INDEXANDFOREWORD
PRECAUTIONSFORDISCONNECTIONANDCONNECTIONOFCONNECTORS................0-50
PRECAUTIONSFORTROUBLESHOOTINGELECTRICALCIRCUITS..........................0-54
METHODFORDISCONNECTINGANDCONNECTINGDEUTSCHCONNECTOR................0-55
METHODFORDISCONNECTINGANDCONNECTINGSLIDELOCKTYPECONNECTOR.........0-56
METHODFORDISCONNECTINGANDCONNECTINGCONNECTORWITHLOCKTOPULL.......0-57
METHODFORDISCONNECTINGANDCONNECTINGCONNECTORWITHLOCKTOPUSH......0-58
METHODFORDISCONNECTINGANDCONNECTINGCONNECTORWITHHOUSINGTOROTATE.0-60
ABBREVIATIONLIST
Thislistofabbreviationsincludestheabbreviationsusedin thetextoftheshopmanualforparts,components,andfunctionswhosemeaningisnotimmediatelyclear.Thespelling isgiveninfullwithanoutlineofthemeaning.
Abbreviationsthatareusedingeneralsocietymaynotbe included.
Specialabbreviationswhichappearinfrequentlyarenotedin thetext.
Thislistofabbreviationsconsistsoftwoparts.Thefirstpart isalistoftheabbreviationsusedinthetextofthemanual, andthesecondpartisalistoftheabbreviationsusedinthe circuitdiagrams.
Listofabbreviationsusedinthetext
Abbrevia-tionActualwordspelledout
ABSAntilockBrakeSystem
Purposeofuse(majorapplicablemachine(*1),or component/system)
Travelandbrake (HD,HM)
AISSAutomaticIdlingSetting System Engine
AJSSAdvancedJoystick SteeringSystem
ARACAutomaticRetarderAcceleratorControl
ARSCAutomaticRetarder SpeedControl
ASRAutomaticSpinRegulator
Steering (WA)
Travelandbrake (HD,HM)
Travelandbrake (HD,HM)
Travelandbrake (HD,HM)
ATTAttachmentWorkequipment
BCVBrakecoolingoilcontrol valve
BRAKE (HD)
CANControllerAreaNetworkCommunicationandelectroniccontrol
CDRCrankcaseDepression Regulator Engine
CLSSClosed-centerLoadSensingSystemHydraulicsystem
Explanation
Thisisafunctionthatreleasesthebrakewhenthe tiresskid(tiresarenotrotated).Thisfunctionapplies thebrakeagainwhenthetiresrotate.
Thisisafunctionthatautomaticallysetstheidle speed.
Thisisafunctionthatperformsthesteeringoperationswithaleverinsteadofusingasteeringwheel. Thisfunctionperformsgearshiftingandchanging forwardandreversedirection.
Thisisafunctionthatautomaticallyoperatesthe retarderwithaconstantbrakingforcewhenlet-ting gooftheacceleratorpedalonthedownhill.
Thisisafunctionthatautomaticallyoperatesthe retardertoensurethatthemachinespeeddoesnot accelerateabovethespeedsetbytheopera-tor whenlettinggooftheacceleratorpedalon thedownhill.
Thisisafunctionthatdrivesbothwheelsauto-maticallyusingtheoptimumbrakingforcewhenthetire ononesidespinsonthesoftgroundsur-faces.
Afunctionorcomponentthatcanbeaddedtothe standardspecification.
Thisisavalvethatbypassesapartofthebrake coolingoiltoreducetheloadappliedtothehy-draulicpumpwhentheretarderisnotbeingused.
Thisisoneofcommunicationstandardsthatare usedinthenetworkonthemachine.
ThisisaregulatorvalvethatisinstalledtoCCVventilator.ItiswrittenasCDRvalveandisnotused independently.
Thisisasystemthatcanactuatemultipleactuators simultaneouslyregardlessoftheload(providesbettercombinedoperationthanOLSS).
Abbreviation
Actualwordspelledout
Purposeofuse(majorapplicablemachine(*1),or component/system)
CommonRailInjectionEngine
CRI
ECM
ElectronicControl Mod-ule
ECMVElectronicControl Mod-ulationValve
ECSSElectronicallyControlled
ECU
Electroniccontrolsystem
Transmission (D,HD,WA,etc)
Travel (WA)
ElectronicControlUnitElectroniccontrolsystem
Explanation
Thisisafunctionthatmaintainsoptimumfuel injectionamountandfuelinjectiontiming.This isperformedtheenginecontrollerwhichelectronicallycontrolssupplypump,commonrail, andinjector.
Thisisanelectroniccontroldevicethatsend thecommandtoactuatorsusingthesignals fromthesensorsonthemachinesothatthe optimumactuationisperformed.(Sameas
Thisisaproportionalelectromagneticvalve thatdecreasesthetransmissionshockbygraduallyincreasingoilpressureforengaging
Thisisadevicethatensuressmoothhighspeedtravelbyabsorbingvibrationofmachine duringtravelwithhydraulicspringeffectof
Thisisanelectroniccontroldevicethatsend thecommandtoactuatorsusingthesignals fromthesensorsonthemachinesothatthe optimumactuationisperformed.(Sameas
EGR
ExhaustGasRecircula-tion Engine
EMMS EquipmentManagementMonitoringSystem
EPCElectromagneticPropor-tionalControl
Machinemonitor
Hydraulicsystem
FOPS FallingObjectProtectiveStructure Cabandcanopy
Thisisafunctionthatrecirculatesapartof exhaustgastocombustionchamber,sothatit reducescombustiontemperature,andreduces emissionofNOx.
Thisisafunctionwithwhichoperatorcan checkinformationfromeachsensoronthe machine(filter,oilreplacementinterval,malfunctionsonmachine,failurecode,andfailure
ElectromagneticproportionalcontrolThisisa mechanismwithwhichactuatorsoperatein proportiontothecurrent.
Thisstructureprotectstheoperator'sheadfrom fallingobjects.(Fallingobjectprotectivestructure)
ThisperformanceisstandardizedasISO3449.
F-N-R Forward-Neutral-ReverseOperationForward-Neutral-Reverse
GPS GlobalPositioningSystem Communication (KOMTRAX,KOMTRAX
GNSS GlobalNavigation Satel-liteSystem Communication (KOMTRAX,KOMTRAX
HSS HydrostaticSteering System
HSTHydroStaticTransmission
Steering (DSeries)
Transmission (D,WA)
Thissystemusessatellitestodeterminethe cur-rentlocationontheearth.
Thisisageneraltermforsystemusessatellites suchasGPS,GALILEO,etc.
Thisisafunctionthatenablesthemachineto turnwithoutsteeringclutchbycontrollingadiffer-enceintravelspeedofrightandlefttracks withacombinationofhydraulicmotorand
Hydraulictransmissionsystemthatusesa combinationofhydraulicpumpandhydraulic motorwithoutusinggearsforsteplessgear
Abbreviation
Actualwordspelledout
Purposeofuse(majorapplicablemachine(*1),or component/system)
Explanation
ICTInformationandCommunicationTechnology
Communicationandelectroniccontrol
IMAInletMeteringActuatorEngine
IMUInertialMeasurement Unit Engine
InletMeteringValveEngine
IMV
CCV
ClosedCrankcase Ventilation Engine
KCSFKomatsuCatalyzedEngine
KDOC
KDPF
KTCS
KomatsuDieselOxidationCatalyst Engine
KomatsuDieselParticulateFilter Engine
KomatsuTractionControlSystem
Travelandbrake (HM)
Ageneraltermfortheengineeringandits social-lyappliedtechnologyofinformationprocessingandcommunication.
Thisisavalvethatadjuststhefuelintake amountatthepumpinletinordertocontrolthe supplypumpfueldischargedvolume.(Same
Thisisadevicetodetecttheangle(orangular velocity)andaccelerationofthe3axesthat con-trolmotions.
Thisisavalvethatadjuststhefuelintake amountatthepumpinletinordertocontrolthe supplypumpcombustiondischargedvolume. (SameasIMA)
Thisisamechanismthatburnstheblowbygas againbyseparatingoilfromblowbygasandreturningittotheintakeside.Itprimarilyconsists offilters.
Thisisafilterthatcapturessootinexhaust gas.
Thisisacatalystthatisusedforpurifyingexhaustgas. ItisbuiltintoKDPForassembledwiththemuffler.
Thisisacomponentthatisusedtopurifythe ex-haustgas.KDOC(catalyst)andKCSF(filtertocapturesoot)arebuilt-init.
Thisisafunctionthatperformsbrakingwiththe optimumforceandrecoversthedrivingforceof thewheelsbyactuatingtheinter-axledifferentiallockwhenthewheelsrunsidlewhilethe machinetravelsonthesoftground. LCDLiquidCrystalDisplayMachinemonitor
Thisisanimagedisplayequipmentsuchasa monitorinwhichtheliquidcrystalelementsare assembled.
Thisisasemiconductorelementthatemitslight whenthevoltageisappliedinforwarddirection.
LocalInterconnectNetwork
Communicationandelectroniccontrol
LSLoadSensingHydraulicsystem
Thisisoneofcommunicationstandardsthat areusedinthenetworkonthemachine.
Thisisafunctionthatdetectsdifferentialpressureofpump,andcontrolsdischargedvolume correspondingtoload. LVDS
LowVoltageDifferential
Communicationandelectroniccontrol
Thisisoneofcommunicationstandardsthat areusedinthenetworkonthemachine.
Thisindicatesengineintakeairflow.Thisisnot usedindependentlybutisusedascombined withsensor.Massairflowsensorcanbecalled asMAFsensor.
Abbreviation
Actualwordspelledout
Purposeofuse(majorapplicablemachine(*1),or component/system)
MMSMultimediaMessaging Service Communication
NCNormallyClosedElectricalsystem,hydraulicsystem
NONormallyOpenElectricalsystem,hydraulicsystem
OLSSOpen-centerLoad SensingSystem
PCPressureCompensation
PCCS Palmcommandcontrolsystem
Hydraulicsystem
Explanation
Thisisaservicethatallowstransmissionand receptionofshortmessagesconsistingofcharactersorvoiceorimagesbetweencellphones.
Thisisacharacteristicofelectricalorhydraulic circuits.Circuitisnormallyclosedifitisnot actu-ated,anditopenswhenitisactuated.
Thisisacharacteristicofelectricalorhydraulic circuits.Circuitisnormallyopenifitisnotactuated,anditcloseswhenitisactuated.
Thisisahydraulicsystemthatcanoperate multi-pleactuatorsatthesametimeregardlessoftheload.
HydraulicsystemThisisafunctionthatcorrectstheoilpressure.
Steering (DSeries)
PCVPre-strokeControl Valve Engine
PPC
ProportionalPressure ControlHydraulicsystem
Thisisafunctionthatelectricallycontrolsthe en-gineandtransmissioninanoptimalway withthecontrollerinstantlyanalyzingdatafrom levers,pedals,anddials.
Thisisavalvethatadjuststhefuelintake amountatthepumpinletinordertocontrolfuel dis-chargedvolumeofsupplypump.
Thisisasystemthatoperatesactuatorsinproportiontotheoilpressure.
PPM PistonPumpand Motor Hydraulicsystem (D,PC,etc)Pistontypehydraulicpumpandmotor.
PTOPowerTakeOffPowertrainsystemPowertake-offmechanism
PTPPowerTiltandpower Pitchdozer
ROPS
Workequipment (DSeries)
Roll-OverProtective Structure Cabandcanopy
SelectiveCatalyticReduction UreaSCRsystem
SCR
SI
LeSystemeInternationald'Unites(Internationalunitsystem) Unit
SOLSolenoidElectricalsystem
Thisisafunctionthatperformshydrauliccontrolofthetiltandpitchofthedozerbladeofthe bull-dozer.
ROPSisaprotectivestructurethatintendedto protecttheoperatorwearingseatbeltfromsufferinginjurywhichmaybecausedifthecabis crushedwhenthemachinerollsover.(Rolloverprotectivestructure)
ThisperformanceisstandardizedasISO3471 orISO12117-2.
Thisisanexhaustgaspurifierusingureawater thatconvertsnitrogenoxides(NOx)intoharmlessnitrogenandwaterbyoxidation-reduction re-action.Itmayalsobementionedasexhaust gaspurificationcatalystorpartofthenameof relateddevices.
Abbreviationfor"InternationalSystemofUnits" Itistheuniversalunitsystemand"asingleunit forasinglequantity"isthebasicprinciple applied.
Thisisanactuatorthatconsistsofasolenoid andanironcorethatisoperatedbythemagneticforcewhenthesolenoidisenergized.
Abbreviation Actualwordspelledout
Purposeofuse(majorapplicablemachine(*1),or component/system)
Tip-OverProtective Structure Cabandcanopy
TOPS
TWV2-WayValveHydraulicsystem
VGT
VHPC
VariableGeometryTurbochargerEngine
VariableHorsePower Control Enginecontrol
*1:Codeforapplicablemachinemodel
D:Bulldozer
HD:Dumptruck
HM:Articulatedumptruck
PC:Hydraulicexcavator
WA:Wheelloader
Explanation
Thisisaprotectivestructurethatintendedto protecttheoperatorwearingseatbeltfromsufferinginjurywhichmaybecausedifthecabis crushedwhenthemachinetipsover.(Roll-over protectivestructureofhydraulicexcavator)
ThisperformanceisstandardizedasISO 12117.
Thisisasolenoidvalvethatswitchesover directionofflow.
Thisisaturbochargeronwhichthecross-sectionareaoftheexhaustpassageisvariable.
Thisisafunctionthatfinelycontrolsthemaximumoutputofthemachinesothathighwork efficiencyandlowfuelconsumptionrateare bothachieved.
Listofabbreviationsusedinthecircuitdiagrams
AbbreviationActualwordspelledout
A/CAirConditioner
A/DAnalogue-to-Digital
A/MAirMixDamper
ACCAccessory
ADDAdditional
AUXAuxiliary
BRBatteryRelay
CWClockwise
CCWCounterClockwise
ECUElectronicControlUnit
ECMElectronicControlModule
ENGEngine
EXGNDExternalGround
F.G.FrameGround
GNDGround
IMAInletMeteringActuator
NCNoConnection
S/T
STRGSteering
SIGSignal
SOLSolenoid
STDStandard
OPT
OPOption
PRESSPressure
SPECSpecification
SWSwitch
TEMPTemperature
T/CTorqueConverter
T/MTransmission
FOREWORD,SAFETY,BASICINFORMATION
HOWTOREADTHESHOPMANUAL REMARK
Someoftheattachmentsandoptionsdescribedinthisshop manualmaynotbeavailableinsomeareas.Iftheyarerequired,consultyourKomatsudistributor.
Thematerialsandspecificationsaresubjecttochangewithoutnotice.
ShopManualsareavailablefor"machinepart"and"engine part".Fortheengineunit,seetheshopmanualforthemachinewhichhasthesameenginemodel.
Actualmachinemaydifferfromtheimageswhicharecontainedinthismanual.Atypicalmodelisshownintheillustrationsofthisshopmanual.
Compositionoftheshopmanual
Thisshopmanualcontainstechnicalinformationnecessaryto performservicesinworkshops.Itisdividedintothefollowing chaptersfortheeaseofuse.
00INDEXANDFOREWORD
Thissectiondescribestheindex,foreword,safety,andbasicinformation.
STRUCTUREANDFUNCTION
Thissectiondescribesthestructureandoperationofeachcomponentwithrespecttoeachsystem."STRUCTUREANDFUNCTION"ishelpfulinnotonlyunderstandingthestructureofeach componentbutperformingtroubleshooting.
20STANDARDVALUETABLE
Thissectiondescribesthestandardvaluesfornewmachineand failurecriteriafortestingandadjusting,andtroubleshooting.Use thestandardvaluestabletocheckthestandardvaluesfortestingandadjusting,andjudgetroublesintroubleshooting.
30TESTINGANDADJUSTING
Thissectiondescribesthemeasuringtoolsandmeasuring methodsfortestingandadjustingaswellastheadjustingmethodofeachpart.ThestandardvaluesandrepairlimitforTESTINGANDADJUSTINGaredescribedin"STANDARDVALUE TABLE".
40TROUBLESHOOTING
Thissectiondescribestroubleshootingoffailurepartandits remedymethodontheoccurrenceofthefailure.Descriptionsof troubleshootingaresortedbyfailuremode.
50DISASSEMBLYANDASSEMBLY
Thissectiondescribesthespecialtools,workprocedures,and safetyprecautionsnecessaryforremoval,installation,disassembly,andassemblyofthecomponentsandparts.Inaddition, tighteningtorques,quantity,andweightofthecoatingmaterials, lubricants,andcoolantnecessarytotheseworksareshown.
60MAINTENANCESTANDARDS
Thissectiondescribesthemaintenancestandardvalueofeach component.Themaintenancestandardshowsthecriteriaand remediesfordisassemblyandassembly.
80THEOTHERINFORMATION
Thissectiondescribesthestructureandfunction,testingand adjusting,andtroubleshootingforalloftheothercomponentsor equipmentwhichcannotbeseparatelyclassifiedintheappendix.
90Circuitdiagrams
Thissectiondescribeshydrauliccircuitdiagramsandelectrical circuitdiagrams.
Symbols
Importantsafetyandqualityportionsaremarkedwiththefollowingsymbolssothatshopmanualisusedeffectively.
SymbolItem
4 3 2 5 6 ,
Signalword
Remarks
DangerThissignalindicatesanextremelyhazardoussituationwhichwillresultin deathorseriousinjuryifitisnotavoided.
WarningThissignalindicatesapotentiallyhazardoussituationwhichwillresultin deathorseriousinjuryifitisnotavoided.
CautionThissignalindicatesapotentiallyhazardoussituationwhichwillresultin injuryorpropertydamagearoundthemachineifitisnotavoided.
Weight
Tightening torque
Thissignalindicatestheweightofpartsandcomponents,anditemswhich requiresgreatattentiontoaselectionofwiresandworkingposturefor slingingwork.
Thissignalindicatesthetighteningtorqueforportionswhichrequiresspecialcareinassemblingwork.
CoatThissignalindicatesaplacetobecoatedwithadhesive,grease,etc.in assemblingwork.
OilandcoolantThissignalindicatesaplacetosupplyoil,coolant,etc.andthequantity
DrainingThissignalindicatesaplacetodrainoil,coolant,etc.andthequantity.
SafetyThissymbolindicatestheworkswhichrequirespecialcautionforthe machinesafetywhenassembling.
Signalwordfornoticeandremarkdescribesthefollowing.
SymbolItemRemark
NOTICENoticeIftheprecautionofthissignalwordisnotobserved,themachinedamageorshorteningofservicelifemayoccur.
REMARKRemarkThissignalwordcontainsusefulinformationtoknow.
Unit
InternationalSystemofUnits(SI)isusedinthismanual.Forreference,unitsthathavebeenusedinthepastaregivenin{}.
SAFETYNOTICEFOROPERATION
Appropriateservicingandrepairareextremelyimportantto ensuresafeoperationofthemachine.Theshopmanuals describetheeffectiveandsafeservicingandrepairmethods recommendedbyKomatsu.Someoftheservicingandrepairmethodsrequiretheuseofspecialtoolsdesignedby Komatsuforspecialpurposes.
Thesymbolmarkisindicatedforsuchmattersthatrequirespecialprecautions.Theworkindicatedwiththiswarningmarkshouldbeperformedaccordingtothe instructionswithspecialattention.Shouldahazardoussituationoccurorbeanticipatedduringsuchwork,besureto keepsafefirstandtakeeverynecessarymeasure.
Safetymatters
Wellorganizedworkplace
Correctworkclothes
Observanceofworkstandard
Enforcementofhandsignals
Prohibitionagainstunlicensedpersonsoperatingandhandlingthemachine
Safetycheckbeforestartingwork
Wearofdustglasses(forcleaningorgrindingwork)
Wearofweldinggogglesandprotectors(forweldingwork)
Beingingoodphysicalcondition,andgoodpreparation
Alwaysbealertandcareful.
Generalprecautions
kIfthemachineishandledincorrectly,itisdangerous. Readandunderstandwhatisdescribedintheoperationandmaintenancemanualbeforeoperation.Read andunderstandwhatisdescribedinthismanualbefore operation.
Readandunderstandthemeaningofallthesafetylabels stucktothemachinebeforeperforminganygreasingorrepairs.Forthelocationsofthesafetylabelsanddetailedexplanationofprecautions,seeOperationandMaintenance Manual.
Toolsandremovedpartsintheworkshopshouldbewellorganized.Alwayskeepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareacleanandmakesure thatthereisnodust,dirt,oil,orwateronthefloor.Smoke onlyinthedesignatedareas.Neversmokewhileworking.
Keepalltoolsingoodcondition,learnthecorrectwaytouse them,andusetheproperones.Checkthetools,machine, forklifttruck,servicecar,etc.thoroughlybeforestartingthe work.
Alwayswearsafetyshoesandhelmetwhenperformingany operation.Donotwearlooseclothes,orclotheswithbuttons missing.
Alwaysweartheprotectiveeyeglasseswhenhittingparts withahammer.
Alwaysweartheprotectiveeyeglasseswhengrindingparts withagrinder,etc.
Whenperforminganyoperationwithmultipleworkers,alwaysagreeontheoperatingprocedurebeforestarting.Be clearinverbalcommunicationandobservehandsignals. Hang"UNDERREPAIR"warningtagintheoperator'scompartmentBeforestartingwork.
Workandoperationwhichrequirelicenseorqualification shouldbeperformedbyqualifiedworkers.
Weldingrepairsshouldbeperformedbytrainedandexperiencedwelders.Whenperformingweldingwork,always wearweldinggloves,apron,weldinggoggles,capandother clothessuitedforweldingwork.
Warmupbeforestartingtheworkwithexercisewhichincreasesalertnessandtherangeofmotioninordertopreventinjury.
Avoidprolongedworkandtakearestattimestokeepupa goodcondition.Takearestatdesignatedsafearea.
Precautionsforpreparatorywork
Placethemachineonafirmandlevelgroundandapplythe parkingbrakeandchockthewheelsortrackstopreventthe machinefrommovingbeforeaddingoilormakinganyrepairs.
Lowertheworkequipment(blade,ripper,bucket,etc.)tothe groundbeforestartingwork.Ifthisisnotpossible,insertthe lockpinoruseblockstopreventtheworkequipmentfrom falling.Inaddition,besuretolockallthecontrolleversand hang"UNDERREPAIR"warningtagonthem.
Whenperformingthedisassemblingorassemblingwork, supportthemachinesecurelywithblocks,jacks,orstands beforestartingthework.
Removeallmudandoilfromthestepsorotherplacesfor goingupanddownonthemachine.Alwaysusethehandrails,laddersorstepswhenforgoingupanddownonthe machine.Neverjumponoroffthemachine.Whenthescaffoldisnotprovided,usestepsorstepladdertosecureyour footing.Donotusehandrails,ladders,orstepsiftheyare damagedordeformed.Repairitorreplaceitimmediately.
Precautionsduringwork
Forthemachinewiththebatterydisconnectswitch,check beforestartingtheworkthatthesystemoperatinglampis notlit.Then,turnthebatterydisconnectswitchtoOFF() position
REMARK
RemovethekeyafteritisturnedtoOFF()positionifthe batterydisconnectswitchisaswitchkeytype.Forthemachinewithoutthebatterydisconnectswitch,turnthestarting switchtoOFFposition,waitfortwominutesormorebefore startingthework.Disconnectthebatterycablebystarting fromthenegative(-)terminalfirst.
Forthemachinewiththequickreleasebatteryterminal(-), checkbeforestartingtheworkthatthesystemoperating lampisnotlit.Then,disconnectthequickreleasebattery terminal(-).
REMARK
Forthemachinewithoutthesystemoperatinglamp,turnthe startingswitchtoOFFposition,waitfortwominutesormore beforestartingthework.Disconnectthequickreleasebatteryterminal(-).
Releasetheremainingpressurefromthecircuitbeforestartingtheworkofdisconnectingandremovingofoil,fuel,water,orairfromthecircuit.Whenremovingthecapofoilfilter, drainplug,oroilpressureplug,itshouldbedoneslowlyotherwisetheoilspills.