Service manual Komatsu WA170M-11E0 H24051 & Up | VENBM10000

Komatsu WA170M-11E0 H24051 & Up VENBM10000 (Preview)

VENBM10000 WA170M-11E0
Content
– Index and Foreword
– Specifications
– Structure and Function
– Standard Value Table
– Testing and Adjusting
– Troubleshooting
– Disassembly and Assembly
– Maintenance Standard
– Appendix
– Other
Index and Foreword
– Abbreviation List
— List of Abbreviations Used in the Text
— List of Abbreviations Used in the Circuit Diagrams
– Foreword, Safety, Basic Information
— How to Read the Shop Manual
— Composition of the Shop Manual
— Symbols
— Signal Word
— Unit
— Safety Notice for Operation
— Safety Considerations
— General Precautions
— Precautions for Preparatory Work
— Precautions During Work
— Precautions for Slinging Work and Making Signals
— Precautions When You Use Mobile Crane
— Precautions When You Use Overhead Traveling Crane
— Selecting Wire Ropes
— Precautions to Prevent Fire
— Fire Caused by Fuel, Oil, Coolant or Window Washer Fluid
— Fire Caused by Accumulated or Attached Flammable Objects
— Fire Caused by Electrical System
— Fire from Pipings
— Fire Caused by High Temperature Exhaust Gas
— Explosion Caused by Light
— Procedures If Fire Occurs
— Precautions for Disposing of Waste Material
— Engine Technology to Conform Exhaust Gas Emission
— About DEF
– Precautions for DEF
— General Character and Precautions for Handling
— Precautions When You Add
— Precautions for Storage
— Precautions for Fire Hazard and Leakage
— Other Precautions
— Store DEF
— Handle DEF in Cold Weather
— Precautions When You Handle Hydraulic Equipment
— Select an Applicable Workplace
— Disassembly and Maintenance Work in the Field
— Seal Openings (Prevention of Flowing Out of Oil)
— Preventing Intrusion of Foreign Materials While You Refill
— Replace Hydraulic Oil While Its Temperature is High
— Do Not Use Hydraulic Oil and Lubricating Oil Again
— Flushing Operation
— Cleaning Operation
— Precautions When You Disconnect and Connect Pipings
— Precautions for Removal and Disassembly Work
— Introduction of Parts for Disassembly of Face Seal Type Hoses and Tubes
— Introduction of Parts for Disconnection of Taper Seal Type Hoses and Tubes
— Introduction of Parts for Disconnection of Split Flange Type Hoses and Tubes
— Introduction of Parts for Removal of O-Ring Boss Type Joint
— Introduction of Parts for Removal of Taper Pipe Thread Type Joint
— Precautions for Installation and Assembly Work
— Precautions at the End Time of Work
— Precautions When You Handle Electrical Equipment
— Handle Wiring Harnesses and Connectors
— Main Causes of Failure in Wiring Harness
— Precautions When You Handle Fuel System Equipment
— Select an Applicable Workplace
— Seal the Opening
— How to Clean Parts When Dirt is Stuck
— Precautions When You Replace Fuel Filter Cartridge
— Precautions for Handling Intake System Equipment
— Select an Applicable Workplace
— Seal the Opening
— Practical Use of KOMTRAX
— Advantage to Use KOMTRAX
— How to Make a Full Use of KOMTRAX
— How to Operate KOMTRAX
— Precautions for Disconnection and Connection of Connectors
— Disconnect Connectors
— Connect Connectors
— Dry Wiring Harness
— Handle Controller
— Precautions for Troubleshooting Electrical Circuits
— How to Disconnect and Connect Deutsch Connector
— How to Disconnect Deutsch Connector
— How to Connect Deutsch Connector
— How to Disconnect and Connect Slide Lock Type Connector
— How to Disconnect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2)
— How to Connect Slide Lock Type Connector (FRAMATOME-3, FRAMATOME-2)
— How to Disconnect Slide Lock Type Connector (FRAMATOME-24)
— How to Connect Slide Lock Type Connector (FRAMATOME-24)
— How to Disconnect and Connect Connector with Lock to Pull
— How to Disconnect Connector with Lock to Pull
— How to Connect Connector with Lock to Pull
— How to Disconnect and Connect Connector with Lock to Push
— How to Disconnect Connector with Lock to Push (BOSCH-3)
— How to Connect Connector with Lock to Push (BOSCH-3)
— How to Disconnect Connector with Lock to Push (AMP-3)
— How to Connect Connector with Lock to Push (AMP-3)
— How to Disconnect Connector with Lock to Push (SUMITOMO-3)
— How to Connect Connector with Lock to Push (SUMITOMO-3)
— How to Disconnect Connector with Lock to Push (SUMITOMO-4)
— How to Disconnect Connector with Lock to Push (SUMITOMO-4)
— How to Disconnect and Connect Connector with Housing to Rotate
— How to Disconnect Connector with Housing to Rotate
— Connect Connector with Housing to Rotate
— Method for Connecting Ring Terminals and Strip Fuses to Power Stud of Printed Circuit Boards
– How to Read the Codes for Electric Cable
— Type, Symbol, and Material
— Color Code Table
— Explanation of Terms for Maintenance Standard
— Standard Dimension and Tolerance
— Standard Clearance and Standard Value
— Standard Interference
— Allowable Limit, Allowable Value, or Allowable Dimension
— Allowable Clearance
— Allowable Interference
– Standard Tightening Torque Table
— Table of Tightening Torque for Bolts and Nuts
— Table of Tightening Torque for O-Ring Boss Piping Joints
— Table of Tightening Torque for O-Ring Boss Plugs
— Table of Tightening Torque for Boss Piping Joints With Flat Seal (DIN3852)
— Table of Tightening Torque for Boss Plugs With Flat Seal (DIN3852)
— Table of Tightening Torque for Hose (24° Cone ACC. DIN3865)
— Table of Tightening Torque for Bolts and Nuts on 102,107 and 114 Series Engines
— Table of Tightening Torque for 102, 107, and 114 Series Engines (Joint Bolts)
— Table of Tightening Torque for Tapered Screws on 102,107, and 114 Series Engines (National Taper Pipe Thread (NPT))
– Conversion Table
— How to Use the Conversion Table
— Examples to Use the Conversion Table to Change a Unit from mm to in.
— Temperature
Specifications
– Dimensions, Weights and Operating Data
— Specifications: Z-Kinematic
— Specifications: TL-Kinematic
— Dimensions, Operating Data with Fork (TL- Kinematic)
– Specifications
– Weight Tables
– Fuel, Coolant and Lubricants by Ambient Temperature
– Basic Procedures of Maintenance
— Oil
— Biodegradable Hydraulic Oils and Lubricants
— Fuel
— Paraffin-Based Fuel
— Coolant and Water for Dilution
— Grease
— Oil and Fuel Storage
— Filter
— Outline of Electric System
– Tightening Torque List – Metric Screws and Nuts
Structure and Function
– Urea SCR System
— Layout Drawing of Urea SCR System
– UREA SCR System Diagram
– Function of UREA SCR System
— Function of DEF System
— Function of DEF Injection
— DEF Purge Function
— Function to Thaw DEF and Prevent Freezing
— Inducement Strategy
— Inducement Strategy When the DEF Level in the Tank Becomes Low
— Inducement Strategy When Abnormality is Found in the DEF Quality or in the Urea SCR System Devices
— Inducement Strategy When Abnormality is Found in the EGR System by the Urea SCR System Devices
— Inducement Strategy for Abnormality Recurrence within 40 Hours
– Component Parts of Urea SCR System
— DEF Mixing Tube
— Structure of DEF mixing tube
— Function of DEF mixing tube
— SCR Assembly
— Structure of SCR assembly
— DEF Tank
— DEF Tank Sensor
— Structure of DEF tank sensor
— Function of DEF tank sensor
— DEF Pump
— Structure of DEF Pump
— DEF Injector
— Structure of DEF Injector
— Function of DEF Injector
— Operation of DEF Injector
— DEF Hose
— Structure of DEF Hose
— Function of DEF Hose
— DEF Tank Heating Valve
— Structure of DEF Tank Heating Valve
— Function of DEF Tank Heating Valve
— Operation of DEF Tank Heating Valve
– Electrical System
— Layout Drawing of Electrical System
– Boot-up System
— Layout Drawing of Boot-up System
— Around Cab and Floor
– Battery Disconnect Switch
— Function of Battery Disconnect Switch
– Preheating System
— Function of Automatic Preheating System
— Operation of Automatic Preheating System
– Engine System
— Layout Drawing of Engine System
– Cooling System
— Layout Drawing of Cooling System
— Specifications of Cooling System
– Cooling Fan Control System
— Cooling Fan Control System Diagram
— Function of Cooling Fan Control System
— Cooling Fan Reverse Rotation Function (Option)
– Component Parts Of Cooling System
— Structure of Cooling Fan Motor
— Specifications of Cooling Fan Motor
– Control System
— Layout Drawing of Control System
— Around Cab and Floor
– Machine Monitor System
— Machine Monitor System Diagram
– KOMTRAX System
— KOMTRAX System Diagram
— Function of KOMTRAX System
– Component Parts of Control System
— Machine Monitors
— Types of gauges and meters displayed on machine monitor
— Types of caution lamps displayed on machine monitor
— Types of Pilot Lamps Displayed on Machine Monitor
— Operator Mode Function of Machine Monitor
— Service Mode Function of Machine Monitor
— KOMTRAX Terminal
— Structure of KOMTRAX Terminal General View
— Function of KOMTRAX Terminal
— Input and output signals of KOMTRAX terminal
— Rearview Monitor and Camera System
— Layout Drawing of Monitor and Camera System
— Structure of Rearview Monitor
— Structure of Rearview Camera
— Rearview Overlay
— Additional Power Connection at Camera Connector
— HST Controller
— Structure of HST Controller
— Real Time Monitoring Function
— Self-Diagnosis Function
— Input and Output Signals of HST Controller Terminal
— CAN Terminating Resistor
— Structure of CAN Terminating Resistor General View
— Specifications of CAN Terminating Resistor
— Function of CAN Terminating Resistor
— Engine Controller
— Structure of Engine Controller General View
— Real Time Monitoring Function
— Self-diagnosis function
— Accelerator Pedal
— Structure and function of accelerator pedal
— Acceleration Signal
— Idling Validation Signal
— Auto-Idle-Stop (optional)
— Output Characteristics
– Hydraulic System
— Layout Drawing of Hydraulic System
— CLSS
— Structure of CLSS
— Function of CLSS
— Component Parts of Hydraulic System
— Structure of Hydraulic Tank
— Specifications of Hydraulic Tank
— Structure of the Pump for Work Equipment / Steering and Cooling Fan
— Specifications of the Pumps for Work Equipment / Steering and Cooling Fan
— Function of the Cooling Fan and Brake Line Pump
— Function of the Work Equipment and Steering Pump
— Operation to Control Discharged Volume
— LS Valve of Work Equipment and Steering Pump
— Function of LS Valve of Work Equipment and Steering Pump
— Function of PC Valve of Work Equipment and Steering Pump
— Structure of main control valve
— Hydraulic Circuit Diagram of Main Control Valve
— Pressure Compensation Valve of Control Valve
— Function of Pressure Compensation Valve of Control Valve
— Operation of Pressure Compensation Valve of Control Valve
— Introduction of LS Pressure in Control Valve
— Function of Introduction of LS Pressure in Control Valve
— Operation of Introduction of LS Pressure in Control Valve
— Function of LS Bypass Valve of Control Valve
— Operation of LS Bypass Valve of Control Valve
— Optional Hydraulic Systems
— Structure of 4th Hydraulic Circuit
— Function of 4th Hydraulic Circuit
— Structure of Tool Control
— Function of Tool Control
— Structure of Rear Connectors for Auxiliary Circuits
— Function of Rear Connectors for Auxiliary Circuits
— Structure and Function of Front Drain Line
– Power Train System
— Layout Drawing of Power Train System
— Operation of Power Train System
– Function of Closed Circuit System
— Specifications of HST System
– Structure of HST System
— 20km/h
— 40km/h
— Component Parts of Power Train System
— Structure of Drive Shafts
— Function of Drive Shaft
— Structure of HST Pump
— Operation of HST Pump
— HST Motor
— HST Drive Mode Control Function (40 km/h)
— Structure of Transfer Box
— Function of Transfer Box
— Structure of Front Axle
— Structure of Rear Axle
— Function of Differential
— Function of Towing System
– Work Equipment System
— Layout of Work Equipment System
— Work Equipment Lock System
— ECSS
— Function of ECSS
— Operation of ECSS
— ECSS Accumulator
— Function
— Return to Dig (Option)
— Structure (Z-Kinematic)
— Structure (TL-Kinematic)
— Function
— Boom Kickout (Option)
— Structure (Z-Kinematic)
— Structure (TL-Kinematic)
— Function
— Bucket Dump Counter (Option)
— Structure (Z-Kinematic)
— Structure (TL-Kinematic)
— Function
— Component Parts of Work Equipment System
— Main Control Valve
— PPC Block
— PPC Accumulator
— PPC Valve (Joystick)
– Z-Loader Linkage
– TL-Loader Linkage with Quick-Coupler
— Quick-Coupler
– Steering System
— Layout Drawing of Steering System
— Hydraulic Circuit Diagram of Steering System
— Layout Drawing of Steering System with Joystick Steering System (JSS) (Option)
— Hydraulic Circuit Diagram of Steering System with Joystick Steering System (JSS) (Option)
— Layout Drawing of Secondary Steering System
— Structure and Function
— Priority Valve
— Orbit-Roll-Valve
— Steering Relief Valve
— Secondary Steering Valve
— Structure of Secondary Steering Valve
— Operation of Secondary Steering Valve
— Steering Column
— Structure of Steering Column
– Brake System
— Brake Charge Valve
— Function:
— Operation:
— Brake Charge Accumulator
— Function:
— Function of Brake Valve
— Operation of Brake Valve
— Layout drawing of Service Brake Assembly
— Structure of Brake System
– Undercarriage and Frame
— Frame, Axle Mount and Center Hinge Pin
— Structure of Frame, Axle Mount and Center Hinge Pin General View
— Function of Frame, Axle Mount and Center Hinge Pin Front Axle Mount
— Rear Axle Mount
— Frame, Axle Mount and Center Hinge Pin
— Tire
— Features of Radial Tire when compared with Bias Tire
— Structure of Radial Tire
— General View
— Structure
— Function of Radial Tire
— Structure of Bias Tire
— General view
— Structure
— Function of Bias Tire
– Work Equipment
— Structure of Work Equipment (Z-Kinematic)
— Structure of Work Equipment (TL-Kinematic)
— Structure of Bucket
— General View and Sectional View
– CAB Related Parts
— ROPS/FOPS CAB
— Structure of ROPS/FOPS CAB
— Function of ROPS/FOPS CAB
— CAB Mount
— Structure of CAB Mount
— General View
— Function of Cab Mount
— Tipping UP the Operator’s CAB (Standard, without Tipping Cylinder)
— Tipping DOWN the Operator’s CAB (Standard, without Tipping Cylinder)
— Tipping UP the Operator’s CAB (Option, with Tipping Cylinder)
— Tipping DOWN the Operator’s CAB (Option, with Tipping Cylinder)
– Auto-Greasing System
— Layout Drawing of Auto Central Lubrication System
— How to Change Auto-Greasing System Interval
— How to Use Auto-Greasing System
— Display and Operating Unit
— General Icons
— Icons Specific to the Individual Menus
— How to Trigger Additional Lubrication
— How to Examine Auto-Greasing System and Fill Grease
— Auto-Greasing Diagram
– Seatbelt Warning System
— Loader Meter System
— Function of Load Meter System
— Usual Components of a load meter system
— Possible position of load meter System in Cabin
— Possible position of load meter System in front frame
— Possible routing of load meter harness – details
— Protective Ventilation System
— Function of protective ventilation system
— Components of protective ventilation system
— Position of protective ventilation system
— Possible adaption points
– Crash Counter
Standard Value Table
– Standard Value Table
— Standard Value Table for Engine
— Standard Value Table for Chassis
– Test Certificate
Testing and Adjusting
– Examine Engine With Software Tool
— Connection of a Computer to the Machine
– Engine and Cooling System
— Examine Engine Speed
— Method for Testing Engine Speed
— Method for Testing Engine Low Idle Speed
— Method for Testing Engine High Idle Speed
— Method for Testing Engine Speed HST Stall
— Method for Testing Engine Speed at Hydraulic Stall
— Method for Testing Engine Speed at Full Stall (HST Stall and Hydraulic Stall)
– Examine Exhaust Gas Color
— Tool to Examine Exhaust Gas Color
— How to Examine Exhaust Gas Color with Smoke Meter
– Cylinder Head
— Measuring and Adjusting Valve Clearance
— Checking the Valve Springs
— Removing the Valve Guides
— Checking the Valve Guides
— Attaching the valve guides
– Failure Diagnosis
— Methods of Measuring Compression Pressure
– Lubricating System
— Checking the Engine Lubricating Oil
– Fuel System
— Priming the Fuel System
— How to Bleed Air from Fuel System
– Examine Fuel Circuit for Leakage
— How to Examine Fuel System for Leakage
— Examine Fuel Circuit for Leakage at Engine Stop
— Examine Fuel Circuit for Leakage at Engine Low Idle
— How to Examine Fuel Circuit for Leakage at Engine High Idle
– Examine KDPF, SCR and Muffler Stack for Looseness and Damage
— How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage
– Examine Installed Condition of Cylinder Heads and Manifolds
— How to Examine Installed Condition of Cylinder Heads and Manifolds
– Examine Engine Piping for Damage and Looseness
— How to Examine Engine Piping for Damage and Looseness
– Examine and Adjust Air Conditioner Compressor Belt Tension
— How to Examine Air Conditioner Compressor Belt
— How to Adjust Air Conditioner Compressor Belt
– Clean DEF Tank
— Method for Cleaning DEF Tank
– Power Train
— Test and Adjust HST Pressure Cut Off
– Test Drive Shaft for Looseness, Backlash, and Damage
— Method for Testing Drive Shaft for Looseness, Backlash, and Damage
– Release the Parking Brake Manually
— Release the Parking Brake
— Restore Parking Brake
– Steering System
— Operating Time for Steering Wheel
— Operating Force of Steering Wheel
– Examine and Adjust Steering Circuit Oil Pressure
— Method for Testing Steering Circuit Oil Pressure
— Method for Adjusting Steering Circuit Oil Pressure
– Bleed Air from Steering Cylinder Circuit
— Method for Bleeding Air From Steering Cylinder Circuit
– Brake System
— Release Remaining Pressure in Brake Accumulator Circuit
— Method for Releasing Remaining Pressure in Brake Accumulator Circuit
— Test Wheel Brake Oil Pressure
— Method for Testing Wheel Brake Oil Pressure
— Test and Adjust Brake Accumulator Charge Pressure
— Bleed Air from Brake Circuit
– Test Braking Performance
— Measuring the Stopping Distance
— Test and Adjust Brake Pedal
– Test Parking Brake Performance
– Hydraulic System
— Release Remaining Pressure from Pressurized Circuit
— Releasing the Remaining Pressure in ECSS
– Examine and Adjust Work Equipment Pressure
— Method for Testing the Unload Oil Pressure by Using the Machine Monitor
— Method for Testing Unload Oil Pressure with Testing Tools
— Method for Testing Work Equipment Relief Pressure by Using the Machine Monitor
— Method for Testing Work Equipment Relief Pressure with Testing Tools
— Method for Testing LS Differential Pressure
– Test Work Equipment PPC Pressure
— Method for Adjusting PPC Oil Pressure
– Bleed Air from Work Equipment PPC Circuit
– Testing and Adjusting Cooling Fan Speed
— Method for Testing the Cooling Fan Speed
— Method for Adjusting the Cooling Fan Speed
– Test ECSS Accumulator Nitrogen Gas Pressure
— Method for Testing the ECSS Accumulator Nitrogen Gas Pressure
— Method for Charging the ECSS Accumulator With Nitrogen Gas
– Electrical System
— Set and Adjust each Equipment
— Set and Operate Machine Monitor
— Switch Panel
— Operator Mode
— Method for Setting Usage Limitation and Changing Maintenance Password
— Setting Usage Limitation (Password)
— Change Password
— Service Mode
— Method for Operating Service Mode
— Method for Checking Self-defined Monitoring Information
— Table of Self-defined Monitoring
— Abnormality Record Menu
— Method for Confirming Abnormality Record (Mechanical Systems)
— Method for Confirming Abnormality Record (Electrical Systems)
— Method for Confirming Maintenance Record
— Method for Operating Maintenance Mode Setting
— Method for Operating Phone Number Entry Setting
— Default Menu
— Method for Setting with Default Setting Menu (Machine Model Select)
— Method for Setting with Default Setting Menu (Option Selection)
— Method for Setting with Default Setting Menu (Unit)
— Method for Setting with Default Setting Menu (Auto Idle Stop Time Fixing)
— How to Adjust Rear View Camera
— How to Handle Rear View Monitor
— Rear View Monitor Display Condition Setting
— Adjust Rear View Camera Angle
— Examine Rear View Camera Reference Line
— Rear View Monitor
— Rear View Monitor Keys
— How to Reset Rear View Monitor
— How to Reset IP Addresses
— How to Set Rear View Monitor
— Adjustment Menu
— Method for Adjusting with Adjustment Menu (T/C Device Calibration)
— Handle Battery Disconnect Switch
— Test Diodes
Troubleshooting
– Related Information on Troubleshooting
— General Troubleshooting Points
– Sequence of Events in Troubleshooting
– Checks Before Troubleshooting
— Engine, Lubricating Oil, Coolant, and DEF
— Hydraulic and Mechanical Equipment
— Electric Equipment
— Exterior
— Interior
– Inspection Procedure Before Troubleshooting
— Walk-around Check
– Procedure for Testing and Troubleshooting
– Information Described in Troubleshooting Table
– Connector Location
– Connector Contact Identification
– Spare Fuses and Relay
— Fuse Allocation 1
— Fuse and Relay Allocation 2
— USB Socket on Central Electric Board (CEB)
– Failure Codes Table
— Circuit Diagram Related to Failure Code (#B0008 to #BK002)
— Circuit Diagram Related to Failure Code (#B0008)
— Circuit Diagram Related to Failure Code (#B0088, #B0093, #B0094)
— Circuit Diagram Related to Failure Code (#B00112, #B00113)
— Circuit Diagram Related to Failure Code (#B0117, #B0118)
— Circuit Diagram Related to Failure Code (#B0168, #B0182, #B0183)
— Circuit Diagram Related to Failure Code (#B0192, #B0193)
— Circuit Diagram Related to Failure Code (#B0201)
— Circuit Diagram Related to Failure Code (#B0202)
— Circuit Diagram Related to Failure Code (#B0203)
— Circuit Diagram Related to Failure Code (#B0204)
— Circuit Diagram Related to Failure Code (#B0217)
— Circuit Diagram Related to Failure Code (#B0219)
— Circuit Diagram Related to Failure Code (#B02E8, #B02E9)
— Circuit Diagram Related to Failure Code (#B0336, #B0337)
— Circuit Diagram Related to Failure Code (#B0341, #B0342)
— Circuit Diagram Related to Failure Code (#B040C, #B040D)
— Circuit Diagram Related to Failure Code (#B041C, #B041D)
— Circuit Diagram Related to Failure Code (#B0420)
— Circuit Diagram Related to Failure Code (#B0426, #B0427, #B0428)
— Circuit Diagram Related to Failure Code (#B0541, #B0543)
— Circuit Diagram Related to Failure Code (#B0545, #B0546)
— Circuit Diagram Related to Failure Code (#B0660)
— Circuit Diagram Related to Failure Code (#B0652, #B0653)
— Circuit Diagram Related to Failure Code (#B0698, #B0699)
— Circuit Diagram Related to Failure Code (#B1011)
— Circuit Diagram Related to Failure Code (#B1146)
— Circuit Diagram Related to Failure Code (#B1149)
— Circuit Diagram Related to Failure Code (#B1151)
— Circuit Diagram Related to Failure Code (#B1192, #B1193)
— Circuit Diagram Related to Failure Code (#B1198)
— Circuit Diagram Related to Failure Code (#B1262)
— Circuit Diagram Related to Failure Code (#B1265)
— Circuit Diagram Related to Failure Code (#B1268)
— Circuit Diagram Related to Failure Code (#B1271)
— Circuit Diagram Related to Failure Code (#B1426)
— Circuit Diagram Related to Failure Code (#B1427, #B1428)
— Circuit Diagram Related to Failure Code (#B1434, #B1435)
— Circuit Diagram Related to Failure Code (#B1436)
— Circuit Diagram Related to Failure Code (#B1454)
— Circuit Diagram Related to Failure Code (#B1505)
— Circuit Diagram Related to Failure Code (#B1507, #B1508, #B1508, #B150A
— Circuit Diagram Related to Failure Code (#B150A)
— Circuit Diagram Related to Failure Code (#B150B)
— Circuit Diagram Related to Failure Code (#B150C)
— Circuit Diagram Related to Failure Code (#B150D, #B150E)
— Circuit Diagram Related to Failure Code (#B1510)
— Circuit Diagram Related to Failure Code (#B1511, #B1512, #B1513, #B1514)
— Circuit Diagram Related to Failure Code (#B151B)
— Circuit Diagram Related to Failure Code (#B151F)
— Circuit Diagram Related to Failure Code (#B152A)
— Circuit Diagram Related to Failure Code (#B152B)
— Circuit Diagram Related to Failure Code (#B152C, #B152D, #B152E, #B152F)
— Circuit Diagram Related to Failure Code (#B1530, #B1531)
— Circuit Diagram Related to Failure Code (#B153C, #B153D)
— Circuit Diagram Related to Failure Code (#B153B)
— Circuit Diagram Related to Failure Code (#B1541, #B1542)
— Circuit Diagram Related to Failure Code (#B1542)
— Circuit Diagram Related to Failure Code (#B1543)
— Circuit Diagram Related to Failure Code (#B154D, #B154E, #B154F)
— Circuit Diagram Related to Failure Code (#B1550, #B1551, #B1552)
— Circuit Diagram Related to Failure Code (#B1555, #B1557, #B1558, #B1559)
— Circuit Diagram Related to Failure Code (#B1561)
— Circuit Diagram Related to Failure Code (#B1655, #B1656, #B1658)
— Circuit Diagram Related to Failure Code (#B1665 to #B1670)
— Circuit Diagram Related to Failure Code (#B1674)
— Circuit Diagram Related to Failure Code (#B1675)
— Circuit Diagram Related to Failure Code (#B1676)
— Circuit Diagram Related to Failure Code (#B1677)
— Circuit Diagram Related to Failure Code (#B1678)
— Circuit Diagram Related to Failure Code (#B1679)
— Circuit Diagram Related to Failure Code (#B167A)
— Circuit Diagram Related to Failure Code (#B167C)
— Circuit Diagram Related to Failure Code (#B167E)
— Circuit Diagram Related to Failure Code (#B1710)
— Circuit Diagram Related to Failure Code (#B1712)
— Circuit Diagram Related to Failure Code (#B1714)
— Circuit Diagram Related to Failure Code (#B1716)
— Circuit Diagram Related to Failure Code (#B1771, #B1772, #B1773)
— Circuit Diagram Related to Failure Code (#B1773)
— Circuit Diagram Related to Failure Code (#B1774, #B1775, #B1776)
— Circuit Diagram Related to Failure Code (#B202A, #B202B, #B202C)
— Circuit Diagram Related to Failure Code (#B204C, #B204D)
— Circuit Diagram Related to Failure Code (#B206C, #B206D)
— Circuit Diagram Related to Failure Code (#B208A, #B208B, #B208C, #B208D)
— Circuit Diagram Related to Failure Code (#B208E)
— Circuit Diagram Related to Failure Code (#B20A0, #B20A2, #B20A3, #B20AD)
— Circuit Diagram Related to Failure Code (#B20B6)
— Circuit Diagram Related to Failure Code (#B20B9, #B20BC, #B20BD)
— Circuit Diagram Related to Failure Code (#B20C0, #B20C1, #B20C4)
— Circuit Diagram Related to Failure Code (#B20EA, #B20EB)
— Circuit Diagram Related to Failure Code (#B20C5, #B20C8)
— Circuit Diagram Related to Failure Code (#B2146, #B2147, #B2148)
— Circuit Diagram Related to Failure Code (#B2149, #B2150, #B2151)
— Circuit Diagram Related to Failure Code (#B21C2, #B21C3, #B21C4)
— Circuit Diagram Related to Failure Code (#B2452, #B2453, #B2454, #B2455)
— Circuit Diagram Related to Failure Code (#B2670, #B2671)
— Circuit Diagram Related to Failure Code (#B2685, #B2686)
— Circuit Diagram Related to Failure Code (#B26E8, #B26E9)
— Circuit Diagram Related to Failure Code (#BG10B)
— Circuit Diagram Related to Failure Code (#BG168, #BG292)
— Circuit Diagram Related to Failure Code (#BG10B)
— Circuit Diagram Related to Failure Code (#BG29E, #BG29E)
— Circuit Diagram Related to Failure Code (#BH292, #BH293, #BH294)
— Circuit Diagram Related to Failure Code (#BH300, #BH301, #BH2302, #BH303)
— Circuit Diagram Related to Failure Code (#BH501, #BH607, #BH610, #BH611)
— Circuit Diagram Related to Failure Code (#BK002)
– Troubleshooting by Failure Code (Display of HST-Controller Code)
— Power On
— 8.2.1 Documentation of Power On (PwrOn)
— 8.2.1 – 2 Interface
— 8.2.1 – 3 Description
— 8.2.1 – 3.3 State 2: Check Sensor Supply Voltages
— 8.2.1 – 3.4 State 3: Check Hardware Monitoring Errors
— 8.2.1 – 3.5 State 4: Check First Application Specific Start Condition
— 8.2.1 – 3.6 State 5: Check Central Switch
— 8.2.1 – 3.7 State 6: Configure Safouts
— 8.2.1 – 3.8 State 7: Check Safouts
— 8.2.1 – 3.9 State 8: Check Diesel Engine Speed
— 8.2.1 – 3.10 State 9: Enable Sensor Supply Monitoring
— 8.2.1 – 3.11 State 10: Check Hardware Monitoring Errors
— 8.2.1 – 3.12 State 11: Check Second Applications Specific Start Condition
— 8.2.1 – 3.12 State 11: Check Second Applications Specific Start Condition
— 8.2.1 – 3.13 State 12: Run
— 8.2.1 – 3.14 Diagnosis Configuration Notes
— 8.2.1 – 4 Input Signals
— 8.2.1 – 5 Parameters
— 8.2.1 – 6 Output Signals
— 8.2.1 – 7 Error Information
— Abbreviations for Failure Code (HST-Controller)
— Failure Code (D811MC)
— Failure Code (D862KA)
— Configuration Diagram of GPS System
— Failure Code [D8ALKA]
— Circuit Diagram of System Operating Lamp
— Failure Code [D8ALKB]
— Circuit Diagram of System Operating Lamp
— Failure Code (DAFGMC)
— Failure Code (DAFQKR)
— Failure Code (DGH2KA)
— Failure Code (DGH2KB)
— Failure Code (DHPEKA)
— Failure Code (DHPEKY)
— Failure Code (DHT8ZG)
— Failure Code (#R0CIB)
— Failure Code (#R0CKB)
— Failure Code (#R0CLB)
— Failure Code (#R0CMB)
— Failure Code (#R0CPV)
— Failure Code (#R0CQB)
— Failure Code (#R0CRB)
— Failure Code (#R0CSB)
— Failure Code (#R0CTB)
— Failure Code (#R0CWB)
— Failure Code (#R0JLB)
— Failure Code (#R0JMB)
— Failure Code (#R0JNB)
— Failure Code (#R0JOB)
— Failure Code (#R0JPB)
— Failure Code (#R0QR2)
— Failure Code (#R0QS2)
— Failure Code (#R0QT4)
— Failure Code (#R0QU3)
— Failure Code (#R0QV4)
— Failure Code (#R0QY4)
— Failure Code (#R0QZ4)
— Failure Code (#R0R0V)
— Failure Code (#R0R1V)
— Failure Code (#R0SHV)
— Failure Code (#R0SIV)
— Failure Code (#R0SJV)
— Failure Code (#R0SKV)
— Failure Code (#R0SLV)
— Failure Code (#R0XS2)
— Failure Code (#R0XS3)
— Failure Code (#R0XS4)
— Failure Code (#R0XSB)
— Failure Code (#R0XSJ)
— Failure Code (#R0XSV)
— Failure Code (#R0XU2)
— Failure Code (#R0XU3)
— Failure Code (#R0XU4)
— Failure Code (#R0XUB)
— Failure Code (#R0XW2)
— Failure Code (#R0XW3)
— Failure Code (#R0XW4)
— Failure Code (#R0XWB)
— Failure Code (#R0YG2)
— Failure Code (#R0YG3)
— Failure Code (#R0YG4)
— Failure Code (#R0YGB)
— Failure Code (#R0YLB)
— Failure Code (#R0YM4)
— Failure Code (#R0YH2)
— Failure Code (#R0YH3)
— Failure Code (#R0YH4)
— Failure Code (#R0YHB)
— Failure Code (#R0YI2)
— Failure Code (#R0YI3)
— Failure Code (#R0YI4)
— Failure Code (#R0YIB)
— Failure Code (#R0YJ2)
— Failure Code (#R0YJ3)
— Failure Code (#R0YJ4)
— Failure Code (#R0YJB)
— Failure Code (#R0YK2)
— Failure Code (#R0YK3)
— Failure Code (#R0YK4)
— Failure Code (#R0YKB)
— Failure Code (#R14W2)
— Failure Code (#R14WB)
— Failure Code (#R14WJ)
— Failure Code (#R14WV)
— Failure Code (#R14X2)
— Failure Code (#R14XB)
— Failure Code (#R14Y2)
— Failure Code (#R14YB)
— Failure Code (#R14Z2)
— Failure Code (#R14ZB)
— Failure Code (#R1502)
— Failure Code (#R1504)
— Failure Code (#R150B)
— Failure Code (#R1513)
— Failure Code (#R1514)
— Failure Code (#R1522)
— Failure Code (#R1523)
— Failure Code (#R1524)
— Failure Code (#R152B)
— Failure Code (#R1532)
— Failure Code (#R1533)
— Failure Code (#R1534)
— Failure Code (#R153B)
— Failure Code (#R15C2)
— Failure Code (#R15C3)
— Failure Code (#R15C4)
— Failure Code (#R15CB)
— Failure Code (#R15CV)
— Failure Code (#R16O2)
— Failure Code (#R16OB)
— Failure Code (#R16OV)
— Failure Code (#R18G2)
— Failure Code (#R18GB)
— Failure Code (#R18GJ)
— Failure Code (#R18GV)
— Failure Code (#R18M2)
— Failure Code (#R18MB)
— Failure Code (#R18MV)
— Failure Code (#R18MJ)
— Failure Code (#R18N2)
— Failure Code (#R18NB)
— Failure Code (#R18O2)
— Failure Code (#R18OB)
— Failure Code (#R18P2)
— Failure Code (#R18PB)
— Failure Code (#R18Q2)
— Failure Code (#R18QB)
— Failure Code (#R18R2)
— Failure Code (#R18RB)
— Failure Code (#R18S2)
— Failure Code (#R18SB)
— Failure Code (#R18T2)
— Failure Code (#R18TB)
— Failure Code (#R18W2)
— Failure Code (#R18WB)
— Failure Code (#R18WJ)
— Failure Code (#R18WV)
— Failure Code (#R18X2)
— Failure Code (#R18XB)
— Failure Code (#R18XJ)
— Failure Code (#R18XV)
— Failure Code (#R1922)
— Failure Code (#R1924)
— Failure Code (#R192B)
— Failure Code (#R1942)
— Failure Code (#R194B)
— Failure Code (#R1952)
— Failure Code (#R195B)
— Failure Code (#R1962)
— Failure Code (#R1963)
— Failure Code (#R1964)
— Failure Code (#R196B)
— Failure Code (#R1972)
— Failure Code (#R1974)
— Failure Code (#R197B)
— Failure Code (#R1982)
— Failure Code (#R1984)
— Failure Code (#R198B)
— Failure Code (#R1CG2)
— Failure Code (#R1CG3)
— Failure Code (#R1CG4)
— Failure Code (#R1CGB)
— Failure Code (#R1CH2)
— Failure Code (#R1CH3)
— Failure Code (#R1CH4)
— Failure Code (#R1CHB)
— Failure Code (#R1CI2)
— Failure Code (#R1CI3)
— Failure Code (#R1CI4)
— Failure Code (#R1CIB)
— Failure Code (#R1CJ2)
— Failure Code (#R1CJ4)
— Failure Code (#R1CJB)
— Failure Code (#R1CKC)
— Failure Code (#R1CLC)
— Failure Code (#R1CMC)
— Failure Code (#R1CNC)
— Failure Code (#R1COB)
— Failure Code (#R1CPB)
— Failure Code (#R1CQC)
— Failure Code (#R1CW2)
— Failure Code (#R1CWB)
— Failure Code (#R1CX2)
— Failure Code (#R1CXB)
— Failure Code (#R1CY3)
— Failure Code (#R1J42)
— Failure Code (#R1J4B)
— Failure Code (#R1J4J)
— Failure Code (#R1J4V)
— Failure Code (#R1K3B)
— Failure Code (#R1KWJ)
— Failure Code (#R1KWV)
— Failure Code (#R1L0B)
— Failure Code (#R1L0J)
— Failure Code (#R1L0V)
— Failure Code (#R1L2B)
— Failure Code (#R1L2J)
— Failure Code (#R1L2V)
— Failure Code (#R1L4V)
— Failure Code (#R1Q82)
— Failure Code (#R1Q8B)
— Failure Code (#R1Q8J)
— Failure Code (#R1Q8V)
— Failure Code (#R1QB2)
— Failure Code (#R1QBB)
— Failure Code (#R1QBV)
— Failure Code (#R1QC2)
— Failure Code (#R1QCB)
— Failure Code (#R1QD2)
— Failure Code (#R1QDB)
— Failure Code (#R1XC2)
— Failure Code (#R1XCB)
— Failure Code (#R1XCJ)
— Failure Code (#R1XCV)
— Failure Code (#R1XD2)
— Failure Code (#R1XDB)
— Failure Code (#R1XJB)
— Failure Code (#R1XM2)
— Failure Code (#R1XMB)
— Failure Code (#R20WB)
— Failure Code (#R20WJ)
— Failure Code (#R20WV)
— Failure Code (#R20XB)
— Failure Code (#R20YB)
— Failure Code (#R2BLB)
— Failure Code (#R25D2)
— Failure Code (#R25D3)
— Failure Code (#R25D4)
— Failure Code (#R25D5)
— Failure Code (#R25DB)
— Failure Code (#R25W2)
— Failure Code (#R25W3)
— Failure Code (#R25W4)
— Failure Code (#R25WB)
— Failure Code (#R268B)
— Failure Code (#R2693)
— Failure Code (#R2694)
— Failure Code (#R2695)
— Failure Code (#R269B)
— Failure Code (#R26AB)
— Failure Code (#R26B3)
— Failure Code (#R26B4)
— Failure Code (#R26B5)
— Failure Code (#R26BB)
— Failure Code (#R26OB)
— Failure Code (#R26P3)
— Failure Code (#R26P4)
— Failure Code (#R26P5)
— Failure Code (#R26PB)
— Failure Code (#R280B)
— Failure Code (#R2813)
— Failure Code (#R2814)
— Failure Code (#R2815)
— Failure Code (#R281B)
— Failure Code (#R2BKB)
— Failure Code (#R2J92)
— Failure Code (#R2J9V)
— Failure Code (#R2JK2)
— Failure Code (#R2JK9)
— Failure Code (#R2JKB)
— Failure Code (#R2JL2)
— Failure Code (#R2JL9)
— Failure Code (#R2JLB)
— Failure Code (#R2JM2)
— Failure Code (#R2JM9)
— Failure Code (#R2JMB)
— Failure Code (#R2JN2)
— Failure Code (#R2JN9)
— Failure Code (#R2JNB)
— Failure Code (#R2JO2)
— Failure Code (#R2JO9)
— Failure Code (#R2JOB)
— Failure Code (#R2JP2)
— Failure Code (#R2JP9)
— Failure Code (#R2JPB)
— Failure Code (#R2JQ2)
— Failure Code (#R2JQ9)
— Failure Code (#R2JQB)
— Failure Code (#R2JR2)
— Failure Code (#R2JR9)
— Failure Code (#R2JRB)
— Failure Code (#R2JS2)
— Failure Code (#R2JS9)
— Failure Code (#R2JSB)
— Failure Code (#R2JT2)
— Failure Code (#R2JT9)
— Failure Code (#R2JTB)
— Failure Code (#R2JU2)
— Failure Code (#R2JU9)
— Failure Code (#R2JUB)
— Failure Code (#R2JY2)
— Failure Code (#R2JY9)
— Failure Code (#R2JYB)
— Failure Code (#R2PS2)
— Failure Code (#R2PS3)
— Failure Code (#R2PS4)
— Failure Code (#R2PSB)
— Failure Code (#R2PW2)
— Failure Code (#R2PW3)
— Failure Code (#R2PW4)
— Failure Code (#R2PWB)
— Failure Code (#R2PX2)
— Failure Code (#R2PX3)
— Failure Code (#R2PX4)
— Failure Code (#R2PXB)
— Failure Code (#R2PY3)
— Failure Code (#R2PY4)
— Failure Code (#R2PY5)
— Failure Code (#R2PYB)
— Failure Code (#R2PZB)
— Failure Code (#R2Q02)
— Failure Code (#R2Q03)
— Failure Code (#R2Q04)
— Failure Code (#R2Q05)
— Failure Code (#R2Q0B)
— Failure Code (#R2Q13)
— Failure Code (#R2Q14)
— Failure Code (#R2Q15)
— Failure Code (#R2Q2B)
— Failure Code (#R2Q32)
— Failure Code (#R2Q33)
— Failure Code (#R2Q34)
— Failure Code (#R2Q35)
— Failure Code (#R2Q3B)
— Failure Code (#R2Q4B)
— Failure Code (#R2Q5B)
— Failure Code (#R2Q62)
— Failure Code (#R2Q63)
— Failure Code (#R2Q64)
— Failure Code (#R2Q6B)
— Failure Code (#R2Q72)
— Failure Code (#R2Q73)
— Failure Code (#R2Q74)
— Failure Code (#R2Q7B)
— Failure Code (#R2PT2)
— Failure Code (#R2PT3)
— Failure Code (#R2PT4)
— Failure Code (#R2PTB)
— Failure Code (#R2PUB)
— Failure Code (#R2PV2)
— Failure Code (#R2PV3)
— Failure Code (#R2PV4)
— Failure Code (#R2PV5)
— Failure Code (#R2PVB)
— Failure Code (#R9512)
— Failure Code (#R951B)
— Failure Code (#W8000)
— Failure Code (#W8001)
— Failure Code (#W8002)
— Failure Code (#W8003)
— Failure Code (#W8004)
— Failure Code (#W8006)
— Failure Code (#W8008)
— Failure Code (#W8009)
— Failure Code (#W8011)
— Failure Code (#W8200)
– Troubleshooting of Electrical System (E-Mode)
— E-1 Engine Does Not Start (Engine Does Not Crank)
— E-2 Automatic Preheating System Does Not Work
— E-3 Machine Monitor Display Nothing (Battery Relay is not Energized)
— E-4 LCD Unit on Machine Monitor Displays Nothing (Battery Relay is Energised)
— E-5 Rearview Monitor Does Not Come On or Backlight Flickers
— E-6 Rearview Monitor Images are Not Shown Clearly
— E-7 Meter Unit Display on Machine Monitor is Abnormal
— E-8 Night Mode on Machine Monitor is Abnormal
— E-9 Some Items of Gauges and Caution Lamps on Machine Monitor Are Not Displayed Properly
— E-10 DEF Level is Not Shown Correctly
— E-11 Fuel Gauge Does Not Show Normally
— E-12 Seatbelt Warning System Abnormal
— E-13 Return To Dig Does Not Operate
— E-14 Boom Kick Out Does Not Operate
— E-15 Air Cleaner Clogging Indicator Lamp Does Not Come On
— E-16 Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking)
— E-17 Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On
— E-18 Alarm Buzzer Does Not Operate / Does Not Stop
— E-19 Directional Selector (FNR) Does Not Work
— E-20 Directional Selector (FNR) in Joystick Steering Does Not Work
— E-21 Horn Does Not Operate (Steering Wheel Specification)
— E-22 Horn Does Not Operate (JSS Specification)
— E-23 Fan Does Not Rotate in Reverse
— E-24 Fan Remains Rotated in Reverse
— E-25 ECSS Function cannot be Selected or Activated
— E-26 KOMTRAX System Does Not Operate Correctly
— E-27 Auto-Greasing Pump Display Shows [Error]
— E-28 Auto-Greasing Pump Display Shows [Low]
— E-29 Auto-Greasing System Does Not Operate or Stop
— E-30 Heater Mirror Does Not Work or TURN OFF
— E-31 Rear Heated Wire Glass Does Not Work or Turn OFF
— E-32 Rear Flasher Operates Abnormal (Synchronizing)
– Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
— Information Mentioned in Troubleshooting Table (H Mode)
— H-1 Machine Can Travel Neither Forward Nor Reverse
— H-2 Machine Can Not Travel Forward (Machine Travels Reverse Normally)
— H-3 Machine Can Not Travel Reverse (Machine Travels Forward Normally)
— H-4 Travel Speed of Forward Travel and Reverse Travel is Slow, or Power is Low
— H-5 Forward Travel Speed is Slow Or Power is Low (Machine Travels Reverse Normally)
— H-6 Reverse Travel Speed is Slow Or Power is Low (Machine Travels Forward Normally)
— H-7 Engine Speed Drops Largely or Engine Stops
— H-8 Machine Does Not Turn
— H-9 Steering Wheel is Heavy to Operate
— H-10 Machine Sways or Large Shocks are Made While Machine Turns
— H-11 Machine Unintentionally Turns to One Side When Machine Travels
— H-12 Wheel Brakes Do Not Work or are Weak
— H-13 Wheel Brakes are Not Released or Drag
— H-14 Parking Brake Does Not Work or It Is Weak
— H-15 Parking Brake Is Not Released or Drags
— H-16 Boom Does Not Rise
— H-17 Boom Moves Slow or Boom Lacks Lifting Force
— H-18 Rising Boom Slows Down at Certain Height
— H-19 Lift Cylinders Do Not Serve to Hold Bucket on Ground
— H-20 Hydraulic Drift of Boom is Large
— H-21 Boom Moves Up and Down During Operation
— H-22 Bucket Does Not Tilt Back
— H-23 Bucket Moves Slow or Lacks Tilt-back Force
— H-24 Bucket Decelerates During Tilt-Back Operation
— H-25 Bucket Cylinder Does Not Hold Bucket on Ground
— H-26 Hydraulic Drift of Bucket is Large
— H-27 Bucket Tilts Back and Forth During Carrying Load (Work Equipment Valve in Hold)
— H-28 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move
— H-29 When Operating Work Equipment Engine Speed Drops Largely or Engine Stops
— H-30 Large Shocks are Made When Work Equipment Starts to Move and Stops
— H-31 When Certain Work Equipment Stalls Hydraulically, Other Work Equipment Moves
— H-32 E.C.S.S. (Travel Damper) Does Not Work and Machine Pitches and Bounces
— H-33 Fan Speed Is Abnormal (Too High or Low, or Stationary)
— H-34 Unusual Noise Is Heard From Around Fan
– Troubleshooting of Engine
— Maintenance Standards For Various Parts
— Tightening Torque for Main Bolts and Nuts
— General Tightening Torque
— Standard Value for Cylinder Head Assembly
— Camshaft and Timing Gear Train Specifications
— Standard Value for Crankshaft and Piston
— Troubleshooting
— 1. Troubleshooting Chart
— 1.1 Troubleshooting Information
— 2. Troubleshooting of Electronic Control System
— 2.1 Fault Detection Capability
— 2.2 SMARTASSIST-DIRECT (SA-D)
— Faulty Startup
— Starter motor does not turn
— Starter Motor Turns
— Engine Stalling After Startup
— Sound or Vibration Anomaly
— Faulty Rotation Control
— Engine Speed Cannot Be Changed With Accelerator (Fixed Speed)
— When There is No Load
— When Performing Work
— Insufficient Engine Output
— Intake-Related Anomaly
— Exhaust-Related Anomaly
— When Performing Work
— Lubricating Oil-Related Anomaly
— Engine Cooling Water-Related Anomaly
— Fuel-Related Anomaly
— Electrical Equipment-Related Anomaly
— Troubleshooting of Engine (S-Mode)
— Information Mentioned in Troubleshooting Table (S Mode)
— S-20 Air Cannot Be Bled From Fuel Circuit
— S-21 Active Regeneration is Done Frequently
— S-22 Active Regeneration takes long
— S-23 White Smoke is Exhausted During Active Regeneration
— S-24 DEF Consumption Is Excessive
— S-25 There is Unusual Smell (Irritating Odor)
— S-26 Foreign Materials Enter DEF (DEF Increases)
– Engine Troubleshooting Manual
Troubleshooting Engine
– TABLE OF CONTENTS
– 1. GENERAL DESCRIPTION OF ENGINE ELECTRONIC CONTROL SYSTEM
— 1.1. Introduction
– 2. DTC (DIAGNOSTIC TROUBLE CODES) GENERAL DESCRIPTION
— 2.1. DTC Code List
— 2.2. Description
— 2.3. Engine ECU Judgment Item
— 2.4. DCU Judgment Item (Applicable only to models with urea SCR system)
– 3. METHOD AND PROCEDURE OF FAILURE DIAGNOSIS
— 3.1. Description
— 3.2. Engine ECU Judgment Item
— 3.3. DCU Judgment Item
Disassembly and Assembly
– Related Information on Disassembly And Assembly
— How to Read This Manual
— Reading the work procedures
— Reading the symbols
— Reading the signal word
— Reading the unit
— Coating Materials List
— Adhesive
— Liquid gasket
— Molybdenum disulfide lubricant
— Seizure prevention compound
— Grease
— Primer
— Adhesive
— Caulking material
– Engine and Cooling System
— Remove and Install Supply Pump Assembly
— Remove and Install Injector Assembly
— Remove and Install Cylinder Head Assembly
— Remove and Install EGR System
— Remove and Install Starter Motor Assembly
— Remove and Install DEF Tank Sensor Flange Assembly
— Removal of DEF Tank Sensor Flange Assembly
— Install DEF Tank Sensor Flange Assembly
— Remove and Install DEF Tank Sensor
— Removal of DEF Tank Sensor
— Installation of DEF Tank Sensor
— Remove and Install DEF Tank Strainer
— Removal of DEF Tank Strainer
— Installation of DEF Tank Strainer
— Remove and Install DOC and SCR Assembly
— Removal of DOC Assembly
— Remove and Install DEF Injector
— Removal of AdBlue/ DEF injector
— Installation of DEF injector
— Remove and Install DEF Pump
— Remove DEF Pump
— Installation of DEF Pump
— Remove and Install DEF Hose
— Removal of DEF Hose
– Power Train
— Pumps for Steering, Work Equipment, Cooling Fan and Service Brake
— Removal of Gear Pump (Cooling Fan and Service Brake)
— Removal of Axial Piston Pump (Work Equipment and Steering)
— Installation of Gear Pump and Axial Pump
— Drive Shafts Assembly
— Removal of Drive Shafts
— Installation of Drive Shafts
— HST Motor Assembly
— Removal of HST motor assembly
— Installation of variable motor assembly
— HST Pump Assembly
— Removal of HST pump assembly
— Installation of HST pump assembly
— Gearbox (Transfer Assembly)
— Precautions for Assembly and Disassembly
— Safety Precautions
— Removal of Gearbox (20 km/h machine)
— Disassembly of Gearbox (20 km/h machine)
— Assembly
— Special Tools
— Installation of Gearbox (20 km/h machine)
— Removal of Gearbox (40 km/h machine)
— Disassembly of Gearbox (40 km/h machine)
— Disassembly of Reduction Gear
— Assembly of Reduction Gear
— Disassembly and assembly of Clutch Shaft
— Special Tools
— Installation of Gearbox (40 km/h machine)
— Rear Axle Assembly
— Removal of Rear Axle Assembly
— Installation of Rear Axle Assembly
— Front Axle Assembly
— Removal of Front Axle Assembly
— Installation of Front Axle Assembly
— Precautions for Assembly and Disassembly of Axle Components
— Safety Precautions
— Checking Wear and Replacing the Braking Discs
— Checking Wear
— Special Tools
— Disassembly and Assembly of Braking Discs
— Disassembly and Assembly of Axle Assembly
— Disassembly and Assembly of Planetary Reduction Gear and Axle Shaft
— Disassembly and Assembly of Bevel Pinion
— Disassembly and Assembly of Swinging Support
— Disassembly and Assembly of Swinging Support
— Manual Emergency Release
— Disassembly and Assembly of Parking Brake
– Work Equipment System
— Remove and Install Main Valve Assembly
— Removal of Main Control Valve Assembly
— Installation of Main Control Valve Assembly
— Remove and Install Pilot Valve Assembly
— Removal of Pilot Control Valve Assembly
— Removal of Standard Multifunction Lever
— Removal of Optional Multifunction Lever
— Assembly of Pilot Control Valve
– Engine Hood
— Remove and Install Engine Hood Assembly
— Removal of Engine Hood Assembly
— Installation of Engine Hood Assembly
– Electrical System
— Remove and Install Engine Controller Assembly
— Remove and Install HST Controller Assembly
— Remove and Install Machine Monitor Assembly
— Removal Machine Monitor Assembly
— Install Machine Monitor Assembly
— Remove and Install Joystick Steering Controller Assembly
Maintenance Standard
– Engine and Cooling
— Maintenance Standard of Engine Mount
— Maintenance Standard of Damper
— Maintenance Standard of Cooling Fan Motor
– Hydraulic System
– Cab and its Attachments
— Cabin – adjustment
Appendix
– Air Conditioner System
— Precautions for Refrigerant
– Air Conditioner Component Standard
— Specifications of air conditioner
– Air Conditioner Component Auto (Option)
— Specifications of air conditioner
— Function of Air Conditioner Unit
— Temperature Control
— Over-cooling (Freezing) Prevention
— ON/OFF of Air Flow
— Automatic Mode of Air Conditioner (Option)
– Configuration and Function of Refrigeration Cycle
— Outline of Refrigeration Cycle
— Compression (Compressor)
— Condensation (Condenser)
— Expansion (Expansion Valve)
— Evaporation (Evaporator)
— Relation Between Refrigerant and Cooling Trouble
– Air Conditioner Troubleshooting Chart
— Cooling trouble
— Heating trouble
– Connection of Service Tool
— Method for Connecting Service Tool
– Precautions for Disconnecting and Connecting Hoses and Tubes in Air Conditioner Pipings
— Precautions for disconnection
— Precautions for connection
– Handle Compressor Oil
— Management of compressor oil (SANDEN: SP-10 for use with R134a)
— Filling of compressor oil
— The quantity of compressor oil when the compressor is replaced
– Software Update for the Machine Monitor
– Connection of Service Tool for Joystick Steering Service
– User_Manual_PVED-CLS_SW.pdf
— Komatsu WA170/PW1xx Joystick Steering with PVEDC-CSL
— Introduction
— Software Design
— General System Setup
— Functional Safety
— Connection Diagram Komatsu WA170/PW180 Joystick Steering with PVED-CLS
— Safety Precautions
— Tuning Precautions
— CAN Adapter Cable
— SW Identification
— Service Tool Screens
— Data Logging
— System Information
— System Information
— Service Screen Pages
— Inputs/Outputs
— PVED-CLS Page
— Faults
— Faults Log
— 6 Point Curve Parameters – Joystick Profiles
— SASA Sensor
— Error Counters
— JSS1 and JSS2 Messages
— Application Software Download
— Application Software Download
— Appendix
— Error List
— Appendix – CAN Messages
— SASA Sensor
— PVED-CLS
— JSS1
— JSS2
— Danfoss Power Solutions
Other
– Hydraulic Circuit Diagram
– Wiring Circuit Diagram
— Contents
— Contents
— 1-0 Symbols Summary, Abbreviations
— 1-1 Joystick Buttons
— 1-2 CAN BUS Summary
— 2-0 Relaybox, Starter, Alternator, Battery, Glow Plug
— 2-1 Grounding
— 2-2 Power Supply, Starter Switch
— 2-3 Power Supply 2
— 2-4 Main Engine (EGR) Rel, XLR Cleaner, DEF Heater
— 2-5 System Operating Lamp, DEF Alive
— 3-0 Secondary Stop, DPF SW, Engine Conn 1
— 3-1 Engine Connections 2
— 3-2 Engine Connections 3, CAN J1939
— 3-3 DCU Connections
— 4-0 Monitor, I/O Contr. 64P, Buzzer, Steering Pressure
— 4-1 KOMTRAX Controller, Service Connector
— 4-2 Fluid-Sensors (Oil, Fuel, Coolant)
— 5-0 HST Controller Inputs
— 5-1 HST Controller, Park Brake, Driving Function
— 5-2 Cruise Ctrl., Auto Inch, Dana Sensor
— 5-3 Brake, Accel. Pedal, Pump, PPC Lock
— 5-4 Creep
— 5-5 Joystick / RH Console Harness
— 5-6 Joystick / RH Console Harness Advance
— 5-7 3rd and 4th Hydraulic Circuit EPC Output
— 6-0 FAN Drive, Reverse Fan
— 6-1 Joystick Steering
— 6-2 Joystick Steering Page 2
— 6-3 Camera
— 7-0 AC Unit
— 7-1 Washer, Wiper, Horn
— 7-2 Rear Window Heater, Mirror Heating & Adjusting
— 7-3 Seat Option, Rear Wiper
— 8-0 Lighting Front
— 8-1 Flasher, Hazard Light
— 8-2 Rear Light, Backup Alarm, Rear Flasher
— 8-3 Work Lamps
— 8-4 Interior Lamp, Rotating Beacon
— 9-0 ECSS, Over Center Valve
— 9-1 Boom Kickout, Boom Float, Return to Dig
— 9-2 Bucket Dump, CLS, Crash Sensor
— 9-3 Protective Ventilation, Quick Coupler, Differential Lock
— 9-4 Radio, Front Socket Boom, Blank Option
— 9-5 5V & 12V Socket, Payload Meter
— 9-6 Attachment Pressure Release
— 10-0 Armrest Internal Wiring
– W1 Connector List 1
— W2 Connector List 1
— W2 Connector List 2
— W2 Connector List 3
— W2 Connector List 4
— W2 Connector List 5
— W2 Connector List 6
— W2 Connector List 7
– W3 Pin Location List 1
— W3 Pin Location List 2
— W3 Pin Location List 3
— W3 Pin Location List 4
— W3 Pin Location List 5
— W3 Pin Location List 6
— W3 Pin Location List 7
— W3 Pin Location List 8
— W3 Pin Location List 9
— W3 Pin Location List 10
— W3 Pin Location List 11
— W3 Pin Location List 12
— W3 Pin Location List 13
— W3 Pin Location List 14
— W3 Pin Location List 15
— W3 Pin Location List 16
— W3 Pin Location List 17
— W3 Pin Location List 18
— W3 Pin Location List 19
— W3 Pin Location List 20
— W3 Pin Location List 21
— W3 Pin Location List 22
— W3 Pin Location List 23
— W3 Pin Location List 24
— W3 Pin Location List 25
— W3 Pin Location List 26
— W3 Pin Location List 27
— W3 Pin Location List 28
— W3 Pin Location List 29
— W3 Pin Location List 30
— W3 Pin Location List 31
— W3 Pin Location List 32
— W3 Pin Location List 33
— W3 Pin Location List 34
— W3 Pin Location List 35
— W3 Pin Location List 36
— W3 Pin Location List 37
— W3 Pin Location List 38
— W3 Pin Location List 39
— W3 Pin Location List 40
— W3 Pin Location List 41
— W3 Pin Location List 42
— W3 Pin Location List 43
— W3 Pin Location List 44
— W3 Pin Location List 45
— W3 Pin Location List 46
– Parts List 4-1
— Parts List 4-2
— Parts List 4-3
— Parts List 4-4
— W5-1 ECU Pin Overview Connector/Controller
— W5-2 ECU Pin Overview Connector/Controller
– Connector Diagram
— Cabin 1
— Cabin 2
— Front Harness
— Front – Additional harnesses
— Rear Harness
— Rear – Additional Harnesses