FH100 -1
FH120 -1
FH135 -1
FH160 -1
FH100-7001
FH120-7001
FH135-7001
FH160-7001 and up
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00 INDEX AND FOREWORD INDEX -
LIST OF ABBREVIATIONS
FOREWORD, SAFETY AND GENERAL INFORMATION
PRECAUTIONS RELATED TO WORK SAFETY-
FIRE PREVENTION-
IF A FIRE BREAKS OUT-
INSTRUCTIONS FOR WASTE DISPOSAL-
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS-
HANDLING
REGARDING STORAGE OF DEF-
REGARDING HANDLING OF DEF IN COLD WEATHER-
INSTRUCTIONS FOR HANDLING HYDRAULIC COMPONENTS-
INSTRUCTIONS FOR DISCONNECTING AND CONNECTING PIPING
INSTRUCTIONS FOR HANDLING ELECTRIC COMPONENTS-
INSTRUCTIONS FOR HANDLING INTAKE SYSTEM COMPONENTS
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD-
STANDARD TIGHTENING TORQUE TABLE
01 SPECIFICATION
SPECIFICATION DRAWING-
FUEL, COOLANT, AND LUBRICANT-
10 STRUCTURE AND FUNCTION
LIST OF ABBREVIATIONS
UREA SCR SYSTEM-
COOLING SYSTEM
COOLING SYSTEM COMPONENT LAYOUT DRAWING
CONTROL SYSTEM COMPONENT LAYOUT DRAWING-
MONITOR PANEL SYSTEM-
REARVIEW MONITOR SYSTEM
KOMTRAX SYSTEM
SEAT BELT INTERLOCK SYSTEM-
CONTROL SYSTEM COMPONENTS
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM COMPONENT LAYOUT DRAWING
HYDRAULIC SYSTEM COMPONENTS-
TRAVEL SPEED LIMIT SYSTEM
WORK EQUIPMENT SYSTEM COMPONENT LAYOUT DRAWING-
STRUCTURE OF VALVE CONTROL-
LIFT INTERLOCK SYSTEM -
WORK EQUIPMENT SYSTEM COMPONENTS- -
SYSTEM -
STEERING SYSTEM COMPONENT LAYOUT DRAWING
ELECTRONIC PROPORTIONAL ACTIVE CONTROL STEERING (EPACS) SYSTEM-
COLUMN-
STEERING SYSTEM COMPONENT- -
BRAKE SYSTEM -
BRAKE SYSTEM COMPONENT LAYOUT DRAWING
PARKING BRAKE REMINDER SYSTEM-
PARKING BRAKE DRAGGING PREVENTION SYSTEM
BRAKE SYSTEM COMPONENTS-
UNDERCARRIAGE AND FRAME
STRUCTURE OF FRAME-
20 STANDARD VALUE TABLE LIST OF ABBREVIATIONS
STANDARD VALUE TABLE FOR ENGINE-
STANDARD VALUE TABLE FOR ENGINE FH100-1-
STANDARD VALUE TABLE FOR ENGINE FH120-1-
STANDARD VALUE TABLE FOR ENGINE FH135-1-
STANDARD VALUE TABLE FOR ENGINE: FH160-1
STANDARD VALUE TABLE FOR MACHINE- -
STANDARD VALUE TABLE FOR MACHINE: FH100-1-
STANDARD VALUE TABLE FOR MACHINE: FH120-1-
STANDARD VALUE TABLE FOR MACHINE: FH135-1-
STANDARD VALUE TABLE FOR MACHINE: FH160-1-
30 TESTING AND ADJUSTING PRECAUTIONS BEFORE WORK
RELATED INFORMATION ON TESTING AND ADJUSTING -
-20-8
-20-17
-20-20
-20-20
TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM-
ENGINE SPEED
TESTING BOOST PRESSURE
TESTING EXHAUST GAS COLOR
TESTING AND ADJUSTING VALVE CLEARANCE
TESTING COMPRESSION PRESSURE-
TESTING BLOWBY PRESSURE-
CLEAN INSIDE OF EGR VALVE-
CHECKING AIR CLEANER AND CLEANING OR REPLACING ELEMENT
CHECKING AND CLEANING AIR CONDITIONER CONDENSER FIN
CHECKING REFRIGERANT (GAS) LEVEL
CHECKING ALTERNATOR BELT
CHECKING AUTO-TENSIONER
TESTING SCR-RELATED FUNCTIONS-
DEF TANK-
STEERING SYSTEM-
TESTING STEERING WHEEL-
CIRCUIT
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE-
TESTING AND ADJUSTING WORK EQUIPMENT PRESSURE- -
TESTING AND ADJUSTING WORK EQUIPMENT PPC PRESSURE-
CHANGING HYDRAULIC OIL-
REPLACING HYDRAULIC OIL LINE FILTER-
CLEANING HYDRAULIC TANK STRAINER-
CHECKING HYDRAULIC TANK BREATHER-
WORK EQUIPMENT-
BLEEDING AIR FROM LIFT CYLINDER
TESTING HYDRAULIC DRIFT AND HYDRAULIC DRIFT FORWARD TILT OF CYLINDERS
ADJUSTING MAST
ADJUSTING FINGER BAR-
ADJUSTING TILT CYLINDER-
CAB AND ITS ATTACHMENTS-
TESTING DIRECTIONAL LEVER
TESTING LIFT LEVER AND TILT LEVER
TESTING ACCELERATOR PEDAL
ELECTRICAL SYSTEM-
SETTING AND OPERATION OF MONITOR PANEL-
KOMTRAX TERMINAL START-UP PROCEDURE
ADJUSTING INSTALLED ANGLE OF REARVIEW CAMERA
HANDLING OF ENGINE CONTROLLER POWER SUPPLY CIRCUIT
GUIDELINE FOR TESTING DIODE- -
40 TROUBLESHOOTING
PRECAUTIONS BEFORE WORK
LIST OF ABBREVIATIONS -
INFORMATION RELATED TO TROUBLESHOOTING-
POINTS TO REMEMBER WHEN PERFORMING TROUBLESHOOTING-
-40-12
-40-17
POINTS TO REMEMBER WHEN PERFORMING TROUBLESHOOTING OF UREA SCR SYSTEM -40-18 HOW TO PROCEED IN TROUBLESHOOTING
CHECK BEFORE TROUBLESHOOTING-
GUIDELINE FOR CHECK BEFORE STARTING TROUBLESHOOTING-
CHECK ACCORDING TO CHECK GUIDELINE
PROCEDURE FOR TROUBLESHOOTING
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS-
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
CONNECTOR LIST AND LAYOUT
CONNECTION TABLE FOR CONNECTOR PIN NO.
T-BOX AND T-ADAPTER LIST
LIST AND LOCATIONS OF INSTALLED FUSES
PRECAUTIONS WHEN REPLACING KDOC
FAILURE CODES TABLE-
TROUBLESHOOTING BY FAILURE CODE
FAILURE CODE [2G40ZG]-
FAILURE CODE [6091NX]
FAILURE CODE [7REAKA]-
FAILURE CODE [7REHKA]
FAILURE CODE [A1U0N3]-
FAILURE CODE [A1U0N4]-
FAILURE CODE [AA10NX]-
FAILURE CODE [AB00KY]-
FAILURE CODE [AB00MA]-
FAILURE CODE [AQ10MB]
FAILURE CODE [AQ10N3]-
FAILURE CODE [AS00R2]-
FAILURE CODE [AS00R3]-
FAILURE CODE [AS00R4]-
FAILURE CODE [AS00R5]-
FAILURE CODE [AS00R6]-
-40-33
-40-78
[AS10KM]-
[AS10NT]
CODE [B@BAZG]
FAILURE CODE [B@BCNS]
FAILURE CODE [B@BCZK] (Serial No.: 7001 to 7137)
FAILURE CODE [B@BCZK] (Serial No.: 7138 and up)
FAILURE CODE [B@CRNS]-
FAILURE CODE [CA115]
FAILURE CODE [CA122]
FAILURE CODE [CA123]
FAILURE CODE [CA131]
FAILURE CODE [CA132]
FAILURE CODE [CA144]
FAILURE CODE [CA145]
FAILURE CODE [CA153]
FAILURE CODE [CA154]
FAILURE CODE [CA187]
CODE [CA221]
[CA222]
[CA227]
[CA234]
[CA238]
[CA295]
CODE [CA322]
CODE [CA324]
CODE [CA331]
FAILURE CODE [CA332]
FAILURE CODE [CA343]
FAILURE CODE [CA351]
FAILURE CODE [CA352]
FAILURE CODE [CA356]
FAILURE CODE [CA357]
FAILURE CODE [CA386]
CODE [CA428]
CODE [CA431]
CODE [CA432]
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FAILURE CODE [CA691]
FAILURE CODE [CA692]
FAILURE CODE [CA697]
FAILURE CODE [CA698]
FAILURE CODE [CA731]
FAILURE CODE [CA778]
FAILURE CODE [CA1117]
FAILURE CODE [CA1664]
FAILURE CODE [CA1669]
FAILURE CODE [CA1673]
FAILURE CODE [CA1677]
FAILURE CODE [CA1678]
FAILURE CODE [CA1682]
FAILURE CODE [CA1683]
FAILURE CODE [CA1684]
FAILURE CODE [CA1686]
FAILURE CODE [CA1691]
FAILURE CODE [CA1694]
FAILURE CODE [CA1695]
FAILURE CODE [CA1696]
FAILURE CODE [CA1712]
FAILURE CODE [CA1713]
FAILURE CODE [CA1714]
FAILURE CODE [CA1715]
FAILURE CODE [CA1776]
FAILURE CODE [CA1777]
FAILURE CODE [CA1843]
FAILURE CODE [CA1844]
FAILURE CODE [CA1885]
FAILURE CODE [CA1887]
FAILURE CODE [CA1896]
FAILURE CODE [CA1898]
FAILURE CODE [CA1938]
FAILURE CODE [CA1942]
FAILURE CODE [CA1961]
FAILURE CODE [CA1962]
FAILURE CODE [CA2185]
FAILURE CODE [CA2186]
FAILURE CODE [CA2198]
FAILURE CODE [CA2272]
FAILURE CODE [CA2288]
FAILURE CODE [CA2311]
FAILURE CODE [CA2349]
FAILURE CODE [CA2353]
FAILURE CODE [CA2357]
FAILURE CODE [CA2373]
FAILURE CODE [CA2374]
FAILURE CODE [CA2375]
FAILURE CODE [CA2376]
[CA2387]
CODE [CA2556]
CODE [CA2637]
FAILURE CODE [CA2771]
CODE [CA2961]
[CA2973]
[CA2976]
[CA3143]
CODE [CA3144]
[CA3146]
[CA3147]
[CA3148]
[CA3151]
CODE [CA3165]
CODE [CA3228]
[CA3229]
[CA3231]
[CA3419]
[CA3421]
[CA3497]
CODE [CA3498]
FAILURE CODE [CA3545]
CODE [CA3547]
FAILURE CODE [CA3558]
FAILURE CODE [CA3559]
FAILURE CODE [CA3562]
CODE [CA3563]
CODE [CA3567]
FAILURE CODE [CA4157]
FAILURE CODE [CA4159]
FAILURE CODE [CA4164]
FAILURE CODE [CA4165]
FAILURE CODE [CA4166]
FAILURE CODE [CA4168]
FAILURE CODE [CA4169]
FAILURE CODE [CA4171]
FAILURE CODE [CA4249]
FAILURE CODE [CA4251]
FAILURE CODE [CA4261]
FAILURE CODE [CA4277]
FAILURE CODE [CA4459]
FAILURE CODE [CA4461]
FAILURE CODE [CA4533]
FAILURE CODE [CA4534]
FAILURE CODE [CA4731]
FAILURE CODE [CA4732]
FAILURE CODE [CA4739]
FAILURE CODE [CA4768]
FAILURE CODE [CA4769]
FAILURE CODE [CA4842]
FAILURE CODE [CA4952]
FAILURE CODE [CA5115]
FAILURE CODE [CA5179]
FAILURE CODE [CA5181]
FAILURE CODE [CA5387]
FAILURE CODE [CA5388]
FAILURE CODE [CA5389]
FAILURE CODE [CA5391]
FAILURE CODE [CA5392]
FAILURE CODE [CA5393]
CODE [CA5394]
FAILURE CODE [CA5395]
FAILURE CODE [CA5396]
FAILURE CODE [CA5631]
FAILURE CODE [CA5632]
FAILURE CODE [CA5938]
FAILURE CODE [D110KA]
FAILURE CODE [D110KB]
FAILURE CODE [D140KB]-
FAILURE CODE [D140KY]-
FAILURE CODE [D160KA]-
FAILURE CODE [D160KB]-
FAILURE CODE [D160KY]-
FAILURE CODE [D161KB]-
FAILURE CODE [D161KY]-
FAILURE CODE [D190KB]-
FAILURE CODE [D190KY]-
FAILURE CODE [D19HKA]-
CODE [D19HKB]-
CODE [D19HKY]-
CODE [D19SKB]-
[D19SKY]-
CODE [D19TKY]-
CODE [D19UKA]-
FAILURE CODE [D19UKB]-
FAILURE CODE [D19UKY]-
[D5XWKA]
[D5XWKB]
[D5ZKKA]-
[D5ZKKB]-
FAILURE CODE [D5ZTKA]
FAILURE CODE [D811MC]
[D862KA]
[D8AQK4]-
[D8AQKR]-
[DAF0MB]-
CODE [DAF0MC]-
FAILURE CODE [DAF3KK]-
FAILURE CODE [DAFGMC]
CODE [DAFLKA]-
CODE [DAFLKB]-
CODE [DAFQKR]
[DAJ000]
CODE [DHHBKA]
FAILURE CODE [DHHBKY]
FAILURE CODE [DHHCKA]
FAILURE CODE [DHHCKY]
FAILURE CODE [DHPCKA]
FAILURE CODE [DHPCKY]
FAILURE CODE [DJF1KA]-
FAILURE CODE [DJF1L8]
FAILURE CODE [DK30KA]-
FAILURE CODE [DK30KY]-
FAILURE CODE [DK5YKA]-
FAILURE CODE [DK5YKY]-
FAILURE CODE [DK5YMA]
FAILURE CODE [DK70KA]-
FAILURE CODE [DK70KY]-
FAILURE CODE [DLT4KA]-
FAILURE CODE [DLT4KA+DLT6KA]-
FAILURE CODE [DLT4LC]
FAILURE CODE [DLT4MA]-
FAILURE CODE [DLT6KA]-
FAILURE CODE [DV00KB]-
FAILURE CODE [DV00KY]-
FAILURE CODE [DV01KB]-
FAILURE CODE [DV01KY]-
FAILURE CODE [DW4CKA]
FAILURE CODE [DW4CKB]
FAILURE CODE [DW4CKY]
FAILURE CODE [DWK0KA]
FAILURE CODE [DWK0KB]
FAILURE CODE [DWK0KY]
FAILURE CODE [DWP0KA]
FAILURE CODE [DWP0KB]
FAILURE CODE [DWP0KY]
FAILURE CODE [DXA1KA]-
FAILURE CODE [DXA1KB]-
FAILURE CODE [DXATKA]-
FAILURE CODE [DXATKB]-
FAILURE CODE [DXATKY]-
FAILURE CODE [DXAUKA]
FAILURE CODE [DXAUKB]
FAILURE CODE [DXAUKY]
FAILURE CODE [DXAVKA]
FAILURE CODE [DXAVKB]
FAILURE CODE [DXAVKY]
FAILURE CODE [M400N1]-
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)-
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
E-1 ENGINE DOES NOT START.-
E-2 ENGINE PREHEATER DOES NOT OPERATE.
E-3 PARKING BRAKE REMINDER BUZZER DOES NOT SOUND.
E-4 PARKING BRAKE REMINDER BUZZER DOES NOT STOP SOUNDING.
E-5 HEADLAMP DOES NOT LIGHT UP OR DOES NOT GO OUT.
E-6 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR DO NOT GO OUT.-
E-7 TURN SIGNAL LAMPS DO NOT LIGHT UP OR DO NOT GO OUT.-
E-8 BRAKE LAMPS DO NOT LIGHT UP OR DO NOT GO OUT.
E-9 BACKUP LAMPS DO NOT LIGHT OR GO OFF
E-10 BACKUP BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING.-
E-11 HORN DOES NOT SOUND OR DOES NOT STOP SOUNDING.-
E-12 FUEL LEVEL IS NOT DISPLAYED CORRECTLY.
E-13 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY.
E-14 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALARM BUZZER DOES NOT SOUND.
E-15 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL IS NOT DISPLAYED.
E-16 SEATBELT CAUTION LAMP DOES NOT GO OUT OR LIGHT UP.
E-17 SEATBELT CAUTION LAMP DOES NOT GO OUT OR LIGHT UP. (FOR FORKLIFT TRUCK WITH DELUXE SUSPENSION SEAT)- -
E-18 SEATBELT CAUTION LAMP DOES NOT GO OUT OR LIGHT UP. (FOR FORKLIFT TRUCK WITH DELUXE SUSPENSION SEAT AND SEAT BELT INTERLOCK SYSTEM)-
SLOWLY
REVERSE (TRAVELS FORWARD NORMALLY).-
H-7 FORKLIFT TRUCK LACKS RIM PULL WHEN TRAVELING BOTH FORWARD AND IN REVERSE.40-872
H-8 FORKLIFT TRUCK LACKS RIM PULL WHEN TRAVELING FORWARD (NORMAL WHEN TRAVELING IN REVERSE).-
H-9 FORKLIFT TRUCK LACKS RIM PULL WHEN TRAVELING IN REVERSE (NORMAL WHEN TRAVELING FORWARD).- -
H-12 FORKLIFT TRUCK DOES NOT TURN.
H-20
H-21 ENGINE SPEED DECREASES EXCESSIVELY OR ENGINE STOPS WHEN COMBINED OPERATION OF WORK EQUIPMENT AND STEERING IS EXECUTED.-
H-22 WORK EQUIPMENT LOCK DOES NOT WORK (WORK EQUIPMENT OPERATES WHEN OPERATOR LEAVES OPERATOR'S SEAT).-
H-23 WORK EQUIPMENT CONTROL LEVER DOES NOT MOVE SMOOTHLY AND IT IS HEAVY TO OPERATE.
H-24 FORK DOES NOT RISE.
H-25 FORK RISES SLOWLY.
H-27 HYDRAULIC DRIFT OF LIFT CYLINDER IS LARGE-
H-28 FORK DOES NOT LOWER.
H-29 FORK LOWERING SPEED IS LOW OR HIGH OR FINE CONTROL PERFORMANCE IS LOW OR RESPONSE
H-30 MAST DOES NOT TILT FORWARD OR BACKWARD.
H-31 MAST MOVES SLOWLY IN BOTH
(S-MODE)-
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO "START" POSITION40-909
S-2 ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT.
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START. (MISFIRING: ENGINE CRANKS BUT DOES NOT START.)
S-4 ENGINE STARTABILITY IS POOR.
S-5 ENGINE DOES NOT PICK UP SMOOTHLY.
S-6 ENGINE STOPS DURING OPERATION.- -
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE-
S-8 ENGINE LACKS POWER- -
S-9 EXHAUST GAS COLOR IS BLACK.
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE. -
S-11 OIL BECOMES CONTAMINATED QUICKLY.-
S-12 FUEL CONSUMPTION IS EXCESSIVE- -
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) -40-925
S-14 OIL PRESSURE DROPS -
S-15 FUEL MIXES INTO ENGINE OIL-
S-16 WATER MIXES INTO ENGINE OIL (MILKY)
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)
S-18 UNUSUAL NOISE IS HEARD.-
S-19 VIBRATION IS EXCESSIVE.-
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.-
S-21 ACTIVE REGENERATION IS EXECUTED EXCESSIVELY.-
S-22 ACTIVE REGENERATION TAKES LONG.-
S-23 WHITE SMOKE IS EMITTED DURING ACTIVE REGENERATION.
S-24 DEF CONSUMPTION IS EXCESSIVE-
S-25 ABNORMAL SMELL (IRRITATING SMELL) IS NOTICED.-
S-26 FOREIGN MATERIALS GET INTO DEF (DEF LEVEL INCREASES).-
50 DISASSEMBLY AND ASSEMBLY PRECAUTIONS BEFORE WORK
LIST OF ABBREVIATIONS
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST-
ENGINE AND COOLING SYSTEM
REMOVAL AND INSTALLATION OF SUPPLY PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF INJECTOR ASSEMBLY- -
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY-
REMOVAL AND INSTALLATION OF EGR VALVE ASSEMBLY- -
REMOVAL AND INSTALLATION OF EGR COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR BELT-
REMOVAL AND INSTALLATION OF ALTERNATOR BELT-
REMOVAL AND INSTALLATION OF AUTO-TENSIONER- - -
REMOVAL AND INSTALLATION OF COOLING ASSEMBLY -
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY-
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY- -
REMOVAL AND INSTALLATION OF ENGINE AND HST PUMP ASSEMBLY-
REMOVAL AND INSTALLATION OF ENGINE FRONT OIL SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR OIL SEAL
REMOVAL AND INSTALLATION OF KDOC ASSEMBLY
REMOVAL AND INSTALLATION OF BELLOWS PIPING ASSEMBLY
REMOVAL AND INSTALLATION OF KDOC AND SCR ASSEMBLY -
REMOVAL AND INSTALLATION OF DEF TANK ASSEMBLY
REMOVAL AND INSTALLATION OF DEF TANK SENSOR FLANGE ASSEMBLY
REMOVAL AND INSTALLATION OF DEF TANK SENSOR
REMOVAL AND INSTALLATION OF SCR ASSEMBLY-
-50-85
AND INSTALLATION OF AIR CLEANER ASSEMBLY
AND INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY-
REMOVAL AND INSTALLATION OF FRONT AXLE AND HST MOTOR ASSEMBLY-
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
AND ASSEMBLY
REMOVAL AND INSTALLATION OF HST PUMP ASSEMBLY-
REMOVAL AND INSTALLATION OF HST MOTOR ASSEMBLY
AND INSTALLATION OF CONTROL VALVE ASSEMBLY-
REMOVAL AND INSTALLATION OF O-RINGS OF ORBITROL VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF HST CHARGE CIRCUIT ACCUMULATOR-
REMOVAL AND INSTALLATION OF PILOT CIRCUIT ACCUMULATOR-
AND INSTALLATION OF BRAKE CIRCUIT ACCUMULATOR-
AND
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
MAINTENANCE STANDARD OF ORBITROL VALVE-
MAINTENANCE STANDARD OF STEERING COLUMN
MAINTENANCE STANDARD OF STEERING CYLINDER-
BRAKE SYSTEM -
MAINTENANCE STANDARD OF FRONT BRAKE
MAINTENANCE STANDARD OF PARKING BRAKE-
MAINTENANCE STANDARD OF BRAKE COOLING PUMP
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF REAR AXLE-
MAINTENANCE STANDARD OF FRAME
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK-
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP-
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF PRIORITY VALVE
MAINTENANCE STANDARD OF WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT-
MAINTENANCE STANDARD OF TILT CYLINDER-
MAINTENANCE STANDARD OF LIFT CYLINDER-
MAINTENANCE STANDARD OF MAST AND FORK
80 OTHERS
PRECAUTIONS BEFORE WORK
LIST OF ABBREVIATIONS
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT-
AIR CONDITIONER COMPONENTS-
AIR CONDITIONER SPECIFICATIONS-
CONFIGURATION AND FUNCTIONS OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE-
AIR CONDITIONER SYSTEM COMPONENTS-
AIR CONDITIONER UNIT-
COMPRESSOR-
CONDENSER -
RECEIVER DRIER-
AIR CONDITIONER CONTROL PANEL-
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
A-1 TROUBLESHOOTING THE POWER CIRCUIT (AIR CONDITIONER DOES NOT OPERATE) - -80-22
A-2 TROUBLESHOOTING THE COMPRESSOR AND REFRIGERANT SYSTEM (DOES NOT COOL) -80-26
A-3 TROUBLESHOOTING THE COMPRESSOR AND REFRIGERANT SYSTEM (MECHANICAL SYSTEM)
A-4 TROUBLESHOOTING THE HOT WATER CIRCUIT SYSTEM-
A-5 ABNORMAL NOISE FROM AIR CONDITIONER-RELATED PARTS
A-6 WATER LEAKAGE FROM AIR CONDITIONER-RELATED PARTS
PRECAUTIONS FOR CONNECTING OR DISCONNECTING AIR CONDITIONER PIPING
-80-31
-80-34 HANDING THE COMPRESSOR OIL-
YEARLY INSPECTION CRITERIA
YEARLY INSPECTION CRITERIA: FH100, 120, 135, 160-1
90 DIAGRAMS AND DRAWINGS
LIST OF ABBREVIATIONS
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS FOR HYDRAULIC CIRCUIT DIAGRAM-
HYDRAULIC CIRCUIT DIAGRAM-
ELECTRICAL CIRCUIT DIAGRAM-
SYMBOLS FOR ELECTRICAL CIRCUIT DIAGRAM-
ELECTRICAL CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (1/16)
ELECTRICAL CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (2/16) -
ELECTRICAL CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (3/16) -
-90-21
-90-23
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CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (4/16)
ELECTRICAL CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (5/16)
CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (6/16)
CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (7/16)
ELECTRICAL CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (8/16)
CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (9/16)
CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (10/16)
ELECTRICAL CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (11/16)
ELECTRICAL CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (13/16)
ELECTRICAL CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (14/16)
CIRCUIT DIAGRAM (HEAD GUARD SPECIFICATION) (16/16)
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (1/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (2/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (3/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (4/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (5/18)- -
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (6/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (7/18)- -
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (8/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (9/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (10/18)- -
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (11/18)
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (12/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (13/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (14/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (15/18)- -
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (16/18)- -
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (17/18)-
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (18/18)-
INDEX-
q 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 together with an outline of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations which appear infrequently are noted by Remarks in the text.
q 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 on the circuit diagrams.
Abbreviations
AbbreviationActual word spelled out
ABSAntilock Brake System
Purpose of use (major applicable machine (*1), or equipment/device)
Explanation
Travel and brakeFunction with which when the tires skid (the wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. (HD and HM series machines)
AISS Automatic Idling Setting System Engine
AJSS Advanced Joystick Steering System
ARAC Automatic Retarder Accelerator Control
ARSC Automatic Retarder Speed Control
ASRAutomatic Spin Regulator
ATTAttachment
BCV Brake Cooling oil control Valve
Steering
Automatic setting function for idling speed
Function so that a lever can perform the steering operations, shifting gear speed operation and changing direction operation instead of a steering wheel. (WA series machines)
Travel and brake
Function so that the retarder works automatically with a certain braking force when the accelerator pedal is released while the machine travels downhill. (HD and HM series machines)
Travel and brake
(HD and HM series machines)
Travel and brake
Function to allow the retarder to work automatically with a certain braking force so that the machine travels with the speed not exceeding the speed set by the operator when the accelerator pedal is released while the machine travels downhill.
Function which automatically uses the optimum braking force to drive both wheels when the rear wheels spin on soft ground surfaces. (HD and HM series machines)
Work equipment
Travel and brake
A device that can be fixed onto a machine in order to enable it to do different jobs.
Valve that bypasses part of the brake cooling oil to reduce the load on the hydraulic pump when the retarder is not being used. (HD series machines)
CANController Area Network Communication and electronic control
CDR Crankcase Depression Regulator Engine
CLSS Closed-center Load Sensing System
Hydraulic system
One of the communication standards that are used in the network on the machine
Regulator valve that is installed to the KCCV ventilator
It is not used independently and described as CDR valve.
This hydraulic system allows for the simultaneous operation of multiple actuators irrespective of the loads on them (it provides better compound operation performance than the OLSS system).
AbbreviationActual word spelled out
Purpose of use (major applicable machine (*1), or equipment/device)
CRICommon Rail InjectionEngine
ECM Electronic Control Module Electronic control system
Transmission
ECMV Electronic Control Modulation Valve
ECSS Electronically Controlled Suspension System
Explanation
Function that maintains an optimum fuel injection amount and fuel injection timing by using the engine controller to perform electronic control of supply pump, common rail, and injector.
Electronic control device that uses the signals from the sensors on the machine to indicate the optimum actuation to the actuators. (Same meaning as ECU)
Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduce transmission shock. (D, HD, and WA series machines, etc.)
Travel
System that ensures smooth high-speed travel by using hydraulic spring effect of accumulator to absorb vibration of the machine during travel (WA series machines)
ECUElectronic Control Unit Electronic control system
EGR Exhaust Gas Recirculation Engine
EMM Equipment Management Monitoring System Monitor panel
EPC Electromagnetic Proportional Control Hydraulic system
FOPS Falling Object Protective Structure Cab and canopy
F-N-RForward-Neutral-ReverseOperation
GPS Global Positioning System
GNSS Global Navigation Satellite System
HSS Hydrostatic Steering System
HST Hydro Static Transmission
ICT Information and Communication Technology
Communication
Electronic control device that uses the signals from the sensors on the machine to indicate the optimum actuation to the actuators. (Same meaning as ECM)
Function to recirculate part of exhaust gas to combustion chamber in order to reduce combustion temperature and to control emission of NOx.
System that allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on monitor.
Electromagnetic proportional control Mechanism that actuator works in proportion to current
Structure that protects operator's head from falling objects. (Structure to protect operator) Performance standardized in ISO 3449
Forward-Neutral-Reverse
Global Positioning System
Satellite positioning system that is used to determine the current location on the earth (KOMTRAX, KOMTRAX Plus)
Communication
Global navigation satellite system. Generic term of positioning systems such as GPS, GALILEO, etc., that use satellites (KOMTRAX, KOMTRAX Plus)
Steering
Steering function that uses a combination of hydraulic motor and bevel shaft to control differences in travel speed of right and left tracks to turn machine without using steering clutch. (D series machines)
Transmission
Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears. (D and WA series machines)
Communication and electronic control
IMAInlet Metering ActuatorEngine
General term of information processing and communication (communication processing) technologies and their socially applied technologies
Valve that adjusts fuel intake amount at inlet port of pump in order to control fuel discharge amount of supply pump. (Same meaning as IMV)
AbbreviationActual word spelled out
Purpose of use (major applicable machine (*1), or equipment/device)
IMUInertial Measurement UnitEngine
IMVInlet Metering ValveEngine
KCCV KOMATSU Closed Crankcase Ventilation Engine
KCSF KOMATSU Catalyzed Soot Filter Engine
KDOC KOMATSU Diesel Oxidation Catalyst Engine
KDPF KOMATSU Diesel Particulate Filter Engine
Travel and brake
KTCS KOMATSU Traction Control System
Explanation
This device measures each angle (or angular velocity) of the 3 axes that define motion.
Valve adjusting fuel intake amount at inlet port of pump in order to control fuel discharge amount of supply pump. (Same meaning as IMA)
This mechanism separates oil in blowby gas and returns it to the intake side to afterburn it there. It consists primarily of filters.
This filter is used to capture soot in exhaust gas. It is built in to KDPF.
This catalyzer is used for purifying exhaust gas. It may be built in to KDPF or combined with the muffler.
This parts contains KDOC (catalyzer) and KCSF (soot filter) in it for purifying exhaust gas. It is installed in place of the currently used muffler.
Function that recovers the drive force of the wheels by braking automatically with the optimum force while at the same time activating the inter-axle differential lock when the wheels idle while the machine travels on soft ground surfaces. (HM series machines)
LCDLiquid Crystal DisplayMonitor panel
LEDLight Emitting DiodeElectronic parts
LIN Local Interconnect Network Communication and electronic control
LSLoad Sensing Hydraulic system
LVDS Low Voltage Differential Signaling Communication and electronic control
MAFMass Air Flow Engine
MMS Multimedia Messaging Service Communication
NCNormally Closed
NONormally Open
OLSS Open-center Load Sensing System
Electrical system and hydraulic system
Electrical system and hydraulic system
Hydraulic system
Liquid crystal display Image display equipment such as the monitor which assembles in the liquid crystal element.
Light Emitting Diode Semi-conductor element that emits light when the voltage is applied in the normal direction.
One of communication standards that is used in the network on the machine
Function that detects differential pressure of pump and controls discharge amount according to load.
One of communication standards that is used in the network on the machine
It means the intake air flow of the engine. It is not used independently but used together with the sensor. The mass air flow sensor may be called MAF sensor.
Service that allows for the transmission and reception of short messages between cell phones that consist of characters, voices or images.
Electric or hydraulic circuit characteristics of a device. The circuit is normally closed when the device is not actuated and opens when it is actuated.
Electric or hydraulic circuit characteristics of a device. The circuit is normally open when the device is not actuated and is closed when it is actuated.
Hydraulic system that can operate multiple actuators at the same time, regardless of the load.
AbbreviationActual word spelled out
Purpose of use (major applicable machine (*1), or equipment/device)
Explanation
PCPressure CompensationHydraulic systemA function used to correct oil pressure.
PCCS Palm Command Control System
SteeringSystem in which a controller instantly analyses data from each lever, pedal, and dial, and performs optimum electronic control of the engine and transmission. (D series machines)
PCVPre-stroke Control ValveEngine
PPC Proportional Pressure Control
PPMPiston Pump and Motor
Hydraulic system
Hydraulic system
Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump.
Proportional pressure control Mechanism that actuator works in proportion to hydraulic pressure
Piston pump and motor. (D series, PC series machines, etc.)
PTOPower Take Off Power transmissionPower take-off mechanism
PTP Power Tilt and power Pitch dozer
Work equipment
Function that performs hydraulic control of the tilt and pitch of the bulldozer blade. (D series machines)
ROPS Roll-Over Protective Structure Cab and canopy
SCR Selective Catalytic Reduction
Urea SCR system
SI Le Systeme International d’ Unites Unit
SOLSolenoid Electric system
TWV2-Way Valve
Hydraulic system
TOPS Tip-Over Protective Structure Cab and canopy
VGT Variable Geometry Turbocharger Engine
VHPC Variable Horse Power Control Engine control
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
Structure that protects the operator who is fastening the seat belt from being crushed if the machine tips over (Rollover protective structure.)
Performance standardized in ISO 3471 or ISO 12117-2
This exhaust gas purifying device uses urea solution to convert nitrogen oxides (NOx) into harmless nitrogen and water by reactive reaction. This may be used in parts of the names of exhaust gas purifying catalyzers or related devices.
Abbreviation for "International system of units" Unit system that is employed worldwide, and "one unit against one factor"
Actuator that moves a part with a movable iron core in the coil (solenoid); it is moved by energizing the coil.
Solenoid valve that switches the direction of flow.
Structure that protects the operator who is fastening the seat belt from being crushed if the machine tips over (Hydraulic excavator tip-over protective structure)
Performance standardized in ISO 12117
The turbocharger on which the cross-section area of the exhaust passage is made variable.
This function finely controls the maximum output of a machine to achieve both high work efficiency and reduced fuel consumption.
Abbreviation
A/CAir Conditioner
A/DAnalogue-to-Digital
A/MAir Mix damper
ACCAccessory
ADDAdditional
AUXAuxiliary
BRBattery Relay
CWClockwise
CCWCounter Clockwise
ECUElectronic Control Unit
ECMElectronic Control Module
ENGEngine
EXGNDExternal Ground
F.G.Frame Ground
GNDGround
IMAInlet Metering Actuator
NCNo Connection
S/T
STRG
Steering
SIGSignal
SOLSolenoid
STDStandard
OPT Option
OP
PRESSPressure
SPECSpecification
SWSwitch
TEMPTemperature
T/CTorque Converter
T/MTransmission
Actual word spelled out
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. When they are requested, consult with Komatsu.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into "Chassis volume" and "Engine volume". For the engine unit, see the engine volume of the engine model mounted on the machine.
q 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.
q All "AdBlue/DEF" shown on the machine monitor is referred to as "DEF" in the shop manual. Some machine monitors installed to the product show "DEF" as "AdBlue/DEF" in the service mode. Thus, be sure to recognize that "DEF" and "AdBlue/DEF" are the same when you read the shop manual.
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the same as the terminology in the shop manual.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00 Index and foreword
This section contain the table of contents, safety, and basic information.
01 Specification
This section explains the specifications of the machine.
10 Structure and function
This section explains the structure and function of each device by system. The "Structure and function" section serves not only to give an understanding of the structure of each device, but also serves as reference material for troubleshooting.
20 Standard value table
This section explains the standard values for new machine and judgment criteria for testing and adjusting, and also troubleshooting. This standard value table is used to check the standard values in testing and adjusting and also to judge parts in troubleshooting.
30 Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and also methods required for adjusting each part. The standard values and judgment criteria for testing and adjusting are explained in Testing and adjusting.
40 Troubleshooting
This section explains how to find failed parts and how to repair them. The troubleshooting is explained by failure mode.
50 Disassembly and assembly
This section explains the special tools and procedures required for the removing, installing, disassembling, and assembling each component, as well as any precautions needed to be taken. In addition, tightening torques and quantity and weights of coating material, oil, grease, and coolant necessary for the work are also explained.
60 Maintenance standard
This section explains maintenance standard values for each device. The maintenance standard sub-section explains judgment criteria and remedies for disassembly and service.
80 Others
This section explains the following items.
q Structure, function, testing, adjusting, and troubleshooting of devices and equipment that cannot be clearly classified into the chassis or engine volume
q This section explains the inspection items, contents and criteria of the specific self-imposed inspection.
90 Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Denotation
Important safety- and quality-related portions in the shop manual are marked with the following symbols so the manual will be used practically.
Denotation Item
DANGER
WARNING
CAUTION
Mass
Tightening torque
Coating
Lubricant and coolant
Drain
Abstract
This symbol indicates that a potentially extremely hazardous situation which, if not avoided, may result in death or serious injury is described.
This symbol indicates that a potentially hazardous situation which, if not avoided, may result in death or serious injury is described.
This symbol indicates that a potentially hazardous situation which, if not avoided, may result in injury or serious damage of the machine or properties in surrounding areas is described.
This symbol shows the weight of parts and components. Refer to this symbol when you handle heavy object for selection of the required equipment such as crane and lifting tools, and for what kind of working posture to take.
This symbol indicates that tightening torque of parts that require special attention for the tightening during assembly is described.
This symbol indicates that a place to be coated with adhesives, grease, etc. during assembly work is described.
This symbol indicates that a location that needs to be refilled with oil, coolant, etc. and its refill capacity are described.
This symbol indicates that a location from which oil, coolant, etc. needs to be drained and its drain amount are described.
Signal word
Signal words of "NOTICE" and "REMARK" describe the following.
Denotation Item
NOTICE
REMARK
Unit
NOTICE
Abstract
If precautions described in this signal word are not observed, the machine may be damaged or its service life may be reduced.
REMARKInformation described under this signal word is useful to know.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have been used in the past are given in { }.
q Proper service and repair are extremely important for safe lift truck operation. The service and repair techniques recommended by KOMATSU and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by KOMATSU for their specific purpose.
q To prevent injury to workers, in this manual the symbol k is used to clearly mark safety precautions. When performing works clearly marked with the symbol k, be sure to follow the given instruction and work with extreme care. If any dangerous situation arises or may possibly arise, first consider safety, and then take all necessary actions to deal with the situation.
Safety points
q Good arrangement
q Correct work clothes
q Following work standard
q Making and checking signs
q Prohibition of operation and handling by unlicensed workers
q Safety check before starting work
q Wearing dust-proof glasses (for cleaning or grinding work)
q Wearing shielding goggles and protectors (for welding work)
q Best physical condition and preparation
q Being careful on work that is familiar
General precautions
k Mistakes in operation are extremely dangerous. Before operating the machine, read the operating manual carefully and be sure you have a thorough understanding of it. Before starting work, read this manual carefully and be sure you have a thorough understanding of it.
q Before carrying out any greasing or repairs, read all the safety labels attached to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
q Select a place in the repair workshop in which to store tools and parts that are removed. Always keep these tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in areas provided for it. Never smoke while working.
q Keep all tools in good working condition. Learn the correct use of them, and which ones are best to use. Carefully check tools, machines, and service cars before starting work.
q When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
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q Always wear safety glasses when using a hammer.
q Always wear safety glasses when cutting parts with a grinder.
q When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Make clear verbal communications during work and perform work following given signals. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment.
q Only the approved personnel can do the work in a closed environment or in a prohibited area.
q Only qualified workers are entitled to carry out work and operations which require license or qualification.
q If welding repairs are needed, ensure a trained and experienced welder carries out the necessary work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
q Performance of warm-up exercises before starting work can warm your body, prevent injury, and increase your attention. Be sure to start work in the best physical condition.
q Avoid working continuously for long hours and take rests at proper intervals to keep in peak condition. Take rests in a fixed safe place.
q Do not push the machine to start its engine. The machine can move off suddenly resulting in operational errors.
q When you work in high places, use a platform.
q Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
q Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
q Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
q When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).
q If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the vehicle has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.
q Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving.
q Before starting work, be sure to lower the work equipment (blade, ripper, bucket, and fork) to the ground. If this is not possible, use lock pins or blocks to prevent the work equipment from falling accidentally. Set the work equipment control lever to the LOCK position and hang the "UNDER REPAIR" warning tag.
q Before starting disassembly or assembly, support the machine with blocks, jacks, or stands before starting work.
q Remove all mud and oil from the steps or other places used to get on and off the machine. Use handrails, ladders, and steps to get on and off the machine. Do not jump on or off the machine. If no scaffolding is provided, prepare stable steps or footstools. When any damage or deformation is recognized on handrails, ladders, or steps, do not use them. Repair or replace them immediately.
Precautions during working
q Before starting work, check that the system operating lamp has gone out, and then disconnect cables from the battery. Always disconnect the cable from the negative (-) terminal first.
q Before disconnecting or removing components of the oil, fuel, water, or air circuits, first release the remaining pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out.
q When removing or installing a measuring plug or a pipe in the fuel circuit, wait 30 seconds or more after the engine has stopped in order to release the remaining pressure. Then start the work.
q Just after the engine has stopped the coolant and oil in the circuits are hot. Take care not to get scalded due to hot coolant and oil. Check that the oil and coolant have cooled down sufficiently. Then start the work.
q Always stop the engine before starting the work. When working on or around a rotating part, be sure to stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get dragged or caught in rotating or moving parts.
q When handling a heavy load (20 kg or more), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample lifting capacity and install them in the proper places. Operate a hoist or crane slowly to prevent the component from hitting any other part. Do not work on any part still being raised by a hoist or crane.
q When removing a part on which internal pressure or reacting force of a spring acts, always leave 2 bolts in diagonal positions. Gradually loosen the bolts alternately to release the internal pressure. Then remove the part.
q When removing components, be careful not to break or damage the electrical wiring. Damaged electrical wiring may be a fire hazard.
q When disconnecting a pipe, be sure to prevent fuel and oil from spilling out of it. Wipe off the fuel or oil spilled on the floor immediately. Fuel or oil left on the floor can cause you to slip and can even start fires.
q As a general rule, do not use gasoline to flush parts. In particular do not use gasoline to clean electrical parts.
q Be sure to reinstall parts that have been removed back in their original places. Replace any damaged parts and parts which must not be reused with new ones. After connecting hoses and wiring harnesses, check that they do not contact other parts and are not damaged when the machine is operated.
q When installing high-pressure pipes, make sure that they are not twisted. Damaged high-pressure pipes are dangerous, so take extreme care to install high-pressure pipes for high-pressure circuits. Check that highpressure pipes are connected properly.
q When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at a high speed, be particularly careful to check that they are installed correctly.
q When aligning 2 holes, never insert your fingers or hand in to a hole. When performing positioning of 2 holes, take extreme care not to get your fingers caught in one of them.
q When measuring hydraulic pressure, check that the measuring tools are correctly installed.
q When removing or installing track shoe assembly of a crawler type machine, give higher priority to safety of the work.
When removing the track shoe assembly from the machine, the track shoe assembly may separate suddenly. For this reason do not position any workers before and after the track shoe assembly.
q Running the engine for a long time in a badly ventilated area can cause gas poisoning. Open windows and doorways in order to improve ventilation.
q Only one appointed worker may make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs and from a place in which he is seen clearly from the operator's seat and in which he too can see the working conditions easily. The sign maker must always stand in front of the load and guide the operator safely.
k Do not do the work while the lifted load is in the range where it possibly falls. It is not allowed to go in the range where the lifted load possibly falls.
k Never select a hauling route in which the load passes above anyone.
k Never allow anyone to stand on the load.
k Do not hold the load by hand easy to prevent swinging or collapsing of the load.
k Evacuate slinging workers other than the sign maker and assistants to a place where they will not get caught between the slung load and any placed load and also will not be struck by the slung load even if the crane starts unexpectedly.
q When you lift or fix the vehicle, see “Operation and Maintenance Manual” or “Field Assembly Instruction”.
k Do not lift or fix the vehicle by the positions where the name plate is not attached.
q When you lift the machine for the disassembly and assembly, follow the instructions on the Disassembly and Assembly.
q Check the slings and other lifting tools before starting slinging work.
q When performing slinging work, wear gloves (preferably leather ones).
q Measure the weight of the load by eye and check its center of gravity.
q Use a sling appropriate to the weight of the load and method of slinging. If wire ropes that are too thick are used to sling a light load, the load may slip off.
q Do not sling a load with 1 wire rope alone. If it is slung in this manner, it may rotate and slip out of the rope. Use 2 or more wire ropes symmetrically for slinging work.
k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load. This can result in a dangerous accident.
q Set the sling angle to 60°or below.
q Do not sling a heavy load (20 kg or more) with ropes forming a sling angle wider than the hook angle.
REMARK
When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the sling angle.
The figure shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various sling angles.
When the 2 ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1000 kg} when the 2 ropes make a sling angle of 120°.
If the 2 ropes sling a 19.6 kN {2000 kg} load at a sling angle of 150°, each of them is subjected to a force as large as 39.2 kN {4000 kg}.
q When installing wire ropes to an angular load, apply pads to protect the wire ropes. When hoisting a slippery load, apply anti-slip measures to the load.
q Use the specified eyebolts and fix wire ropes, chains, etc. to them using shackles, etc.
q Apply wire ropes to the middle portion of a hook.
k Do not use a hook without a latch system.
k Applying a wire rope near the tip of a hook may cause the rope to slip off the hook during hoisting.
REMARK
A hook has the maximum strength at its middle portion.
q If you notice that a wire rope has strands that are cut (A), is too thin (B), and/or kinked (C), it may be broken. Never use it.
Precautions during hoisting
q Operate a crane slowly to hoist a load until wire ropes are stretched. When settling the wire ropes to a sling fitting by hand, do not grasp the fitting. Rather press the ropes from above. If you grasp the fitting, your fingers may be caught between them.
q After the wire ropes are stretched, stop hoisting at once and check how the load off the floor and conditions of the sling fittings and pads.
q If the load is unstable or the wire rope or chains are twisted, lower the load and re-hoist it.
q Never hoist a load diagonally.
Precautions during lowering
q When lowering a slung load, stop lowering temporarily with the load 30 cm above the floor. Then lower it slowly.
q Check that the load is stable, and then remove the sling.
q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
REMARK
Carefully read the Operation and Maintenance Manual of a crane in advance in order to perform safe crane operation.
k When handling a heavy load (20 kg or more), use a hoist or crane.
In Disassembly and assembly, the weight of a part heavier than 20 kg is indicated after the mark of 4
REMARK
The symbol 4 shows the weight of the parts with weight of 20kg or more for convenience of workers. But the weight can possibly be shown even if it is less than 20kg in accordance with the work environment. Do the work safely in response to the work environment and the physical build, preexisting condition, and physical condition of the operator. And obey the laws and regulations of each country.
q Before starting work, inspect wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application caution lamp, and strictly observe the following safety items.
q Be sure not to touch the lifting tool and lifted load directly. Use push-pull sticks or tagline ropes.
q Observe the signs for sling work.
q Operate the hoist at a safe place.
q Never fail to check that the direction indicated on the direction indicator plates (east, west, south, and north) corresponds to that selected on the control buttons.
q Do not sling a load at a slant. Do not move the crane while the slung load is swinging.
q Do not raise or lower a load while the crane is moving either longitudinally or laterally.
q Do not drag a sling.
q When lifting up a load, stop it just after it leaves the ground to check safety. Then lift it up.
q Consider the travel route in advance and ensure load is lifted to a safe height.
q Place the control switch on a position where it will not be an obstacle to work or passage.
q After operating the hoist, do not swing the control switch.
q Remember the location of the main switch so in an emergency you can immediately turn off the power.
q If the hoist stops because of a power failure, keep the power switch turned off. When turning on a hoist which was stopped due to activation of an electric shock prevention earth leakage breaker, check that relevant devices are not in an operational state.
q If you discover an obstacle around the hoist, stop the operation.
q After finishing work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
Select adequate ropes depending on the weight of parts to be hoisted. Refer to the table below.
REMARK
The allowable load is one-sixth of the breaking strength of the rope used (safety coefficient: 6). Wire rope (Type 6X37-A specified in JIS G3525) (Standard "Z" twist rope without galvanizing)
Precautions for machine lifting operation (loading machine onto trailer etc.)
q Never lift up a machine at its head guard. If you need to perform lifting of machines frequently, use a dedicated lifting device.
q Crane operation should be operated by a qualified person who has completed the training course.
q Attach wire ropes at the specified slinging points.
REMARK
Find the proper slinging points in the Operation and Maintenance Manual.
q Use undamaged wire ropes of sufficient strength for lifting machines.
Precautions for jack-up operation (for checking or replacing a tire)
k Do not position yourself beneath the lift truck during jackup operation.
q Check the following items before starting jack-up operation.
q No person is on the machine.
q No load is on the machine.
q Stop jacking up when the tires are slightly raised from the ground. Put blocks under both sides of the frame to prevent the machine from falling.
q Chock the tires to prevent the machine from moving off.
Precautions for slinging operation (for checking or replacing a tire)
q Never lift up a machine at its head guard. If you need to perform lifting of machines frequently, use a dedicated lifting device.
q The lifting operation should be done by a qualified person who has completed the slinging work training course.
q Attach wire ropes to the specified slinging points.
q Use wire ropes that have no damage and sufficient strength for lifting machines.
q Chock the tires to prevent the machine from moving off.
q Put blocks under both sides of the machine to prevent it from falling.
for inspection and inflation of the tire
q Do not inflate the tire with haste when the tire inflation pressure is low and the machine stability is lowered. Damage of the rim can decrease the inflation pressure. When the rim is damaged or the tire is torn, inflating the tire to a high pressure can cause the tire to burst. This can cause personal injury or death.
q Do not work from the side of the tire when checking the tire inflation pressure. Stand to the front of the tread face of the tire.
q Attending the special training course is required to perform tire inflation work. Be sure to leave the work to a qualified person.
q The inflation pressure of the machine tire is several times higher than a car tire.Thus it is dangerous to inflate the tire.
q Wear protective eyeglasses when inflating the tire. Otherwise dirt blown with compressed air may enter your eye.
Leave tire disassembly and assembly work to a specialist. Since the tire inflation pressure is very high, the tires must be handled carefully.
1)Before removing the tire, completely release air from the tire. Loosen hub nut (1), and remove the tire.
2)Never touch rim nut (2). It is dangerous to do this.
3)After replacing the tire, test-drive the machine. Then check the mounting nuts for looseness. If a mounting nut lacks tightening torque, tighten it to the specified torque.
4)For the tightening torque, see "Standard value table" .
for disconnecting air conditioner piping NOTICE
When replacing the air conditioner unit, compressor, receiver drier, etc., collect refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner piping.
REMARK
Be sure to ask a qualified person for advice for collection, refilling, and charging of refrigerant (air conditioner gas: R134a).
Never release refrigerant (air conditioner gas: R134a) to the atmosphere.
k The refrigerant (air conditioner gas: R134a) can cause blindness if it enters an eye. It can also cause frostbite when it comes into contact with skin. Wear protective eyeglasses, gloves, and long-sleeved working clothes when collecting and charging with it.
q When loosening a nut for an air conditioner pipe, be sure to use 2 wrenches, one for restraining the nut on the far side and the other for loosening the nut.
Instructions for connecting air conditioner piping
q When installing an air conditioner pipe, take care that dirt, dust, water, etc. will not enter it.
q Before connecting an air conditioner pipe, check that an O-ring is fitted to the joint of the pipe.
q A used O-ring will be deformed. Do not reuse it.
q Use a soft tool to remove an O-ring so that the pipe is not damaged.
q Check that the O-ring is not damaged or deteriorated.
q Apply compressor oil for the refrigerant (air conditioner gas: R134a) to the O-ring.
REMARK
Do not apply oil to threaded portions of bolts, nuts, and unions.
Manufacturer
Denso ND-OIL8
Part name
Valeo thermal systems ZXL100PG (PAG46 or equivalent)
Sanden SP-10
When tightening a nut for an air conditioner pipe, be sure to use 2 wrenches (use a torque wrench for tightening). While restraining the nut on the far side by using one wrench, tighten the nut to the specified torque by using the other wrench.
REMARK
The figure shows installation of an O-ring. Each joint of air conditioner piping has an O-ring. For the tightening torque, see "Precautions for disconnecting and connecting air conditioner piping" in "Others".
Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any flame or fire close to flammable substances such as fuel, oil, coolant or window washer fluid. There is a danger that they may catch fire. Strictly follow the instructions shown below.
q Do not smoke or use any flame near fuel or other flammable substances.
q Shut down the engine before adding fuel.
q Do not leave the machine when adding fuel or oil.
q Tighten all the fuel and oil caps securely.
q Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.
q After adding fuel or oil, wipe up any spilled fuel or oil.
q Put greasy rags and other flammable materials into a safe container in order to maintain a high level of safety in the workplace.
q When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline. Th ere is danger that they may catch fire.
q Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
q Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
q When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.
Fire caused by accumulation or attachment of flammable material
q Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
q To prevent fires from beginning, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.
Fire coming from electric wiring
Short-circuiting of the electrical wiring may cause a fire. Strictly follow the instructions shown below.
q Clean all the electrical wiring connections, and fix them firmly.
q Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.
Fire from piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out. This can lead to fire and serious personal injury or death.
Fire around the machine due to highly heated exhaust gas
This machine is equipped with a KDPF (Komatsu Diesel Particulate Filter) or KDOC (Komatsu Diesel Oxidation Catalyst) muffler.
KDPF or KDOC muffler is a system for removing soot in exhaust gas. During the purification process (regeneration), this machine may discharge hot exhaust gas higher than that of existing models. Do not bring any flammable material close to the outlet of the exhaust pipe.
q If there are thatched houses, dry leaves or pieces of paper around the job site, set the system to "Regeneration Disable" before starting operation in order to prevent fire hazard of highly heated exhaust gas caused by KDPF regeneration.
See the operation and maintenance manual for the setting procedure.
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q When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.
q When taking the electrical power for the lighting equipment from the machine, follow the instructions in the operation and maintenance manual.
q Turn the starting switch to the OFF position to shut down the engine.
q Use the handrails and steps to exit the machine.
q Do not jump from the machine. You may fall and suffer serious injury.
q The fumes generated by a fire contain harmful materials which have a bad influence on a human body if they are ingested in any way.
Do not breathe in fumes.
q After a fire, there may be harmful compounds remaining. If they come into contact with skin they may have a bad influence on your body.
Be sure to wear rubber gloves when handling the materials left after a fire. It is recommended that the material used for the gloves be polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).
When wearing cotton-work-gloves, wear rubber gloves under them.
To prevent environmental pollution, pay full attention to the way in which to dispose of waste materials.
q Always put the oil and coolant drained from the machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, the sea, or lakes.
q Observe the related laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and DEF.
Some kinds of rubber or certain plastics might produce poisonous gas harmful to people when they are burned.
This machine conforms to either regulation of Tier4 Final (North America) or Stage IV (Europe). This machine is equipped with the following two exhaust gas treatment systems:
q Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to purifyexhaust gas. This process performs the combustion of soot referred to as “regeneration”.
q Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1. This solution will be represented as DEF throughout this manual.
About DEF
DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc.
If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
q In Europe, use AdBlue®.
q In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute). The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade mark of API (American Petroleum Institute).
DEF is a clear and colorless 32.5 % urea aqueous solution. Its main ingredient is urea, a substance commonly used in cosmetics, drugs, and fertilizers. In the cases shown below, be sure to take the following actions immediately.
q If DEF adheres to your skin, it can cause inflammation, depending on physical makeup. In such a case, promptly take off contaminated clothes or shoes and flush with lukewarm water. Then, wash out DEF from your skin completely with soap and water. If you detect any external change on your skin or feel pain, seek medical treatment immediately.
q If you swallow DEF accidentally, do not try to disgorge it but rinse your mouth with water completely and then seek medical treatment immediately.
q If DEF gets in your eyes, immediately rinse your eyes with clean water for several minutes and then seek medical treatment immediately.
q When you perform a task in which DEF is likely to spatter, be sure to wear protective eyeglasses. When you perform a task in which you may touch DEF, be sure to wear rubber gloves.
Never refill the DEF tank with fluids other than DEF. Refilling the tank with diesel fuel or gasoline can cause a fire. If any additive agent is mixed in, a toxic gas may be produced. Poisonous ammonia gas may spout out when the cap of the DEF tank on the forklift truck is opened. Never bend over the refilling port when opening the cap or during refilling.
DEF can produce poisonous ammonia gas when it is at a high temperature. Be sure to seal the container completely when storing it. Be sure to open the container in a well-ventilated place. For how to store DEF, see "Regarding storage of DEF".
When storing DEF, be sure to store it in the container as purchased avoiding direct sunlight. Never pour it from the original container into another container. If it is stored in an iron or aluminum container, poisonous gases or products of corrosion may be produced due to chemical reactions.
While DEF is an incombustible substance, note that it can produce ammonia gas if a fire breaks out. Take appropriate actions according to instructions shown in "Actions to take in case of fire".
When DEF spills, immediately wipe it off and flush with water. If spilled DEF is left alone, poisonous gases or products of corrosion may be produced due to chemical reactions.
Handle DEF as industrial waste when disposing of it. For the handling of industrial waste, see "Precautions for industrial waste disposal". Note that a container with DEF in it is also regarded as industrial waste. Dispose of such a container in the same fashion.
If an iron or aluminum container is used to hold waste fluid of DEF, poisonous gases or products of corrosion may be produced due to chemical reactions. Be sure to use resin (PP or PE) containers or stainless steel containers to hold waste fluid of DEF.
Never touch the water discharged from the urea SCR. The water is acidified by the action of the sulfur content in the fuel and built-in oxidation catalyst. If it comes into contact with your skin, wash it off completely with water. Never try to relocate or modify the exhaust gas aftertreatment devices. Doing so violates relevant statutes and also has disastrous effects on the surrounding environment by releasing poisonous gases.
q DEF can produce poisonous ammonia gas when it is at a high temperature. Be sure to seal the container completely when storing it. Be sure to open the container in a well-ventilated place.
q When storing DEF, be sure to store it in the container as purchased avoiding direct sunlight. Never pour it from the original container into another container. If it is stored in an iron or aluminum container, poisonous gases or products of corrosion may be produced due to chemical reactions.
q DEF freezes up at a temperature of -11°C or below. It is recommended to store it at a temperature of -5°C or higher.
The following table shows the relationship of storage temperature upper limit and storage life of DEF.
Temperature at storage space
Storage life
Max 10°C Up to 36 months
Max 25°C Up to 18 months
Max 30°C Up to 12 months
Max 35°C Up to 6 months
*: Do not store DEF in an environment of 35°C or higher.
q DEF freezes up at a temperature of -11°C or below. If DEF in the DEF tank freezes, components inside the tank may be damaged due to swelling. The parts inside the tank may be damaged. Be sure to refill with DEF to the specified level in cold weather (to the refill line for possible freezing or below).
q In cold weather, park or store the forklift truck indoors at high temperatures (-11°C or higher) so that DEF in the tank will not freeze up. If the forklift truck cannot be parked or stored indoors at high temperatures (-11°C or higher) and the forklift truck is left outdoors in cold weather, DEF in the tank may freeze up. Discharge DEF before storing the forklift truck so that it will not be damaged by freeze-up.
With the increase in pressure and precision of hydraulic components, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic components, it is necessary that particular care be taken.
q Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or in places in which there is a lot of dust.
k When removing or disassembling a hydraulic component, a part may fly out or oil may spout out due to the remaining pressure in the hydraulic circuit. This may result in death or serious injury. Be sure to release the remaining pressure from the hydraulic circuit in advance.
q If disassembly or maintenance work is carried out on a hydraulic component in the field, there is danger of dust entering the component. Because it is difficult to check the performance after repairs in the field, unit exchange of the component is recommended.
q Perform disassembly and maintenance of hydraulic components in a specially prepared dust-proof workshop. Conduct the performance check by using special test equipment.
Sealing openings (preventing oil spill)
Plug the openings of removed pipes and components in order to prevent foreign materials from entering and oil from flowing out.
NOTICE
Never work on a pipe or component with its opening left either exposed or plugged with cloths. This is because foreign material may enter or the environment may be polluted by oil leaks. Never dispose of waste oil carelessly. Deliver waste oil to your customer and ask them to dispose of it or bring the oil and dispose of it properly.
REMARK
For openings that cannot be plugged, use caps, tape, or plastic bags to seal them.
Prevent dirt and dust from entering during refilling operations
q When refilling with hydraulic oil, be careful not to allow dirt particles into the tank.
q Clean the oil filler port and the area around it, also the charging pump, and oil jug.
q An oil cleaning equipment can filter contaminants accumulated in the oil during storage. it is recommended that oil cleaning equipment be used in order to refill with hydraulic oil.
Change hydraulic oil when the temperature is high
q When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil. For this reason it is recommended that oil be changed when it is still warm.
q When changing oil, ensure as much as possible of the old hydraulic oil is drained.
NOTICE
Old hydraulic oil contains contaminants and sludge. The old hydraulic oil mixed into the new hydraulic oil can decrease the service life of new oil.
REMARK
Be sure to drain the old oil from filters and drain plugs in the circuit as well as the hydraulic tank.
Avoid reuse of hydraulic oil and lubricant
Avoid reuse of hydraulic oil and lubricant drained from the machine. If they are reused, foreign matter may enter the inside of hydraulic component and cause failure.
Flushing operations
q After disassembling and assembling the component, and when changing the oil to a new one, it is required to use flushing oil to remove contaminants and sludge left in the hydraulic circuit as well as remaining oil containing them completely from the circuit.
q Normally, perform flushing twice: primary flushing by using with flushing oil (1), and secondary flushing by using with the specified hydraulic oil.
Cleaning operations
Perform oil cleaning to remove sludge or contaminants in the hydraulic oil circuit of a machine of which a hydraulic component (pump, control valve, etc.) has been repaired or is in operation.
REMARK
The oil cleaning equipment can remove the ultra fine (about 3 μm) particles that the filter built in the hydraulic system cannot remove. For this reason it is an extremely effective device.
Strictly observe the following items when performing "Testing and adjusting " work and "Removal and Installation" or "Disassembly and assembly" work for a machine.
Instructions for removal and disassembly works
q If the coolant contains antifreeze, handle it as for chemicals. Do not drain the coolant to the sewage needlessly.
q After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
q When draining oil, prepare a container with sufficient capacity.
q Check the match mark which indicates the installed position, and put match marks if needed before removal of the piping to prevent incorrect installation.
q When disconnecting a wiring connector, hold the connector part so that excessive force will not apply to the wiring.
q Attach tags to wires and hoses to show their installed positions to prevent incorrect installation.
q Check the quantity and thickness of a shim pack before keeping the pack.
q When hoisting a component, prepare slings with sufficient strength.
q When removing a component by using forcing screws, tighten the forcing screws alternately.
q Before removing a component, clean its surrounding area, and cover the removed component to prevent any foreign material from entering it.
q To disconnect the face seal type hose from the cylinder tube, loosen the joint by gripping the two wrenches together, one is the wrench (1) on the hose side, and another is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only. Check after disconnecting the hose that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Retighten it if the tightening torque is insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.
q After disconnecting pipes or removing pipe joints, be sure to fit following plugs shown below.
NOTICE
When installing piping, be sure to check part number of parts to use on the parts book and use the parts that conform to the use condition.
Part numbers of O-rings shown in the table below are those of temporary parts to be used when disassembling or transporting machines.
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Introduction of parts to be used when disconnecting face seal type hoses and tubes
Nominal No.
02 07376-70210
03 07376-70315 02789-00315 02896-11009 04 07376-70422 02789-00422 02896-11012
07376-70522 02789-00522 02896-11015 06 07376-70628 02789-00628 02896-11018
Introduction of parts to be used when disconnecting taper seal type hoses and tubes
Nominal No.
02 07376-50210 07222-00210
03 07376-50315 07222-00312 04 07376-50422 07222-00414 05 07376-50522 07222-00515 06 07376-50628 07222-00616 10 07376-51034 07222-01018 12 07376-51234 07222-01219 14 07376-51443 07222-01422
Introduction of parts to be used when disconnecting split flange type hoses and tubes
Nominal No.
Bolt pitchHose sideTube side
O-ring (4)Bolt (5)Washer (6) abFlange (1)Split flange (2) Sleeve head (3)
0438.117.507379-0040007371-3040007378-1040007000-1202101010-8082501643-50823
0542.919.807379-0050007371-3050007378-1050007000-1302201010-8083001643-50823
0647.622.207379-0064007371-3064007378-1060007000-1302507372-5103501643-51032
1052.426.207379-0104407371-3104907378-1100007000-1303207372-5103501643-51032
12 58.730.207379-0125007371-3125507378-1120007000-1303807372-5103501643-51032
66.731.807379-0126007371-5126007378-1121007000-1303801010-8124501643-51232
69.935.807379-0146007371-3146507378-1140007000-1304807372-5124001643-51232
14
20
79.436.507379-0147007371-5147007378-1141007000-1304801010-8145501643-31445
77.842.807379-0207107371-3207607378-1200007000-1206007372-5124001643-51232
96.844.507379-0208007371-5208007378-1201007000-1206001010-8186501643-31845
2488.950.807379-0248407371-1248407378-1240007000-1207007372-5124001643-51232
30106.46207379-0301007371-1301007378-1300007000-1208507372-5165001643-51645
34120.669.807379-0341107371-1341107378-1340007000-1210007372-5165001643-51645
40130.277.807379-0401207371-1401207378-1400007000-1211007372-5165001643-51645
50152.49207379-0501107371-1501107378-1500007000-1213507372-5165501643-51645
Introduction of parts to be used when removing O-ring boss type joints Nominal
07040-14220 07002-14234
52 07040-15223 07002-15234
Introduction of parts to be used when removing taper pipe thread type joints
07042-01422
07042-02026
07043-01422
07043-02026
q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
q Install the hoses without twist and interference, and securely fasten the clamps located in-between if they are.
q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
q Bend the cotter pins and lock plates securely.
q When applying adhesive, clean and degrease the part, and apply two to three drops of adhesive to the threaded portion.
q When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dirt or damage.
q Clean all of the parts, and correct any damage, bruises, burrs, or rust found on them if they are found.
q Coat the rotating parts and sliding parts with engine oil.
q Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
q After installing the snap ring, check that the snap ring is settled in the ring groove completely.
q When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water. Then connect them securely.
q Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook.
q When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on one side.
q Apply liquid gasket (LG-5) or fluid sealant (LS-2), as a rule, to the threaded portion of a taper external thread screw subjected to pressure.
REMARK
When it is hard to degrease threaded portions, sealing tape may be used. When winding sealing tape around a taper external thread screw that tightens in a clockwise direction, wind it in a clockwise direction, that is, in the direction of the threads advance, viewed from the top of the threads, starting at the position 2 threads apart from the top.
NOTICE
If sealing tape is wound in the reverse direction, the tape will be loosened and come off or sealing tape at the top will be pushed out when the screw is tightened. This will result in oil leakage. To disconnect the face seal type hose from the cylinder tube, loosen the joint by gripping the two wrenches together, one is the wrench (1) on the hose side, and another is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only. Check after disconnecting the hose that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.
NOTICE
When hydraulic cylinders are used for the first time after reassembly of the hydraulic component such as hydraulic cylinders, pumps, etc. and piping after removing them for repair, be sure to perform air bleeding of the hydraulic circuit according to the following procedure.
1.Start and run the engine at low idle.
2.Operate the work equipment control lever to repeat the operation to extend and retract each hydraulic cylinder four to five times while stopping it approximately 100 mm before the stroke ends.
3.Operate the work equipment control lever to repeat the operation to extend and retract each hydraulic cylinder to the stroke ends three to four times.
NOTICE
After the completion of repair and when operating a machine which is to be stored long term, perform the air bleeding using the same procedure as the one described above.
Precautions at the time of completing work
Refilling with water, oil, grease, and DEF
q For machines equipped with the urea SCR system, refill with DEF to the specified level before starting the engine.
q Supply the specified amount of grease correct by Komatsu to the work equipment.
q When the coolant is drained, check that the drain valve is securely tightened and then refill to the specified level with the coolant Komatsu recommends. Start the engine to circulate the coolant in the piping, and then add the coolant to the specified level again.
q When the hydraulic components are removed and installed, refill to the specified level with the oil Komatsu recommends. Start the engine to circulate the oil in the piping, and then add the oil to the specified level again.
q If the hydraulic piping or hydraulic component is removed, be sure to bleed air from the system by referring to "Testing and adjusting".
Check of installed condition of cylinder heads and manifolds
q Check the cylinder head and intake and exhaust manifold mountings for looseness.
q Retighten them if they are loosened.
a For the tightening torque, see "Disassembly and Assembly".
Check of engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, mounting bolts, nuts, and clamps for looseness, and joints for leakage of suction air or exhaust gas.
Retighten or repair them if they are loosened or damaged, or if gas leakage is found.
Cooling system
Check the piping for damage, mounting bolts, nuts, and clamps for looseness, and joints for water leakage. Retighten or repair them if they are loosened or damaged, or if water leakage is found.
Fuel system
Check the piping for damage, mounting bolts, nuts, and clamps for looseness, and joints for fuel leakage. Retighten or repair them if they are loosened or damaged, or if fuel leakage is found.
Check of exhaust system and mountings for looseness and damage
REMARK
The exhaust system includes the following items. (With or without and system configuration depend on machine model and specification.)
q KDPF
q DEF mixing piping
q SCR assembly
q KDOC muffler
q Muffler
q Exhaust pipe
q Parts needed for connecting above items
Visually check the exhaust system and mounting for crack and damage. Replace the parts if they are damaged. Check the mounting bolts, nuts, and clamps of the exhaust system and mountings for looseness. Retighten them if they are loosened.
Check of functions of exhaust muffler system
REMARK
The exhaust muffler system includes the following items. (With or without and system configuration depend on machine model and specification.)
q KDPF
q DEF mixing piping
q SCR assembly
q KDOC muffler
q SCR assembly
q Muffler
q Exhaust pipe
q Parts needed for connecting above items
Check that no unusual noise is heard compared to that heard when the machine was new. If any unusual noise is heard, repair the system. Refer to "Troubleshooting" and "Disassembly and assembly".
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be carried out. Among the above works, this section describes the correct work procedures needed for "Handling electric components" aiming to master correct repair procedures for mechatronics and to improve the quality of repairs.
q A wiring harness consists of wire connecting one component to another component, connectors used for connecting and disconnecting one wire to/from another wire, and protectors or tubes used for protecting the wires.
q A wiring harness is easily and directly subjected to rain water, heat, vibrations, etc. when compared to other electric components that are housed in a case or box. It is also frequently removed and installed each time the machine is inspected or repaired, so it can be easily deformed and damaged. Therefore take extra care when handling and servicing wiring harnesses.
q If DEF attaches to wiring harnesses or connectors, they will corrode and cause defective contact. Since DEF has high corrosiveness against metal, take care not to attach it to electric components, wiring harnesses, and connectors.
Major causes of wiring harness failure
Defective contact of connectors (defective contact between male and female connectors) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. If defective contact due to corroded or oxidized contact surface is found, repeat connecting and disconnecting the connectors about 10 times. This may return the surface to shiny again (and contact may become normal).
The pins of male and female connectors are connected to wires by crimping or soldering. If there is excessive force brought to bear on the wire, joint (1) may peel and cause improper connection or breakage.
If the wire is held and the connector is pulled apart, or the machine or component is lifted with a crane with the connector still connected, or a heavy object hits the wiring, either the crimping of the connector may separate, the soldering may be damaged, or the wire may be broken.
The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet.
Do not spray water directly on the connector.
The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. If water gets into the connector, the pins will be short-circuited by the water. Immediately dry the connector in which water gets or take other appropriate action before passing electricity through it.
dirt, and dust entering connector at the time of disconnection
Water, dirt, or dust attached to the outside of a connector can get into the connector when it is disconnected. Use a dry cloth to wipe off water, dirt, and dust attached on the connector, or blow off them with compressed air.
If oil or grease attaches to a connector and forms an oil film on the mating surface between male and female pins, there will be defective contact because oil does not conduct electricity. If oil, grease, dirt, or dust attaches to a connector, wipe it off with a dry cloth or blow off it with compressed air, and then spray contact restorer .
q When wiping the mating portion of a connector, be careful not to use excessive force that can deform pins.
q If there is oil or water in the compressed air, the contacts will become even dirtier. In this case remove the oil and water from the compressed air completely before cleaning with compressed air.
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Machines equipped with the common rail fuel injection system (CRI) consist of more precise parts than those with a conventional fuel injection pump and nozzle system. If foreign materials get mixed in with the fuel, this can cause a failure. When inspecting and servicing the fuel system, be more careful than before about foreign materials becoming mixed in.
Use care for working environment
Avoid replacing filters or repairing the machine in rain or high winds, or in a dusty place.
Sealing openings
Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign materials from entering.
NOTICE
Never work on a pipe or component with its opening left exposed or plugged with cloths because foreign material may enter or environment may be polluted by the oil leaked. Never dispose of waste oil carelessly. Deliver waste oil to your customer and ask to dispose of it or bring the oil and dispose of it properly.
How to clean parts when dirt is stuck to them
If any dirt or dust attaches to the parts of the fuel system, clean it off thoroughly with clean fuel.
Instructions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
Machines equipped with the common rail fuel injection system (CRI) consist of more precise parts than those with conventional fuel injection pump and nozzle systems. In order to prevent foreign material from entering this system, these machines employ special filters with high filtration performance. If a filter other than the genuine one is used, the fuel system may have a failure. Accordingly, never use such a filter.
Machines equipped with the variable turbocharger (VGT or variable flow turbocharger) have more precise parts than those with conventional turbochargers. If foreign materials enter the system, those machines may have a problem. When inspecting and servicing the intake system, be more careful than before about foreign materials becoming mixed in.
Use care for working environment
Avoid repairing the machine in rain or high winds, or in a dusty place.
Sealing openings
Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering.
REMARK
Never perform repair works under conditions in which the openings are left open or plugged with rags since foreign material may enter.
a When replacing HST controller and monitor panel, combine their part Nos. correctly. If they are combined incorrectly, the automatic engine stop function may work abnormally and failure codes may be displayed wrongly.
q Before replacing HST controller and monitor panel installed to the machine, check their part Nos.
a Location of printed part No. of HST controller
a Location of printed part No. of monitor panel
q Confirm the combination of replacement parts with the table below.
Parts to be replaced
Replaceable part Nos.
HST controller part No.Monitor panel part No.
HST controllerSame part No. as before replacement (*1)— Monitor panel—Same part No. as before replacement (*1)
HST controller and monitor panelLatest part No. (*2)Latest part No. (*2)
*1: If the same part Nos. as before replacement are unavailable, replace both of HST controller and monitor panel with the latest part Nos. (*2).
*2: For the latest part Nos., see the latest parts catalog.
KOMTRAX system sends various information about the machine by wireless communication. KOMTRAX operators can refer to the information at their offices to provide various services to the customers.
When KOMTRAX system installed on a machine is enabled, you can check machine information by using KOMTRAX system to perform effective inspection and diagnosis of the machine.
REMARK
The KOMTRAX system may not be delivered to certain areas.
q You can check operation locations of the machines on a map on PC screen.
q You can check machine operation information such as SMR, operating hours, fuel consumption, and occurred cautions and failure codes.
q You can check service hours and replacement time of consumable parts of the machine such as fuel filters, hydraulic oil filters, hydraulic oil, and engine oil.
q You can check information on how the machine is used (idling time, traveling time, digging time, and hydraulic relief time), and infer operation conditions of the machine.
q You can prepare various reports such as "ECO drive assist" and "Operation summary", and use them as support materials for customers and operators.
Use of KOMTRAX realizes following support actions.
q Quick response to unexpected repair request
1)Check occurred cautions and failure codes by using KOMTRAX when a repair request from a customer is received.
2)Promptly arrange required tools and replacement parts depending on the occurred failure codes.
3)Check the location of the target failed machine on the KOMTRAX map and visit there.
q Proactive maintenance
1)Check the KOMTRAX service summary screens to find machines with a red or yellow flag that means high priority failure codes occurred on them.
2)Consult with customers to check the condition and prepare a call planning.
3)Promptly arrange required tools and replacement parts depending on the occurred failure codes.
q Executing periodic maintenance and inspection services
1)Check the KOMTRAX service summary screens to find machines with a red flag that means some of their consumable parts exceed expiry date.
2)Submit a written estimate for labor charge and cost of consumable parts to be replaced to the customer.
3)Offer to execute periodic inspection (PM clinic, etc.) depending on the SMR.
For the operation method of each KOMTRAX screen, see "KOMTRAX operation manual for key person".
REMARK
q Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
q Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil will flow out when the hose is disconnected. Accordingly, prepare an oil container.
Disconnection work
1.Hold adapter (1) and push hose joint (2) into mating adapter (3).
REMARK
It can be pressed in approximately 3.5 mm. Do not hold rubber cap (4).
2.With hose joint (2) pressed into adapter (3), push rubber cap (4) against adapter (3) until "click" is heard.
3.Hold hose adapter (1) or hose (5) and pull it out.
REMARK
Since some hydraulic oil will flow out, prepare an oil container.
1.Hold hose adapter (1) or hose (5) and insert it in mating adapter (3) aligning their centers with each other.
REMARK
Do not hold rubber cap (4).
2.After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition.
REMARK
When the hose is pulled back, the rubber cap will move approximately 3.5 mm toward the hose. This, however, is not a problem.
Disconnection work
1.While holding the fitting, push body (2) in straight until sliding prevention ring (1) hits contact surface (a) at the hexagonal part on the male side.
2.While keeping the condition of Step 1, turn lever (3) to the right (clockwise).
3.While keeping the conditions of Steps 1 and 2, pull out whole body (2) to disconnect it.
REMARK
Since some hydraulic oil flows out, prepare an oil container.
Connection work
While holding the fitting, push body (2) in straight until sliding prevention ring (1) hits contact surface (a) at the hexagonal part on the male side to connect it.
Disconnection work
1.While holding the fitting, push body (2) in straight until sliding prevention ring (1) hits contact surface (a) at the hexagonal part on the male side.
2.While keeping the condition of Step 1, push cover (3) until it hits contact surface (a) at the hexagonal part on the male side.
3.While keeping the conditions of Steps 1 and 2, pull out whole body (2) to disconnect it.
REMARK
Since some hydraulic oil flows out, prepare an oil container.
Connection work
While holding the fitting, push body (2) in straight until sliding prevention ring (1) hits contact surface (a) at the hexagonal part on the male side to connect it.
Disconnecting connectors
1.Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully. Then hold the male and female connectors in each hand and pull apart.
NOTICE
Never pull it apart using only one hand.
REMARK
For lock type connectors with a stopper, press down stopper (1) with your thumb and pull the connectors apart.
2.When removing from clips
q Both the connector and clip have stoppers (2), which are engaged with each other when the connector is installed.
q When removing a connector from a clip, pull the connector in a direction parallel to the clip for releasing stoppers.
NOTICE
If the connector is twisted up and down or to the left or right, the housing may break.
q Removing resin clip (1). Raise stopper (2) of resin clip (1) then pull out the resin clip.
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3.Action to take after removing connectors
After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting into the connector.
NOTICE
When leaving the machine being disassembled for long periods, its connectors are likely to have problems of defective contact. Be sure to cover them with a vinyl bag.
1.Check the connector visually.
q Check that there is no dust, dirt, oil, or water stuck to the connector pins (mating portion).
q Check that there is no deformation, defective contact, corrosion, or damage to the connector pins.
q Check that there are no flaws and cracks on the outside of the connector.
NOTICE
Wipe off dust, dirt, oil, or water with a dry cloth if they are attached. If any water has got inside the connector, warm the inside of the connector and wire tube with a dryer. Be careful not to make it too hot as this will cause short circuits.
Replace damaged connectors having flaws or cracks with new ones.
2.Connect the connector securely.
Position the connector (1) correctly, and then fit it securely.
REMARK
For lock type connectors with a stopper, fit the connector until stopper engaging sound (click sound) is heard.
3.Correct any protrusion of the boot and any misalignment of the wiring harness.
q For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
REMARK
If the connector cannot be corrected easily, release the clamp and adjust its position.
q If harness clamps for the connector have been released, be sure to return them to their original position. Check also that there are no loose clamps.
REMARK
If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.
1.Disconnect the connector and wipe off the water with a dry cloth.
NOTICE
If the connector is blown dry using compressed air, there is a risk that oil in the air may cause defective contact. Remove all oil and water from the compressed air before using it for blow dry.
2.Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector.
NOTICE
Hot air from the dryer can be used. In this case regulate the time that the hot air is used in order not to allow the connector or related parts become too hot. This will cause deformation or damage to the connector.
3.Carry out a continuity test on the connector. After the connector has dried, connect T-adapter (1) to the connector being disconnected from the wiring harness and carry out a continuity test to check that water does not cause short circuit between pins.
REMARK
After completely drying the connector, blow it with contact restorer and then connect it again.
k When carrying out arc welding on the chassis of the machine for repair, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
NOTICE
q The controller contains a microcomputer and electronic control circuits. The machine is controlled by the electronic circuit inside the controller, so handle the controller carefully.
q Do not place objects on top of the controller.
q Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand.
q During rainy weather, do not leave the controller in a place where it is exposed to rain.
q Do not place the controller on oil, water, or soil, or in any hot place, even for a short space of time. (Place it on a suitable dry stand).
Instructions for troubleshooting of electric circuits
q Be sure to set the starting switch to OFF position before disconnecting and connecting connectors.
q Before carrying out troubleshooting, check that all the related connectors are properly connected.
REMARK
For the check, repeat disconnection and connection of related connectors several times.
q Always connect any disconnected connectors before going on to the next step.
NOTICE
If the starting switch is set to ON position with the connector being disconnected, an error that is unrelated to the actually error occurring location may be displayed.
q When carrying out troubleshooting of circuits (measuring voltage, resistance, continuity, or current), move the related wires and connectors several times and check that there is no change in the reading of the multimeter.
NOTICE
If the reading of the multimeter changes, the circuit being diagnoses probably has defective contacts.
How to disconnect DT connectors
While pressing both sides of locks (a) and (b), pull out female connector (2).
How to connect DT connectors
1.Fit in female connector (2) horizontally until the lock clicks. (In the direction of arrow x)
2.Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down to check that the locks are set normally. (In the direction of arrows x, y, and z)
REMARK
The figure on the right shows that lock (a) is pulled down (not set completely) and lock (b) is set completely.
How to disconnect slide lock type connectors (FRAMATOME-3 and FRAMATOME-2)
1.Slide lock (L1) to the right.
2.While pressing lock (L2), pull out connector (1) toward you.
REMARK
When pressing lock (L2) does not float part (A) and connector (1) can not be pulled out toward you, use a flat-head precision screwdriver to float part (A) while pressing lock (L2), and pull out connector (1) toward you.
How to connect slide lock type connectors (FRAMATOME-3 and FRAMATOME-2)
Fit in the connector straight until the lock clicks.
How to disconnect slide lock type connectors (FRAMATOME-24)
1.Slide lock (red) (L1) downward.
2.While pressing lock (L2), pull out connector (1).
REMARK
In the figure, lock (L2) is shown at the back of connector (1).
How to connect slide lock type connectors (FRAMATOME-24)
Fit in the connector straight until the lock clicks.
How to disconnect connectors that require pulling lock
While pulling lock (B) (harness side) of connector (2) outward, pull out connector (2).
How to connect connectors that require pull lock
Fit in the connector straight until the lock clicks.
How to disconnect connectors that require pressing lock (BOSCH-3)
While pressing connector lock (C), pull out connector (3) in the direction of the arrow. q 114 series
q 107 series
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up connector lock (C) with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
How to connect connectors that require pressing lock (BOSCH-3)
Fit in the connector straight until the lock clicks.
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How to disconnect connectors that require pressing lock (AMP-3)
While pressing connector lock (E), pull out connector (5) in the direction of the arrow.
How to connect connectors that require pressing lock (AMP-3)
Fit in the connector straight until the lock clicks.
How to disconnect connectors that require pressing lock (SUMITOMO-3)
While pressing connector lock (E), pull out connector (5) in the direction of the arrow.
REMARK
Pull out the connector upward.
How to connect connectors that require pressing lock (SUMITOMO-3)
Fit in the connector straight until the lock clicks.
How to disconnect connectors that require pressing lock (SUMITOMO-4)
While pressing connector lock (D), pull out connector (4) in the direction of the arrow.
How to connect connectors that require pressing lock (SUMITOMO-4)
Fit in the connector straight until the lock clicks.
How to disconnect connectors that require turning housing
Turn housing (H1) to the left, and pull out the connector.
REMARK
Housing (H1) is left on the harness side.
How to connect connectors that require turning housing
1.Fit in the connector to the end while aligning its groove with mating part.
2.Turn housing (H1) to the right until the lock clocks.
In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by symbols. The wire code is helpful in understanding the electrical circuit diagram.
REMARK
For the electric cords which are UL (Underwriters Laboratories)-standardized, see [UL (Underwriters Laboratories) - standardized electric cords]
Example) AEX0.85L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
AEX
0.85
Indicates the type of wire with symbol.
Type, symbol, and material of wire are shown in (Table 1).
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.)
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in (Table 2).
L Indicates color of wire by color code.
Color codes are shown in (Table 3).
UL (Underwriters Laboratories) - standardized electric cords
Example) AWG18L (1007): Indicates blue cord, appliance wiring material of AWG size 18.
AWG18
Indicates dimensions of wire by AWG size.
Dimension (AWG size) conforms to [UL (Underwriters Laboratories) - standardized electric cords] (Table 2).
L Indicates the wire color which is shown with the color code. Color codes are shown in (Table 3).
1007
Indicates the type of wire with symbol. Type, symbol, and material of wire are shown in [UL (Underwriters Laboratories) - standardized electric cords] (Table 1).
Type, symbol, and material
AV and AVS are different in thickness and outside diameter of the coating. CAVS has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating.
(Table 1)
Low-voltage wire for automobile AV
Thin-cover lowvoltage wire for automobile (Type 1) AVS
Thin-cover lowvoltage wire for automobile (Type 2) CAVS
Thin-cover lowvoltage wire for automobile AVSS - 40 to + 80
Heat-resistant low-voltage wire for automobile AEX
Heat-resistant cross linked polyethylene -50 to +110
Wires for carrying large flowing current (Nominal No. 5 or more)
General wiring (Nominal No. 3 and below)
General wiring Nominal No. 1.25 and below)
General wiring (Nominal No. 2f and below)
General wiring in extremely cold district, wiring at high-temperature place
UL (Underwriters Laboratories) - standardized electric cords (Table 1) Kind
Appliance wiring material
Annealed copper for electric appliance Polyvinyl chloride Max 80°C
Heat-resistant cross linked polyethylene
Dimensions
(Table 2)
sectional
REMARK "f" of nominal No. denotes "flexible".
UL (Underwriters Laboratories) - standardized electric cords (Table 2)
ductor
Color codes table (Table 3)
Color code
BBlack
BrBrown
BrBBrown & Black
BrRBrown & Red
BrWBrown & White
Color of wire
Color code
Color of wire
LgWLight green & White
LgYLight green & Yellow
LRBlue & Red
LWBlue & White
LYBlue & Yellow
BrYBrown & Yellow OOrange
ChCharcoal PPink
DgDark green
GGreen
GBGreen & Black
GLGreen & Blue
GrGray
GRGreen & Red
GWGreen & White
RRed
RBRed & Black
RGRed & Green
RLRed & Blue
RWRed & White
RYRed & Yellow
SbSky Blue
GYGreen & Yellow YYellow
LBlue YBYellow & Black
LBBlue & Black
LgLight green
LgBLight green & Black
LgRLight green & Red
REMARK
YGYellow & Green
YLYellow & Blue
YRYellow & Red
YWYellow & White
In a color code consisting of two colors, the first color is the color of the background and the second color is the color of the marking.
Example: "GW" means that the background is Green and the marking is White.
Type of wireAVS, AV, CAVS, AVSS, and UL (Underwriters Laboratories) standardAEX
LightRWRBRYRGRL—O—
InstrumentYYRYBYG YL*1 YW*1 YGr SignalGGWGRGYGB GL*1 GBr
Type of circuit ChargeRWG————R—
Others
*1 They are not set for AVSS.
*2 "0.75f to 2f" are not set for AVSS.
The chapter on maintenance standards explains the criteria for determining whether to replace or repair components and parts of a machine being disassembled and serviced. The criteria are described using the following terms.
q To be accurate, the finishing size of parts is a little different from one to another.
q To specify a finishing size of a part, a basic size is set, and then an allowable difference from that size is indicated.
q The above basic size is called the "standard dimension" and the allowable range of difference from the standard size is called the "tolerance".
q For the indication style of the standard dimension and tolerance, see the table below.
q (The standard dimension is listed on the left side and the tolerances with plus and minus signs are listed on the right side.)
Example:
q Note that the tolerance may be indicated in the text and a table as [standard dimension (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (-0.022/-0.126)
q Usually, the size of a hole and the size of the shaft to be fitted into that hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
q For the indication style of the standard and hole dimensions and tolerances, see the table below. (The standard dimension is listed on the left side and signed tolerances for a shaft and those for a hole are listed on the center and on the right side respectively.)
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q The clearance made when new parts are assembled is called the "standard clearance". This is indicated by the range from the minimum clearance to the maximum clearance.
q When repairing parts, as a rule adjust the clearance to the standard clearance.
q A value of performance and function of new products or equivalent is called the "standard value". This is indicated by a range or a target value.
q When repairing parts, as a rule set the value of performance/ function to the standard value.
q When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the "interference".
q The range (A - B) from the difference (A) between the minimum dimension of the shaft and the maximum dimension of the hole to the difference (B) between the maximum dimension of the shaft and the minimum dimension of the hole is the "standard interference".
q After repairing or replacing parts, measure dimensions of their hole and shaft and check that the interference is in the standard range.
q Dimensions of a part changes because of wear and deformation while it is used. The limit of the changed dimension is called the "repair limit".
q If a part is worn beyond the repair limit it must be replaced or repaired.
q The performance and function of a product reduces while it is being used. A value below which the product cannot be used without causing a problem is called the "allowable value" or "allowable dimension".
q If a product cannot meet the allowable value, it must be checked or repaired. Since the allowable value is estimated from various tests or experiences in most cases, it must be judged after considering the operating condition and customer's requirements.
q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "allowable clearance".
q If the clearance between parts exceeds the allowable clearance, they must be replaced or repaired.
q The permissible maximum interference between the hole of a part and the shaft of another part to be assembled is called the "allowable interference".
q The allowable interference shows the repair limit of the part of smaller tolerance.
q If the interference between parts exceeds the allowable clearance, they must be replaced or repaired.
Table of tightening torque for bolts and nuts
REMARK
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
Thread diameter (mm)Width across flats (mm) Tightening torque (Nm {kgm}) 6 10 11.8 to 14.7 {1.2 to 1.5} (*2)10 8 13 27 to 34 {2.8 to 3.5} (*2)12 10 17
to 74 {6 to 7.5} (*1,*2)14 12 19
to 123 {10 to 12.5} (*1,*2)17
785 to 980 {80 to 100}
1150 to 1440 {118 to 147}
1520 to 1910 {155 to 195}
1960 to 2450 {200 to 250}
2450 to 3040 {250 to 310}
to 3630 {295 to 370}
*1: For split flange bolt
*2: For Flanged bolt
REMARK
For the following flanged bolts with mark "7" on the head, tighten them to the torque shown in the table below.
to 9.8 {0.6 to 1.0}
REMARK
Unless otherwise specified, tighten the bolts and nuts with unified coarse thread to the torque shown in the table below.
Type of bolt
Nominal designationthreads per inch, screw series
(Nm {kgm})
(Nm {kgm})
1/4-20UNC 9.8 to 14.7 {1 to 1.5}12.7{1.3}2.9 to 3.9 {0.3 to 0.4}3.43{0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5}29.4{3}6.9 to 8.8 {0.7 to 0.9}7.8{0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6}52.0{5.3}9.8 to 14.7 {1 to 1.5}11.8{1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10}86.3{8.8}19.6 to 24.5 {2 to 2.5}21.6{2.2}
1/2-13UNC 108 to 147 {11 to 15}127{13}29.4 to 39.2 {3 to 4}34.3{3.5}
9/16-12UNC 157 to 216 {16 to 22}186{19}44.1 to 58.8 {4.5 to 6}51.0{5.2}
5/8-11UNC 226 to 294 {23 to 30}265{27}63.7 to 83.4 {6.5 to 8.5}68.6{7}
3/4-10UNC 392 to 530 {40 to 54}461{47}108 to 147 {11 to 15}127{13}
7/8-9UNC 637 to 853 {65 to 87}745{76}177 to 235 {18 to 24}206{21}
Type of boltAB
Nominal designationthreads per inch, screw series Tightening torque (Nm {kgm})Tightening torque (Nm {kgm}) RangeTargetRangeTarget
1-8UNC 883 to 1196 {90 to 122}1040{106}245 to 333 {25 to 34}284{29}
11/8-7UNC 1187 to 1608 {121 to 164}1393{142}333 to 451 {34 to 46}392{40}
11/4-7UNC 1598 to 2157 {163 to 220}1873{191}451 to 608 {46 to 62}530{54}
11/2-6UNC 2354 to 3177 {240 to 324}2765{282}657 to 892 {67 to 91}775{79}
REMARK
Unless otherwise specified, tighten the bolts and nuts with unified fine pitch thread to the torque shown in the table below.
Type of bolt A B
Nominal designationthreads per inch, screw series
1/4-28UNF 14.7 to 19.6 {1.5 to 2}17.7{1.8}3.9 to 4.9 {0.4 to 0.5}4.41{0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4}34.3{3.5} 7.8 to 9.8 {0.8 to 1}8.8{0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7}61.8{6.3} 14.7 to 19.6 {1.5 to 2}16.7{1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11}96.1{9.8}24.5 to 29.4 {2.5 to 3}26.5{2.7}
1/2-20UNF 127 to 167 {13 to 17}147{15}34.3 to 49.0 {3.5 to 5}41.2{4.2}
9/16-18UNF 186 to 245 {19 to 25}216{22}49.0 to 68.6 {5 to 7}58.8{6}
5/8-18UNF 255 to 343 {26 to 35}294{30}73.5 to 98.1 {7.5 to 10}83.4{8.5}
3/4-16UNF 441 to 598 {45 to 61}520{53}127 to 167 {13 to 17}147{15}
7/8-14UNF 716 to 961 {73 to 98}843{86}196 to 265 {20 to 27}226{23}
1-14UNF1020 to 1373 {104 to 140}1196{122}284 to 382 {29 to 39}333{34}
11/8-12UNF 1353 to 1844 {138 to 188}1598{163}382 to 520 {39 to 53}451{46}
11/4-12UNF 1804 to 2432 {184 to 248}2118{216}510 to 686 {52 to 70}598{61}
11/2-12UNF 2707 to 3658 {276 to 373}3177{324}765 to 1030 {78 to 105}892{91}
REMARK
Unless otherwise specified, tighten the O-ring boss pipe joint to the torque shown in the table below.
REMARK
Unless otherwise specified, tighten the O-ring boss plug to the torque shown in the table below.
Table of tightening torque for hose (taper seal type and face seal type)
REMARK
q Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table.
q The torque values apply to the fittings with their threads coated with engine oil (wet threads).
(14)55246 to 343 {25.0 to 35.0}294{30.0}42
REMARK
q For face seal joints (sleeve nut type) made of steel pipe for plated low- pressure pipe and used in engines, tighten them to the torque shown in the table below.
q The torque values apply to the fittings with their threads coated with engine oil (wet threads).
q Face seal joints with the dimension shown in ( ) are also used depending on the specification.
Applicable pipe outside diameter (mm) Width across flats (mm)
Tightening torque (Nm {kgm})Face seal
RangeTarget
REMARK
Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table.
Thread diameter (mm)
Tightening torque (Nm {kgm})
Tightening torque table (joint bolt) for 102, 107 and 114 series engines
REMARK
Unless otherwise specified, tighten the metric thread joint bolts used on the 102, 107 and 114 series engines to the torques shown in the following table.
Thread diameter (mm)
torque (Nm {kgm})
6 8±2{0.81±0.20}
8 10±2{1.02±0.20}
10 12±2{1.22±0.20}
12 24±4{2.45±0.41}
Tightening torque table (American taper pipe thread (NPT)) for 102, 107 and 114 series engines
REMARK
Unless otherwise specified, tighten American taper pipe threads for the 102, 107 and 114 series engines to the torques shown in the following table.
14 36±5{3.67±0.51} Material
1/8 20±2{2.04±0.20 15±2{1.53±0.20}
1/4 25±3{2.55±0.31} 20±2{2.04±0.20}
3/8
How to use the unit conversion table
The unit conversion table is designed to facilitate conversion of a numeric value expressed in an unit to that expressed in other unit. For detailed usage, see the following example of use.
Example of use of unit conversion table when converting a value in mm to that in inches
Converting "55 mm" to an inch value
1.Find a value of "50" in the most left column, take it as (A), and make a horizontal line from (A).
2.Find a value of "5" in the uppermost line, take it as (B), and then make a vertical line from (b).
3.Find the intersection of the 2 lines, and take it as (C). The value of point (C) indicates the value in inches converted from a value in mm. Thus, "55 mm" is converted to 2.165 inches.
Converting "550 mm" to a value in inches
1.The table does not have a value of "550". Therefore divide "550" by "10" (move decimal point to the left by 1 digit). This replaces the original value by 55 mm.
2.Follow the above steps to convert "55 mm" to "2.165 inches".
3.The original value (550 mm) has been divided by "10", so multiply "2.165 inches" by 10 (move decimal point to the right by 1 digit) to return the value obtained to the actual value converted. Thus, "550 mm" is converted to 21.65 inches.
Converting a value in mm to that in inches
501.9692.0082.0472.0872.1262.1652.2052.2442.2832.323
803.1503.1893.2283.2683.3073.3463.3863.4253.4653.504 903.5433.5833.6223.6613.7013.7403.7803.8193.8583.898 1 mm = 0.03937 in 0123456789 000.0390.0790.1180.1570.1970.2360.2760.3150.354
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