tube(*1)

T: Turbine impeller

5: SCR assembly(*1)

6: EGR cooler

7: EGR valve

*1: This may not be installed on some machine models and specifications.

•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, turbine inlet pressure (P3) must be set higher than 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 shaft joined to turbine impeller (T) drives blower impeller (C) and sends much air to the cylinder for combustion.

If VGT (2) sends more air, the fuel injection rate can be increased, thus the engine output is increased. In addition, the air cooled by aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel injection rate can be increased and the engine output is increased.

NOTICE

Adequate amount of clean high quality oil is required to maintain VGT performance. Be sure to use Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when replacing oil or oil filter.

REMARK

It sounds like air is leaking from VGT or a boost pipe, but it is not abnormal.

Operation of VGT

REMARK

Six cylinder engine is shown in this item.

1. The exhaust gas enters (C) of turbine housing (4) and flows out through portion (P) and (D). Portion (P) is surrounded by plate (5) fixed to turbine housing, nozzle ring (7), and vanes (6). The area of its passage is changed by sliding push rod (8) to the right or left.

2. Hydraulic actuator (3) moves piston in the actuator up and down with the hydraulic pressure controlled by EPC valve installed to the front cover, and slides push rod (8) to the right and left.

3. The exhaust gas flowing through vanes (6) rotates blower impeller (10) through shaft (9) joined to turbine impeller (11). As the result, the blower impeller works as a compressor, and the intake air entering through (A) is compressed and discharge through (B).

4. When the exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed is in low range), push rod (8) slides to the right and narrows portion (P).

5. The exhaust gas acting on turbine impeller (11) increases, the turbocharger speed increases, and more air (oxygen) is taken in.

VGT speed sensor (2) detects the rotation of the turbocharger

When Nozzle Ring is “Closed”

1. During low speed operation (rotation), exhaust gas inlet passage (P) is narrow (L1). (It is not fully closed, however.)

2. If the turbine inlet pressure increases while the nozzle ring is closed, the turbine inflow speed increases, and accordingly the turbocharger speed increases.

When Nozzle Ring is “Open”

1. During high speed operation (rotation), exhaust gas inlet passage (P) is wide (L2).

2. As the engine speed increases and the turbine inlet pressure (exhaust gas pressure) increases exhaust gas inlet passage (P) is widened (L2) so that the exhaust gas acts on turbine impeller (11) efficiently.

REMARK

•Nozzle ring (7), vanes (6), and push rod (8) are made in one unit, and it slides only and does not rotate.

•Hydraulic actuator (3) is equipped with VGT position sensor. VGT position sensor is calibrated together with the variable mechanism of VGT and the result is written in the memory in VGT position sensor. Accordingly, if any of hydraulic actuator (3), VGT position sensor, and VGT unit fails, whole VGT must be replaced.

Operation of Hydraulic Actuator

The shape is subject to machine models.

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1. Hydraulic actuator (1) is controlled by EPC valve (3) installed to EGR valve (2) and driven hydraulically.

2. The hydraulic pressure supplied by boost oil pump (4) is used for this purpose.

3. The position of hydraulic actuator (1) is fed back to engine controller by the signals from VGT position sensor

EGR System

EGR

Abbreviation for Exhaust Gas Recirculation

Layout Drawing of EGR System

REMARK

• Six cylinder engine is shown in this item.

•The shape is subject to machine models.

2: EGR valve

3: Intake pipe

Function of EGR System

5: Exhaust manifold

6: EGR cooler

•EGR valve (hydraulically driven type) (2) 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 side.

•EGR cooler (6) cools down the exhaust gas.

Engine coolant is used for cooling.

1: VGT

4: Intake connector

•It controls EGR circuit on the basis of the information from the sensors installed to various parts so that clean exhaust gas is always discharged to obtain EGR ratio corresponding to the operating condition. (EGR ratio means the ratio of EGR gas contained in the intake gas.)

•It monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure from occurring.

EGR System Circuit Diagram

C: Blower impeller

1: Air Cleaner

2: KDPF, DEF mixing tube, SCR assembly

3: Ambient pressure sensor

4: Aftercooler

5: EGR cooler

6: EGR valve

7: Hydraulic actuator (power piston)

8: EPC valve (for EGR valve)

Operation of EGR System

T: Turbine impeller

9: EGR valve lift sensor

10: EPC valve (for VGT)

11: Exhaust manifold

12: Engine boost oil pump

13: Intake manifold

14: Charge (boost) pressure and temperature sensor

15: Engine controller

16: Mass air flow and temperature sensor

1. The engine controller outputs signals in order to open EGR valve (6) 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 (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (11) into EGR cooler (5) through the EGR piping.

3. The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in the intake connector, and then flows in intake manifold (13).

EGR Valve

EGR

Abbreviation for Exhaust Gas Recirculation

Structure of EGR Valve

REMARK

The shape is subject to machine models.

Sectional View

7:

Structure

• EGR valve consists of the EGR gas flow control mechanism and EPC valve.

•There are 2 EPC valves, one for the EGR control and one for the VGT control.

A: EGR gas inlet (from EGR cooler)

B: EGR gas outlet (to intake manifold)

C: Servo drive oil inlet

D: Servo drive oil outlet

E: VGT control hydraulic outlet

F: VGT drive pressure outlet

1: Valve

2: Spring

3: Power piston

4: Spool

5: Spring

6: EGR valve lift sensor

EPC valve (for EGR)

8: EPC valve (for VGT)

Operation of EGR Valve

1. The oil from engine boost oil pump enters through port (C) of EGR valve. The control pressure from EPC valve is transmitted to port (E).

2. Spool (4) is moved to the right by the reaction force of spring (5), and EGR valve (1) is closed by the reaction force of spring (2). Accordingly, the exhaust gas from EGR cooler does not flow to the intake side.

3. To open EGR valve (1), the control pressure from EPC valve is transmitted to port (E) first. The position of spool (4) is determined by the balance of the control pressure and spring (5).

4. Since the hydraulic circuit 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. Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) is stopped at a position determined by spool (4).

8. The engine controller controls the valve position by controlling the spool position with the control pressure of EPC valve.

9. 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).

10. EGR valve lift sensor senses the displacement of spool (4).

EGR Cooler

EGR

Abbreviation for Exhaust Gas Recirculation

Structure of EGR Cooler

REMARK

The shape is subject to machine models.

General View and Sectional View

Detailed Drawing of Flat Tube

Operation of EGR Cooler

A: EGR gas inlet

B: Air vent

C: Coolant outlet

D: EGR gas outlet (to EGR valve)

E: Coolant inlet

1: Flat tube

1: Flat tube

2: Inner fin

1. EGR gas enters through (A) and flows through flat tubes (1) (11 pieces).

2. Coolant enters through (E), flows outside of flat tubes (1) in the case, and goes out through (C).

3. Flat tube (1) has inner fins (2), thus EGR gas is cooled efficiently and discharged through EGR gas outlet (D).

KCCV System

KCCV

Abbreviation for KOMATSU Closed Crankcase Ventilation

Layout Drawing of KCCV System

REMARK

The shape is subject to machine models.

General View

A: Blowby gas (from flywheel housing)

B: Blowby gas from which engine oil is removed (to VGT)

C: Engine oil segregated at the filter (to oil pan)

1: KCCV ventilator

2: VGT

3: Blowby duct

4: Flywheel housing

5: Check valve

6: CDR valve

7: Crankcase pressure sensor

Function of KCCV System

•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 (1) 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

Drawing on the left shows the conventional flow of blowby gas. Drawing on the right shows the flow of blowby gas which is sucked in KCCV ventilator and recirculated.

A: Blowby gas

B: Clean gas

1: Air cleaner

2: Turbocharger

3: Aftercooler

4: Cylinder block (crankcase)

C: Engine oil

5: Breather

6: KCCV ventilator

7: Engine oil pan

8: VGT

1. This system removes engine oil (C) from blowby gas (A) in cylinder block (4) by using the filter in KCCV ventilator (6), and recirculate clean gas (B) to the air intake side of VGT (8).

2. Separated engine oil (C) is drained to engine oil pan (7) through the check valve.

KCCV Ventilator

KCCV

Abbreviation for KOMATSU Closed Crankcase Ventilation

Structure of KCCV Ventilator

REMARK

The shape is subject to machine models.

General View and Sectional View

A: Blowby gas inlet (from flywheel housing)

B: Blowby gas outlet (to VGT intake side)

1: Case

2: CDR valve

3: Crankcase pressure sensor

Structure

Oil drain port (to engine oil pan)

4: Relief valve

5: Impactor

6: Filter

•Filter is classified by the working direction for filter replacement into the top load type (removed upward) and bottom load type (removed downward).

•Crankcase pressure sensor is installed to blowby gas inlet piping if it is top load type, and installed to upper part of KCCV ventilator body if it is bottom load type.

Function of KCCV Ventilator

•If the blowby gas is returned to the intake side of VGT and crank case pressure becomes negative, the dust may be sucked in through crank seal. The pressure inside the crankcase is controlled by CDR valve (2) to prevent this to occur

•Crankcase pressure may increases and oil leakage may occur if filter (6) of KCCV ventilator is clogged. Thus, crankcase pressure sensor detects the clogging of filter (6).

C:

•Keep KCCV ventilator warm with warmed-up engine coolant, to prevent the blowby gas passage from being clogged due to freeze.

•Relief valve (4) is inside case (1) and it protect both KCCV ventilator and the engine when filter (6) is blocked.

Operation of KCCV Ventilator

1. When blowby gas enters blowby gas inlet (A) and passes through the hole of impactor (5) in filter (6), large particles in the oil mist are separated.

2. Small particles in the oil mist are separated by filter (6).

3. The separated oil oozes out from the bottom of the filter (6), and flows to oil drain port (C), and then flows to the engine oil pan.

4. The crankcase pressure sensor (3) senses the crankcase pressure (blowby gas pressure). If the engine controller detects filter clogging by detected value of crankcase pressure sensor (3), it displays failure code CA555. If the pressure increases further, it displays failure code CA556.

5. Relief valve (4) is installed in case (1) and operates when filter (6) is blocked.

6. When the crankcase pressure becomes negative, CDR valve (2) operates for it not to become excessively negative.

CDR Valve

CDR

Abbreviation for Crankcase Depression Regulator

Operation of CDR Valve

1. Spring (2) normally pushes up diaphragm (1), and the blowby gas flows from crankcase side (A) into turbocharger side (air intake side) (B).

2. As the intake air at turbochaeger side (air intake side) (B) increases, pressure on crankcase side (P1) decreases.

3. The reaction force of spring (2) is overwhelmed by ambient pressure (P2). Diaphragm (1) shuts the passage and temporarily blocks the flow.

4. When the blowby gas accumulates in the crankcase, pressure (P1) on the crankcase side increases, and it pushes up diaphragm (1) again and blowby gas starts to flow.

KDPF

KDPF

Abbreviation for KOMATSU Diesel Particulate Filter

Structure of KDPF

REMARK

The shape is subject to machine models.

General View

A: From VGT

1: Inlet unit

2: Hanger bracket

3: Outlet unit

4: Sensor bracket band

5: KCSF unit

6: Sensor bracket

7: KDPF outlet temperature sensor

Structure

B: To DEF mixing connector

8: Temperature sensor controller

9: KDOC outlet temperature sensor

10: KDOC inlet temperature sensor

11: KDPF differential pressure sensor port

12: KDPF differential pressure sensor

13: KDPF differential pressure sensor port

•KDPF has a function to introduce the exhaust gas, and it consists of inlet unit (1) to store the oxidation catalyst (KDOC), KCSF unit (5) to store the soot collecting filter with catalyst, and outlet unit (3) to discharge the exhaust gas.

•Inlet unit (1) stores KDOC consisting of ceramic honeycomb with the oxidation catalyst.

•The ceramic honeycomb contributes to properly perform two following processes, which are to oxidize NO (nitrogen monoxide) contained in the exhaust gas into NO2 (nitrogen dioxide), and to burn the fuel injected

during automatic regeneration and manual stationary regeneration. (Automatic regeneration means the method to purify (oxidize) the soot accumulated on soot collecting filter (KCSF) in KDPF.)

•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.

•KCSF unit (5) consists of ceramic honeycomb with the oxidation catalyst as well as KDOC does. This ceramic honeycomb collects soot.

The inside of KCSF unit (5) 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 KDPF temperature sensor (assembly of 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 monitors the combinations of temperatures measured by 3 temperature sensors to see if KCSF unit (5) and KDOC function normally , and to troubleshoot various components.

The differential pressure sensor detects the pressure difference between before and after the KCSF unit (5) to monitor the accumulation of soot in KCSF unit (5), and to troubleshoot various components.

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 NO 2 (nitrogen dioxide), and regenerates (*1) KCSF.

•KCSF (2) captures soot.

•Accumulated soot in KCSF (2) in operation range where the temperature of exhaust gas is relatively high state 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.

•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 the amount of accumulated soot and the temperature of engine exhaust gas exceed the specified level, engine controller performs “automatic regeneration” to burn (oxydize) the soot.

While performing automatic regeneration, the engine controller calculates the exhaust gas temperature at KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust gas. (This is called “exhaust gas temperature raise control”)

The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the injector, and 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 soot captured in KCSF (2).

REMARK

When regeneration function on the machine monitor is disabled, or outside air temperature is extremely low, or continuous light load operation is carried out, relatively low exhaust temperature continues. In such case, “automatic regeneration” is not performed and the amount of soot accumulation is increased.

•If “automatic regeneration” is not performed due to the excess amount of accumulated soot in KCSF (2), perform “manual stationary regeneration” to burn (oxydize) the soot and reduce the amount of soot inside KCSF (2).

REMARK

Excessive amount of the soot interferes the flow of exhaust gas to worsen fuel consumption and engine combustion state. It may lead to other failures. If the amount of soot increases further, “manual stationary regeneration” cannot be performed safely. This will result in a KDPF failure and replacement is unavoidable. Make sure to follow the procedures in the Operation and Maintenance Manual when performing “manual stationary regeneration”.

*1: Soot purification (oxidation) treatment

Types of Regeneration Function

Regeneration means to purify (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF or maintain the urea SCR system normal.

Passive Regeneration

When the exhaust temperature of the engine is relatively high, the oxidation power of soot in the exhaust gas components is increased by the catalysis of KDOC to oxidize (burn) the soot accumulated in KCSF naturally

Active Regeneration (Engine Exhaust Temperature Rise Control + Fuel Dosing)

•Automatic regeneration

•When soot is accumulated more than a certain level or the urea SCR system makes a request to maintain itself normal, the engine enters the exhaust temperature rise control mode (*1) and performs fuel dosing (*2) and starts regeneration automatically.

The automatic regeneration is also performed by the direction from the engine controller at a set time after 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: Fuel injection performed to accelerate regeneration by increasing the exhaust temperature.

•Manual stationary regeneration

•When the exhaust temperature does not reach a certain level, depending on the operating condition of the machine, or when the operator disables regeneration, the automatic regeneration is not performed and accumulated soot in KCSF increases. Also, when the automatic regeneration is performed upon receiving a request from the urea SCR system, the exhaust temperature may not reach a certain level, depending on the operating condition of the machine. In these cases, a request for the manual stationary regeneration request is displayed on the machine monitor, and the operator must perform regeneration by the operation on the machine monitor screen.

In addition, when the engine controller 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 the Operation and Maintenance Manual for each machine.

•Always use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a failure in KDPF.

•Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the specified one is used, it can clog KDPF quickly, and that can increase fuel consumption and cause a failure in KDPF.

•Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally and may have trouble.

•Do not give strong impacts to KDPF by standing on it, dropping it, or hitting it, etc. KDPF has ceramic parts in it, and they may be broken by a strong impact.

•During the “automatic regeneration” and the “manual stationary regeneration”, especially at low temperature, white smoke may be discharged through the exhaust pipe outlet for a short time. This phenomenon is not abnormal. Be sure to perform regeneration in a well-ventilated area, since carbon monoxide may be generated.

•During the “automatic regeneration” and the “manual stationary regeneration”, the temperature of the exhaust gas discharged from the exhaust pipe may increase above 650 °C. To prevent a fire, check that there is no combustible around the exhaust pipe. Also, check that there is no person in the blow-out direction of the exhaust gas and confirm the safety around the machine.

REMARK

•If the mixing ratio of the bio-fuel in the diesel fuel is high, the regeneration of KDPF may become more frequent.

•Even when soot is not accumulated much, the engine controller may start “automatic regeneration”. This is automatic regeneration to maintain the function of KDPF or urea SCR system normal, and is not an abnormal operation. Automatic regeneration to maintain the function of urea SCR system normal or manual stationary regeneration takes approximately 1 hour.

•During the “automatic regeneration” and the “manual stationary regeneration”, VGT operates automatically and the engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and accordingly the exhaust sound changes. These phenomena are not abnormal.

•During the “automatic regeneration” and the “manual stationary regeneration”, the exhaust pipe may smell different from usual. This is not abnormal phenomenon.

•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, 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 mode)

100 to 250 °C

100 to 250 °C

400 to 550 °C

Cooling System

Layout Drawing of Cooling System

1: Aftercooler

2: Fuel cooler inlet

3: Fuel cooler

4: Fuel cooler outlet

5: Condenser

6: Air conditioner condenser opening and closing bracket

7: Oil cooler inlet

8: Reservoir tank

9: Aftercooler outlet hose

10: Fan guard

11: Radiator inlet hose

12: Radiator

13: Radiator cap

Specifications of Cooling System

Radiator

Core type: CF90-4

Fin pitch: 3.5/2 mm

Total heat dissipation area: 60.87 m2

14: Oil cooler

15: Oil cooler outlet

16: Aftercooler inlet hose

17: Shroud

18: Fan clutch assembly

19: Radiator outlet hose

20: Radiator drain valve

Cracking pressure of pressure valve: 0.05 MPa {0.5 kgf/cm2}

Cracking pressure of vacuum valve: -0.005 MPa {-0.05 kgf/cm2}

Oil Cooler

Core type: Thickness 62

Fin pitch: 3.5/2 mm

Total heat dissipation area: 21.46 m2

Aftercooler

Core type: Aluminum wave

Fin pitch: 4.0/2 mm

Total heat dissipation area: 9.98 m2

Fuel Cooler

Core type: Drawn cup

Fin pitch: 4.0/2 mm

Total heat dissipation area: 0.30 m2

Fan

Fan

Speed Control System of Fan Clutch

Speed Control System Diagram of Fan Clutch

*1: Only when air conditioner is used

*2: Control line corresponding to the control state of air conditioner is selected.

a: Hydraulic oil temperature sensor signal

b: CAN signal (coolant temperature sensor signal, engine speed sensor signal)

c: Cooling fan speed sensor signal

e: CAN signal (air conditioner fresh air temperature sensor signal, air conditioner compressor signal)

d: Solenoid signal

1: Engine controller

2: Coolant temperature sensor

3: Engine speed sensor

4: Hydraulic oil temperature sensor

5: Air conditioner compressor

6: Air conditioner fresh air temperature sensor

7: Air conditioner controller

8: Machine monitor

9: Pump controller

10: Fan clutch

Function of Fan Speed Control System of Fan Clutch

• Fan speed is controlled by engine speed, hydraulic oil temperature, and coolant temperature.

•Fan speed is controlled also by outside air temperature and information of air conditioner control (air conditioner compressor signal) while air conditioner is operated.

•Excess noise and fuel consumption are reduced by decreasing the fan speed when these temperatures are low. Fan Speed Control System of Fan Clutch

Engine Output Control System of Fan Clutch

Engine Output Control System Diagram of Fan Clutch

a: Hydraulic oil temperature sensor signal

b: CAN signal (coolant temperature sensor signal, engine speed sensor signal)

c: Cooling fan speed sensor signal

1: Engine controller

2: Coolant temperature sensor

3: Engine speed sensor

4: Hydraulic oil temperature sensor

5: Air conditioner compressor

Function

of Engine Output

Control

d: Solenoid signal

e: CAN signal (air conditioner fresh air temperature sensor signal, air conditioner compressor signal)

6: Air conditioner fresh air temperature sensor

7: Air conditioner controller

8: Machine monitor

9: Pump controller

10: Fan clutch

System of Fan Clutch When Normal

The pump controller calculates the horsepower consumed by the fan, and controls engine output curves (A1) and (B2) with the fan speed to reduce unnecessary fuel consumption.

Image of engine output (when fan speed varies)

When One-Touch Power Maximizing Function is Operated

The engine output curves (A2) and (B2) are kept constant regardless of the fan speed. Accordingly, the horsepower consumed by the main pump varies with the fan speed.

Image of engine output (when fan speed varies)

Component Parts of Cooling System

Fan Clutch

Structure of Fan Clutch

General View

Specifications of Fan Clutch

Type: Fluid coupling

Function of Fan Clutch

Fan speed which is transmitted from the engine to the shaft is decreased by built-in fluid coupling to achieve the target speed.

1: Connector

2: Fan

3: Clutch body

4: Shaft (engine mounted portion)

Layout Drawing of Control System (Machine with KOMTRAX Terminal)

Control System

Structure and Function

Layout Drawing of Control System (Machine with KOMTRAX Terminal)

Chassis Part

1:

Camera

2: CAN terminating resistor 3: Engine controller

Around Cab and Floor

1: Machine monitor

2: Control box

3: GNSS receiver

4: KOMTRAX communication antenna

5: KOMTRAX GPS antenna

6: Pump controller

7: Resistor for PC-EPC valve

8: KOMTRAX terminal

9: Work equipment controller

10: ICT sensor controller

Machine Monitor System

System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal)

a: Power supply

b: CAN signal

c: Sensor signal and switch signal

1: Machine monitor

2: Battery

3: Pump controller

4: Engine controller

5: Air conditioner controller

6: KOMTRAX terminal

7: Sensors and switches

*1:Machine without KomVision.

*2:Machine with KomVision.

d: Drive signal

e: Camera signal

f: Image signal

8: Wiper motor and window washer motor

9: Rearview camera (*1)

10:ID key controller

11:KomVision controller (*2)

12:KomVision camera (*2)

13:Work equipment controller

14:ICT sensor controller

Function of Machine Monitor System

•The monitor system keeps the operator informed of all the machine conditions, by monitoring them by using the sensors and switches installed in various parts of the machine and processing them instantly to display on the machine monitor.

The information displayed on the machine monitor falls into the following types:

•Alarm when the machine has trouble

•Machine state display (coolant temperature, power train oil temperature, hydraulic oil temperature, fuel level, etc.)

•Display of camera image (machine with camera)

•The switches on the machine monitor also have the functions to control the machine.

KomVision System

Layout Drawing of KomVision System

Chassis Part

1: R.H. front camera

2: R.H. camera

3: Rear camera

4: L.H. camera

Around Cab and Floor

1: Machine monitor

2: KomVision controller

System Diagram of KomVision System

1: Machine monitor

2: KomVision controller

3: L.H. camera

*1: When four cameras are installed

Function of KomVision System

4: Rear camera

5: R.H. camera

6: R.H. front camera (*1)

•KomVision system is the system that captures the vision around the machine by cameras attached to the various positions of the machine, and reflects the vision on the machine monitor

•The machine monitor shows the bird's eye view and the camera view.

•The bird's eye view displayed on the machine monitor is an image which is electrically composed with images captured by cameras attached to the machine.

•The camera image displayed on the machine monitor is an image which is captured by camera installed to the machine. The images to be displayed can be selected freely.

k The image displayed on the machine monitor does not reflect all around the machine. Perform the visual check always when operating the machine.

k Do not rely only on the image displayed on the machine monitor for the safety.

k The cameras do not capture the objects which are located higher than the cameras. Be careful about the objects which are located higher than the cameras such as a work equipment of the large machine, a branch of the tree, etc.

REMARK

•The upper part of the monitor screen does not always mean the front of the machine when the machine is with swing function.

•The upper part of the monitor screen recognizes the work equipment side of the upper structure as the front side, and the longitudinal and lateral directions are determined with that. The direction of the undercarriage is not recognized.

•For the function and the method of operation of KomVision system, see “Operation and Maintenance Manual”.

•Resetting of the items will be required when the blade is replaced or the track length is changed by referring to TESTING AND ADJUSTING, “SETTING OF KomVision (MAIN SETTING)”.

Shooting Area of KomVision Camera

The area KomVision cameras can capture for the bird's eye view varies as shown below, it depends on how many cameras are installed to the machine.

When Three Cameras are Installed

1: L.H. camera

2: Rear camera

3: R.H. camera

4-Camera Mount Version

1: L.H. camera

2: Rear camera

3: R.H. camera

4: R.H. front camera

KOMTRAX System

System Diagram of KOMTRAX System

KOMTRAX system consists of KOMTRAX terminal, communication antenna, and GPS antenna

Function of KOMTRAX System

•KOMTRAX system transmits various types of information on the machine. KOMTRAX administrator sees the information in the office and supplies various services to the customers.

•KOMTRAX system can transmits the following information.

•Positional information

•Working information

•Alarm and failure information

•Fuel consumption information

•Maintenance information

•Machine working condition information

REMARK

To provide the services, you need to establish radio station for KOMTRAX separately.

Component Parts of Control System

Machine Monitor

Function of Machine Monitor

•The machine monitor has the monitor display function, mode selection function, and switch function of the electrical components, etc. It also has the built-in warning buzzer

•CPU (Central Processing Unit) is mounted inside, and it processes, displays, and outputs information.

•The monitor system monitors the machine state by obtaining the information with the sensors and switches installed in various parts of the machine, processes the information instantly to display on the machine monitor, and informs the operator of the machine condition.

The information displayed on the machine monitor falls into the following types.

•Alarm when the machine has trouble

•Machine state display (engine coolant temperature, hydraulic oil temperature, fuel level, etc.)

•Display of camera image

•The switches on the machine monitor have functions to control the machine.

REMARK

•The machine monitor consists of the display and switch section. The display is LCD (Liquid Crystal Display), and the switch section consists of flat sheet switches.

•If there is abnormality in the machine monitor, controller, or wiring between the machine monitor and controller, the machine monitor does not display normally.

•The battery voltage may drop sharply when the engine is started depending on the ambient temperature and battery condition. In this case, the display may disappear for a while, but it is not an abnormal phenomenon.

•If environmental temperature of the machine monitor is high, brightness may be automatically reduced to protect the liquid crystal.

•Intensity or color of the objects may change because of the automatic adjustment function of the camera.

•See “Operation and Maintenance Manual” for the following items.

•Display (screen display)

•Switches

•Guidance icons and function switches

and Output Signals of Machine

Monitor

Never connect these pins. Malfunctions or failures

*1: Never connect these pins. Malfunctions or failures may occur

070-20P “CM03”

*1: Never connect these pins. Malfunctions or failures may occur 070-8P “CM04”

Gauges and Meters Shown on Machine Monitor

GaugeItem displayed

Range

(*1)

Engine coolant temperature gauge

Description

Temperature

Monitor background

W1105 °CRed

W2102 °CRed

W3100 °CBlue

W485 °CBlue

W560 °CBlue

W630 °CWhite

Range

(*1)

Hydraulic oil temperature gauge

Temperature

Monitor background

H1105 °CRed

H2102 °CRed

H3100 °CBlue

H485 °CBlue

H540 °CBlue

H620 °CWhite

RangeQuantity

(*1)

Fuel level gauge

(*2)

ECO gauge

Remarks

• Indicates corresponding temperature range.

• Alarm buzzer sounds at 105 °C or higher.

• If monitor background color is white, warm up the engine.

• Indicates corresponding temperature range.

• Alarm buzzer sounds at 105 °C or higher.

• If monitor background color is white, warm up the hydraulic components.

Monitor background Indicates corresponding level range.

F1304 ℓBlue

F2245 ℓBlue

F3200 ℓBlue

F4100 ℓBlue

F560 ℓBlue

F641 ℓRed

SegmentLoad levelIndicates instantaneous fuel consumption (average of fuel consumption by 3 seconds) in 10 steps.

Green1 to 8 Light to medium

Orange9, 10Heavy

(Displays when ECO Guidance → Configurations → ECO Gauge on user menu is set to ON.)

GaugeItem displayed

Description

RangeQuantity Gauge range

A1100 %Green

A275 %Green

DEF level gauge

Remarks

Indicates corresponding level range.

A350 %Green

A425 %Green

A510 %Green

A62.5 %Red

A70 %Red

Service meter00000.0 h to 99999.9 h

Indicates accumulated engine operating hours (alternator is generating). (Press F4 switch to change to clock display.) Clock

• 12-hour system display (AM/PM)

• 24-hour system display

(*2)

Fuel consumption gauge

• 1 Day

• Split time

• None

Displays time. (Press F4 switch to change to service meter display.)

Displays average fuel consumption. (Display can be switched by selecting another item in ECO Guidance → Configurations → Average Fuel Consumption Display on user menu.)

*1: The gauge pointer disappears if the gauge signal is not available due to an open circuit in the CAN communication line.

*2: Display can be switched by selecting another item in ECO Guidance → Configurations on user menu.

Caution Lamps Shown on Machine Monitor

Description

SymbolDisplay item

Engine coolant temperature (*1)

Hydraulic oil temperature (*1)

Remaining fuel level (*1)

Radiator coolant level (*1)

Battery charge (*1)

Engine oil pressure (*1)

Engine oil level (*1)

Remarks Range

Caution lamp display (background color) Action level display

Min. 102 °CLit (red)L02

30 °Cor more, 102 °Cor below Lit (blue)-

Lower than 30 °C Lit (white)-

Min. 102 °CLit (red)L02

20 °Cor more, 102 °Cor below Lit (blue)-

20 °Cor belowLit (white)-

• Monitor background color changes depending on the temperature detected.

• Alarm buzzer sounds when the temperature exceeds 105 °C.

• If monitor background color is white, warm up the engine.

• Monitor background color changes depending on the temperature detected.

• Alarm buzzer sounds when the temperature exceeds 105 °C.

• If monitor background color is white, warm up the hydraulic components.

56 ℓor belowLit (red)-Background color of monitor changes according to the remaining amount.

Min. 56 ℓ Lit (blue)-

For an entire hour (Below specified level) Lit (red)L02

• Caution lamp background color changes depending on the hours detected.

• When the background color of caution lamp is red, the alarm buzzer sounds. (Below specified level) Lit (yellow)L01 (*3)

Normal Not lit -

When the charging is faulty (charge voltage < battery voltage) Lit (red)L03

When it is abnormal (Below specified pressure) Lit (red)L03

When it is abnormal (Below specified level) Lit (yellow)L01 (*3)

Caution lamp lights up and alarm buzzer sounds when an abnormality is detected while engine is running.

Caution lamp lights up and alarm buzzer sounds when an abnormality is detected while engine is running.

Caution lamp lights up when an abnormality is detected while engine is stopped.

SymbolDisplay item

Air cleaner clogged (*1)

Water separator (*1)

Range

When it is abnormal

Description

Caution lamp display (background color)

Maintenance due time warning

State of system

State of engine system

State of hydraulic system

State of KDPF system

Remarks

Action level display

(Above specified pressure) Lit (yellow)L01 (*3)

When it is abnormal

(There is water collected above the specified amount.) Lit (red)-

When maintenance due time is over Lit (red)-

When maintenance notice time is over (*2) Lit (yellow)-

When action level L04, L03 are sensed Lit (red)L04, L03

When action level L01 is detected Lit (yellow)L01 (*3)

When action level L04, L03 are sensed Lit (red)L04, L03

When action level L01 is detected Lit (yellow)L01 (*3)

When action level L04, L03 are sensed Lit (red)L04, L03

When action level L01 is detected Lit (yellow)L01 (*3)

When action level L04, L03 are sensed Lit (red)L04, L03

When action level L01 is detected Lit (yellow)L01 (*3)

Caution lamp lights up when an abnormality is detected while engine is running.

Caution lamp lights up when an abnormality is detected while engine is running.

• The display changes according to how long it has passed since the maintenance due time was over

• After starting switch is turned to ON position, caution lamp lights up if condition for lighting it up is satisfied, and then goes out in 30 seconds.

• Caution lamp lights up when an abnormality is detected in machine system.

• Alarm buzzer sounds when the background color of the caution lamp is red.

• Caution lamp lights up when an abnormality is detected in engine system.

• Alarm buzzer sounds when the background color of the caution lamp is red.

• Caution lamp lights up when an abnormality is detected in hydraulic system.

• Alarm buzzer sounds when the background color of the caution lamp is red.

• Caution lamp lights up when a failure is detected in KDPF system.

• Alarm buzzer sounds when the background color of the caution lamp is red.

SymbolDisplay item

KDPF soot accumulation

Range

Engine overrun

State of air conditioner

DEF level

State of DEF system

Engine stops while the temperature of DEF system is high.

Engine abruptly stops by AIS

Description

Caution lamp display (background color)

Remarks

Action level display

When action level L04, L03 are detected Lit (red)L03

When action level L01 is detected Lit (yellow)L01 (*3)

When the engine overruns Lit (red)L02

When the air conditioner is abnormal Lit (yellow)L01 (*3)

Max. 0.09 %Lit (red)L04

Max. 2.5 %Lit (red)L03

Max. 10 %Lit (red)Exceeds 10 %Lit (blue)-

When action level L04, L03 are sensed Lit (red)L04, L03

When action level L01 is detected Lit (yellow)L01 (*3)

High temperature is detected in DEF system 150 times or more Lit (yellow)L01 (*3)

Engine abruptly stops 2000 times or more Lit (red)L03

Engine abruptly stops 1000 times or more, and less than 2000 times Lit (yellow)L01 (*3)

• Caution lamp lights up when soot is accumulated in KDPF or when purifying function deteriorates abnormally

• Alarm buzzer sounds when the background color of the caution lamp is red.

Caution lamp lights up and alarm buzzer sounds when engine overrun is detected.

Caution lamp lights up when an abnormality is detected in air conditioner system.

• Caution lamp background color changes depending on the remaining level.

• Alarm buzzer sounds at 2.5 % or lower.

• Caution lamp lights up when an abnormality is detected in DEF system.

• When the background color of caution lamp is red, the alarm buzzer sounds.

When the engine is stopped with high temperature of DEF being detecetd more than 150 times, the caution lamp lights up.

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SymbolDisplay item

Action level

Camera system (*4)

Range

Camera system (*4)

ICT component abnormality

Description

Caution lamp display (background color)

Remarks

Action level display

When action level L04 is detected Lit (red)L04

When action level L03 is detected Lit (red)L03

When action level L02 is detected Lit (red)L02

When action level L01 is detected Lit (yellow)L01 (*3)

When action level L01 is detected Lit (yellow)L01

When action level L03 is detected Lit (red)L03

When action level L01 is detected Lit (yellow)L01

Range Monitor display (background color)

Action level monitor

When action level L04 is detected Lit (red)L04

When action level L03 is detected Lit (red)L03

When action level L02 is detected Lit (red)L02

When action level L01 is detected Lit (yellow)L01

• Caution lamp lights up when abnormality is detected in the machine.

• Alarm buzzer sounds when the background color of the caution lamp is red.

Caution lamp lights up when an abnormality caused by open circuit of cables, looseness of connectors, or abnormality of camera signals caused by disconnection is detected.

Caution lamp lights up when an abnormality is detected in KomVision system.

• Monitor lights up when abnormality is detected in ICT component.

• Alarm buzzer sounds when the background color is red.

SymbolDisplay item

ICT System Abnormality

ICT calibration is not done yet.

IMU initial process abnormality

State of cylinder function

Description

Range Caution lamp display (background color)

Range

Action level display

Monitor display (background color) Action level monitor

When action level L04 is detected Lit (red)L04

When action level L03 is detected Lit (red)L03

When action level L02 is detected Lit (red)L02

When action level L01 is detected Lit (yellow)L01

When action level L01 is detected Lit (yellow)L01

When action level L0ob is detected Lit (yellow)-

Cylinder reset is not yet done Lit (yellow)-

Remarks

• Monitor lights up when abnormality is detected in ICT system.

• Alarm buzzer sounds when the background color is red.

• Monitor lights up when calibration is detected as not having been performed yet.

Monitor lights up when internal sensor output error is detected in IMU.

Lights up if resetting for one of arm, boom, bucket is not yet done after you turn the starting switch to the ON position.

*1: These are included in the check before starting items. These symbols are lit for 2 seconds after the starting switch is turned to the ON position, and goes back to the standard state if no failure is found.

*2: Maintenance notice time can be changed on Maintenance Mode Display Setting of service mode.

*3: These items are lit for 2 seconds, and then go out.

*4: For machine with KomVision.

Pilot Lamps Shown on Machine Monitor

SymbolItem displayed Description Remarks

Automatic preheating

Preheating

• Operates automatically at low temperature. (Be lit for approx.30 sec. at maximum.)

• Goes out after engine is started.

Elapsed time after turning starting switch to HEAT (preheat)

Manual preheating

Monitor display

0 to 30 seconds Lights up

30 to 40 seconds Flashes

40 seconds or longer

One-touch power maximizing switch

One-touch power maximizing

Lights off

Monitor display

ON Lights up (Goes out approx. 8.5 seconds after, if held down)

OFFLights off

Swing lock switch

Swing lock

Wiper

Air conditioner

Swing parking brake cancel switch

Monitor display

OFFOFFLights off ON OFFLights up OFF ONFlashes ON ONFlashes

INT: Intermittent operation ON: Continuous operation Goes off: Stopped

Lights up: ON

Lights off: OFF

Seat belt

Lights up: Not fastened

Lights off: Fastened

Stopping engine

Lights up: When engine is stopped

Lights off: When engine is running

Displays the operation state of preheating.

Indicates operation state of onetouch power maximizing function.

Displays operation state of swing lock.

Displays the operation state of front window wiper

Indicates the operation state of air conditioner and blower

Indicates whether seat belt is fastened.

Indicates the operation state of engine.

SymbolItem displayed

Aftertreatment devices regeneration

Aftertreatment devices regeneration disable

Message (Unread)

Message (No return message, alreadyread message)

Auto-deceleration

Working mode

Travel speed

Lock lever

ECO guidance

Description

Lights up: Aftertreatment devices regeneration in progress

Lights off: Aftertreatment devices regeneration completed

Lights up: Aftertreatment devices regeneration disabled

Lights off: When aftertreatment devices regeneration disable is canceled

Lights up: There is unread message.

Lights off: No message.

Lights up: There is already-read message but return message for it is not sent yet.

Lights off: No message.

Lights up: ON

Lights off: OFF

P: Heavy-duty operation

E: Low-fuel consumption operation

L: Fine control operation

B: Breaker operation

ATT/P: 2-way attachment operation

ATT/E: 2-way attachment operation with low fuel consumption

Lo: Low-speed travel

Mi: Middle-speed travel

Hi: High-speed travel

Lights up: Lock position

Lights off: FREE position

• Idle stop guidance

• Deterrence guidance of hydraulic relief

• Economy mode recommended guidance

• Travel at reduced engine speed recommended guidance

• Low fuel level guidance

Remarks

Indicates regeneration state of aftertreatment devices.

• Indicates regeneration state of aftertreatment devices.

• When manual stationary regeneration is necessary, KDPF soot accumulation caution lamp lights up.

Displays the state of message.

Displays the state of message.

Displays operation state of autodeceleration function.

Displays the set working mode.

Displays the set mode of travel speed.

Displays position state of lock lever

Displays the guidance to support operation of the machine.

Operator Mode Function of Machine Monitor

The information items in this mode are displayed ordinarily. The operator can display and set them by operating the switches. Display and setting of some items need special operations of the switches.

Items available in the operator mode are as follows:

*1: The operator mode items are classified as follows.

A: Display from the time when the starting switch is turned to “ON” position to the time when display changes to the standard screen, and display after starting switch is turned to “OFF” position

B: Display when the machine monitor switch is operated

C: Display when condition is satisfied

D: Display that requires special operations of switches

*2: Display sequence from the time when the starting switch is turned to ON position to the time when the standard screen appears varies depending on the settings and conditions of the machine as follows:

V: When engine start lock is enabled

W: When engine start lock is disabled

X: When working mode at start is set to “Breaker mode (B)”

Y: When any abnormality is detected by the check before starting

Z: When any item is detected as the maintenance due time is over

REMARK

•For how to operate the operator mode functions, see the Operation and Maintenance Manual.

•For the operating method of the engine start lock function, see “Password setting and canceling manual”.

Display

Display of end screen

C

Selection of auto-deceleration

Selection of working mode

Selection of travel speed

Stop operation of alarm buzzer

Operation of windshield wiper

Operation of window washer

Operation of air conditioner

Operation to display camera mode

Check of maintenance information

Setting and display of user menu

• ECO Guidance

• Machine Setting

• Aftertreatment Devices Regeneration

• SCR Information

• Maintenance

• Monitor Setting

• Display of message (including KOMTRAX messages for user)

Display of ECO guidance

Display of caution monitor

Display of KDPF regeneration

Display of action level and failure symbol D

Checking function by LCD (Liquid Crystal Display)

Function to check service meter

Function of usage limitation setting/change password

Service Mode Function of Machine Monitor

The information items in this mode are not normally shown. Technicians can operate the specific switches to change display and settings. These are used for the special settings, test, adjust, and troubleshoot.

You can select the below items for the service mode.

REMARK

See TESTING AND ADJUSTING, “SERVICE MODE” to operate the each function of the service mode.

Pre-defined Monitoring

Monitoring

Abnormality Record

Maintenance Record

Maintenance Mode Setting

Phone Number Entry

Default

Diagnostic Tests

Mechanical Sys Abnormality Record

Electrical Sys Abnormality Record

Adjust

No-Injection Cranking

KOMTRAX Settings

Service Message

Key-on Mode

Unit

With/Without Attachment

Camera Setting

Auto Idle Stop Time Fixing

With/Without KomVision

Cylinder Cutout Mode Operation

Active Regeneration for Service

KDPF Memory Reset

SCR Service Test

Stop at DEF Inj Overheat Count Reset

Engine Controller Active Fault Clear

Ash in Soot Accumulation Correction

Reset Number of Abrupt Engine Stop by AIS

Pump Absorption Torque (F)

Pump Absorption Torque (R)

Travel Low Speed

Att Flow Adjust in Combined Ope

Calibrate F Pump Swash Plate Sensor

Calibrate R Pump Swash Plate Sensor

Fan Speed Mode Select

KomVision Adjustment

Terminal Status

GPS and Communication State

Modem Information

KomVision Controller

Structure of KomVision Controller

General View

Input and Output Signals of KomVision Controller

AMP-81P“CA01”

Pin No.

21NTSC signal output 3ch

22NTSC signal output 2ch

23NTSC signal output 1ch

24NTSC signal output 0ch

25Power supply for camera (8 V) Output

40Image signal system GND 3ch

41Image signal system GND 2ch

42Image signal system GND 1ch

43Image signal system GND 0ch

44Power supply for camera (8 V)

Pin No.

52(*1)

53(*1)

56(*1)

59(*1)

60(*1)

61(*1)

62(*1)

63Power supply for camera (8 V)

65(*1)

66(*1)

67(*1)

68(*1)

69(*1)

70(*1)

72(*1)

73(*1)

74(*1)

75(*1)

76(*1)

78(*1)

79(*1)

80(*1)

81(*1)

*1: Never connect these pins, otherwise it may cause malfunction or failures.

Pin No.

Pin No.

Signal name

Input and output signals

86(*1) -

87System operating lamp output Output 88(*1)89WAKE Input 90(*1)

96ACC (key input) Input

97ACC (key input) Input

98NTSC output GND Output 99(*1)

104Power supply GND Input

105Power supply GND Input

106NTSC signal output Output

110CAN signal + Input and output

111CAN0 signal - Input and output

112Continuous power supply Input

113Continuous power supply Input 114(*1)

*1: Never connect these pins, otherwise it may cause malfunction or failures.

KomVision Camera

Structure of KomVision Camera

General View

Input and Output Signals of KomVision Camera

DT-4P

Pin No.

Signal name

Input and output signals

1Camera power supply Input

2Video output Output

3(*1) -

4GND -

*1: Never connect these pins. It may cause malfunction or failure.

KOMTRAX Terminal

Structure of KOMTRAX Terminal

General View

Model: TC630/TC635

1: GPS antenna connection

2: Machine harness connection (070-18P)

3: Machine harness connection (070-12P)

Function of KOMTRAX Terminal

4: Communication antenna connection

5: LED lamp display

• This terminal uses the communication technology of cell phone.

•This terminal is the wireless communication equipment which enables to transmit GPS locational information and various machine information which is received from network signal or input signal. It can transmit the information via communication antenna.

•The condition of KOMTRAX terminal can be checked on the “KOMTRAX Setting” screen in the service mode of the machine monitor.

•Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.

•The terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its display section.

REMARK

•When commencing the operation of the KOMTRAX system or changing the country in which the system is used, you must give notice to Komatsu Ltd.

•When operating the system in Japan, it is required to install a terminal for exclusive use in Japan.

Input and Output Signals of KOMTRAX Terminal

070-18P“CK01”

Pin No.

Signal name

Input and output signals

9(*1) -

10CAN (C)_H Input and output

11CAN (C)_L Input and output

12(*1) -

13(*1) -

14External starting signal Input and output

15System operating lamp Output

16(*1) -

17(*1) -

18(*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.

070-12P“CK02”

Pin No.

Signal name

Input and output signals

1GND -

2GND -

3Starting switch (ACC) Input

4Alternator (R) Input

5(*1) -

6Power supply Input

7Power supply Input

8(*1) -

9(*1)10(*1) -

11Starting switch (C) Input

12(*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.

Gateway Function Controller

Function of Gateway Function Controller

1: Machine wiring harness connection port (AMP-81P)2: GNSS antenna connection port

The Gateway function Controller is used to transmit various information about machines obtained from network signals and input signals, and GPS location information via wireless communication. It sends the information through the communication terminal.

You can check the condition of this controller on the KOMTRAX Setting screen in the service mode of the machine monitor.

You cannot use the Gateway function Controller in countries or regions that do not have legal authorization. NOTICE

The means of communication (telecommunications company) vary in response to the country or region used. Communication devices have a built-in communication device that matches the country or region. You need to report a notification in some cases if you want to change the country where you use this. For more information, please contact your local KOMTRAX representative.

Input and Output Signals of Gateway Function Controller

AMP-81P [CN-CK05]

Pin No.

Name of signal

Input and output signals

1Turn on the power supply. Input

2Power supply GND Input

3Turn on the power supply. Input

4Power supply GND Input

5(*1)

6(*1)

7CAN_H (Komnet/r) Input and output

8CAN_H (sensor 2) Input and output

9Centralized warning lamp output (additional function side) Output

10(*1)

11(*1)

12(*1)

Pin No.

Name of signal

Input and output signals

13(*1) -

14Ethernet_RX- (service tool) Input

15Ethernet_RX+ (service tool) Input

16Ethernet_TX- (service tool) Output

17Ethernet_TX+ (service tool) Output

18Ethernet power supply output (POE) Output

19Power supply for sensor (5V) Output

20Rewriting state display output Output

21(*1)

22C terminal signal input Input

23(*1)

24ACC signal input Input

25(*1)

26CAN_L (Komnet/r) Input and output

27CAN_L (sensor 2) Input and output

28(*1) -

29(*1)

30(*1)

31(*1)

32(*1)

33(*1)

34(*1)

35(*1)

36(*1)

37Sensor GND Input

38Power supply for sensor (12V) output Output

39Communication terminal starting output 1 Output

40(*1)

41R terminal signal input Input

42(*1)

43(*1)

44(*1)

45CAN_H (Komnet/c) Input and output

46CAN_H (sensor 1) Input and output

47(*1)

48(*1)

49(*1)

50(*1)

51(*1)

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