Shop Manual
WHEEL LOADER
00 INDEX AND FOREWORD ABBREVIATION LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 FOREWORD, SAFETY, BASIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 HOW TO READ THE SHOP MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 SAFETY NOTICE FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11 PRECAUTIONS TO PREVENT FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-21 ACTIONS IF FIRE OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-23 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-24 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-25 PRECAUTIONS FOR DEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-26 STORE AdBlue/DEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-28 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-29 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . . . . . . . . . . . . . . . . . . . . . . . . . 0-32 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-43 HANDLING WIRING HARNESSES AND CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-43 MAIN CAUSES OF FAILURE IN WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-43 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-46 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-47 PRACTICAL USE OF KOMTRAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-48 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . . . . . . . . . . . . . . . . 0-50 PRECAUTIONS FOR TROUBLESHOOTING ELECTRICAL CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . 0-54 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . . . . . . . . . . . . . . . . 0-55 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . . . . . . . . . 0-56 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . . . . . . . 0-57 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . . . . . . 0-58 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE. 0-60 HOW TO READ ELECTRICAL WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-62 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-64 STANDARD TIGHTENING TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-67 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-75
KOMATSU
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ABBREVIATION LIST
INDEX AND FOREWORD
ABBREVIATION LIST
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
Abbreviations that are used in general society may not be included.
Special abbreviations which appear infrequently are noted in the text.
This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text AbbreviaActual word spelled out tion
Purpose of use (major applicable machine (*1), or component/system) Travel and brake
ABS
Antilock Brake System (HD, HM)
AISS
Automatic Idling Setting System
AJSS
Advanced Joystick Steering System
ARAC
ARSC
ASR
Automatic Retarder Accelerator Control
Automatic Retarder Speed Control
Automatic Spin Regulator
ATT
Attachment
BCV
Brake cooling oil control valve
Engine Steering (WA) Travel and brake (HD, HM) Travel and brake (HD, HM) Travel and brake
Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate. This is a function that automatically 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. This is a function that automatically operates the retarder with a constant braking force when let- ting go of the accelerator pedal on the downhill. This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the opera- tor when letting go of the accelerator pedal on the downhill.
(HD, HM)
This is a function that drives both wheels auto- matically using the optimum braking force when the tire on one side spins on the soft ground sur- faces.
Work equipment
A function or component that can be added to the standard specification.
BRAKE (HD)
This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hy- draulic pump when the retarder is not being used.
CAN
Controller Area Network
Communication and electronic control
This is one of communication standards that are used in the network on the machine.
CDR
Crankcase Depression Regulator
Engine
This is a regulator valve that is installed to CCV ventilator. It is written as CDR valve and is not used independently.
CLSS
Closed-center Load Sensing System
Hydraulic system
This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).
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KOMATSU
INDEX AND FOREWORD
ABBREVIATION LIST
Purpose of use (major apAbbrevia- Actual word spelled out plicable machine (*1), or Explanation tion component/system) Common Rail Injection Engine CRI
ECM
Electronic Control Mod- ule
Electronic control system
Transmission ECMV
Electronic Control Mod- ulation Valve
ECSS
Electronically Controlled
(WA)
Electronic Control Unit
Electronic control system
Exhaust Gas Recircula- tion
Engine
Machine monitor
EMMS
Equipment Management Monitoring System
EPC
Electromagnetic Propor- tional Control
Hydraulic system
Cab and canopy
FOPS
Falling Object Protective Structure
F-N-R
Forward-Neutral-Reverse
GPS
Communication Global Positioning System (KOMTRAX, KOMTRAX
GNSS
Global Navigation Satel- lite System
HSS
Hydrostatic Steering System
(D, HD, WA, etc) Travel
ECU
EGR
Operation
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 This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging This is a device that ensures smooth highspeed travel by absorbing vibration of machine during travel with hydraulic spring effect of 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 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 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. Forward - Neutral - Reverse This system uses satellites to determine the cur- rent location on the earth.
Communication (KOMTRAX, KOMTRAX Steering
HST
KOMATSU
(D Series)
Transmission Hydro Static Transmission (D, WA)
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 differ- ence in travel speed of right and left tracks with a combination of hydraulic motor and Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear
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ABBREVIATION LIST
INDEX AND FOREWORD
Purpose of use (major apAbbrevia- Actual word spelled out plicable machine (*1), or Explanation tion component/system) ICT
IMA
A general term for the engineering and its Information and Com- Communication and elec- social- ly applied technology of information promunication Technology tronic control cessing and communication. Inlet Metering Actuator Engine
Inertial Measurement Unit
Engine
Inlet Metering Valve
Engine
Engine
CCV
Closed Crankcase Ventilation
KCSF
Komatsu Catalyzed
Engine
KDOC
Komatsu Diesel Oxida- Engine tion Catalyst
KDPF
Komatsu Diesel Partic- Engine ulate Filter
IMU
IMV
KTCS
Travel and brake Komatsu Traction Control System (HM)
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 This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that con- trol 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. 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 ex- haust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. 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.
Liquid Crystal Display
Machine monitor
LED
Light Emitting Diode
Electronic parts
LIN
Local Interconnect Net- Communication and elec- This is one of communication standards that work tronic control are used in the network on the machine.
LCD
LS LVDS
MAF
00-4
This is a semiconductor element that emits light when the voltage is applied in forward direction.
This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.
Load Sensing
Hydraulic system
Low Voltage Differential
Communication and elec- This is one of communication standards that tronic control are used in the network on the machine.
Mass Air Flow
Engine
This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.
KOMATSU
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INDEX AND FOREWORD
ABBREVIATION LIST
Purpose of use (major apAbbrevia- Actual word spelled out plicable machine (*1), or Explanation tion component/system) MMS
NC
NO
Multimedia Messaging Service
Communication
This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
Normally Closed
This is a characteristic of electrical or hydraulic Electrical system, hydrau- circuits. Circuit is normally closed if it is not lic system actu- ated, and it opens when it is actuated.
Normally Open
This is a characteristic of electrical or hydraulic Electrical system, hydrau- circuits. Circuit is normally open if it is not actulic system ated, and it closes when it is actuated.
OLSS
Open-center Load Sensing System
Hydraulic system
This is a hydraulic system that can operate multi- ple actuators at the same time regardless of the load.
PC
Pressure Compensation
Hydraulic system
This is a function that corrects the oil pressure.
Steering
This is a function that electrically controls the en- gine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.
PCCS
PCV
Palm command control system
Pre-stroke Control Valve
(D Series)
Engine
This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel dis- charged volume of supply pump.
PPC
Proportional Pressure Control
Hydraulic system
This is a system that operates actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
Hydraulic system (D, PC, etc)
Piston type hydraulic pump and motor.
PTO
Power Take Off
Power train system
Power take-off mechanism
Work equipment PTP
Power Tilt and power Pitch dozer
This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bull- dozer.
Roll-Over Protective Structure
(D Series) Cab and canopy
ROPS
Selective Catalytic Re- Urea SCR system duction SCR
SI
SOL
KOMATSU
Le Systeme International d' Unites (International unit system)
Unit
Solenoid
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. (Rollover 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 re- action. 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. 00-5
ABBREVIATION LIST
INDEX AND FOREWORD
Purpose of use (major apAbbrevia- Actual word spelled out plicable machine (*1), or Explanation tion component/system) Tip-Over Protective Structure
Cab and canopy
TOPS
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.
Hydraulic system
This is a solenoid valve that switches over direction of flow.
TWV
2-Way Valve
VGT
Variable Geometry Turbocharger Engine
This is a turbocharger on which the cross-section area of the exhaust passage is variable.
VHPC
Variable Horse Power Control
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.
Engine control
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
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KOMATSU
INDEX AND FOREWORD
ABBREVIATION LIST
List of abbreviations used in the circuit diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP
Option
PRESS
Pressure
SPEC
Specification
SW
Switch
TEMP
Temperature
T/C
Torque Converter
T/M
Transmission
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FOREWORD, SAFETY, BASIC INFORMATION
INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION HOW TO READ THE SHOP MANUAL REMARK
Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
The materials and specifications are subject to change without notice.
Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.
Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
Composition of the shop manual This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use. 00 INDEX AND FOREWORD This section describes the index, foreword, safety, and basic information. 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. 00-8
KOMATSU
INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
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 STANDARDS 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.
KOMATSU
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FOREWORD, SAFETY, BASIC INFORMATION
INDEX AND FOREWORD
Symbols Important safety and quality portions are marked with the following symbols so that shop manual is used effectively. Symbol
Item
Remarks
Danger
This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.
Warning
This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.
Caution
This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.
Weight
This signal indicates the weight of parts and components, and items which requires great attention to a selection of wires and working posture for slinging work.
Tightening torque
This signal indicates the tightening torque for portions which requires special care in assembling work.
2
Coat
This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.
5
Oil and coolant
This signal indicates a place to supply oil, coolant, etc. and the quantity
6
Draining
This signal indicates a place to drain oil, coolant, etc. and the quantity.
,
Safety
This symbol indicates the works which require special caution for the machine safety when assembling.
4 3
Signal word Signal word for notice and remark describes the following. Symbol
Item
Remark
NOTICE
Notice
If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur.
REMARK
Remark
This signal word contains useful information to know.
Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.
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KOMATSU
INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
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 occur or be anticipated during such work, be sure to keep safe first and take every necessary measure.
Safety matters
Well organized work place
Correct work clothes
Observance of work standard
Enforcement of hand signals
Prohibition against unlicensed persons operating and handling the machine
Safety check before starting work
Wear of dust glasses (for cleaning or grinding work)
Wear of welding goggles and protectors (for welding work)
Being in good physical condition, and good preparation
Always be alert and careful.
KOMATSU
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FOREWORD, SAFETY, BASIC INFORMATION
INDEX AND FOREWORD
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.
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KOMATSU
INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
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.
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