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Komatsu A96001 Shop Manual

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Manual
WA500
WHEEL LOADER
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
June 2017
-8
WA500-8 A96001
6D140E-7
and up
Copyright 2017 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM030802

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Summary of Contents for Komatsu A96001

  • Page 1 6D140E-7 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 00 INDEX AND FOREWORD WA500-8 00-1 Find manuals at https://best-manuals.com...
  • Page 4 INDEX 00 INDEX AND FOREWORD INDEX 00 INDEX AND FOREWORD ........................00-1 ABBREVIATION LIST ........................... 00-24 FOREWORD, SAFETY, BASIC INFORMATION ................... 00-30 HOW TO READ THE SHOP MANUAL................... 00-30 SAFETY NOTICE FOR OPERATION..................... 00-32 PRECAUTIONS TO PREVENT FIRE..................... 00-40 ACTIONS IF FIRE OCCURS ......................00-42 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ............
  • Page 5 00 INDEX AND FOREWORD INDEX RPM SET............................10-63 COMPONENT PARTS OF ENGINE SYSTEM ................10-67 COOLING SYSTEM..........................10-87 LAYOUT DRAWING OF COOLING SYSTEM ................10-87 COOLING FAN CONTROL SYSTEM..................... 10-89 COMPONENT PARTS OF COOLING SYSTEM................10-94 CONTROL SYSTEM..........................10-108 LAYOUT DRAWING OF CONTROL SYSTEM ................10-108 MACHINE MONITOR SYSTEM ....................10-110 REARVIEW MONITOR SYSTEM....................10-112 KOMTRAX SYSTEM........................10-113...
  • Page 6 INDEX 00 INDEX AND FOREWORD STRUCTURE OF BUCKET......................10-441 STRUCTURE OF WORK EQUIPMENT LUBRICATION..............10-443 CAB AND ITS ATTACHMENTS ......................10-445 ROPS CAB ...........................10-445 20 STANDARD VALUE TABLE ........................20-1 CONTENTS ............................20-2 ABBREVIATION LIST ..........................20-3 STANDARD VALUE TABLE FOR ENGINE ..................... 20-9 STANDARD VALUE TABLE FOR ENGINE: WA500-8..............
  • Page 7 00 INDEX AND FOREWORD INDEX TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE ....30-157 TEST BRAKING PERFORMANCE ....................30-163 TEST BRAKE PEDAL ........................30-164 BLEED AIR FROM BRAKE CIRCUIT ...................30-165 TEST AND ADJUST BRAKE PEDAL AND LINKAGE ..............30-168 ADJUST LEFT BRAKE PEDAL OPERATION SWITCH ..............30-169 TEST LOWERING OF WHEEL BRAKE PRESSURE..............30-170 TEST WEAR OF WHEEL BRAKE DISC ..................30-173 TEST PARKING BRAKE OIL PRESSURE ..................30-175...
  • Page 8 INDEX 00 INDEX AND FOREWORD PROCEDURE FOR TESTING AND TROUBLESHOOTING ............40-78 SYMPTOM AND TROUBLESHOOTING NUMBERS ..............40-80 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE............ 40-85 CONNECTORS LIST AND LAYOUT....................40-87 CONNECTOR CONTACT IDENTIFICATION ................40-110 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..............40-150 FUSE LOCATION TABLE ......................40-156 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)......40-160 PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR ........40-164...
  • Page 9 00 INDEX AND FOREWORD INDEX FAILURE CODE [AS10KM]......................40-281 FAILURE CODE [AS10NR] ......................40-282 FAILURE CODE [AS10NT] ......................40-283 FAILURE CODE [B@BAZG] ......................40-284 FAILURE CODE [B@BCNS] ......................40-285 FAILURE CODE [B@BCZK] ......................40-286 FAILURE CODE [B@C7NS] ......................40-288 FAILURE CODE [B@CENS] ......................40-290 FAILURE CODE [B@HANS] ......................40-291 FAILURE CODE [CA115] ......................40-292 FAILURE CODE [CA122] ......................40-295 FAILURE CODE [CA123] ......................40-297...
  • Page 10 INDEX 00 INDEX AND FOREWORD FAILURE CODE [CA595] ......................40-391 FAILURE CODE [CA687] ......................40-393 FAILURE CODE [CA689] ......................40-395 FAILURE CODE [CA691] ......................40-397 FAILURE CODE [CA692] ......................40-399 FAILURE CODE [CA697] ......................40-401 FAILURE CODE [CA698] ......................40-402 FAILURE CODE [CA731] ......................40-403 FAILURE CODE [CA778] ......................40-406 FAILURE CODE [CA1117] ......................40-408 FAILURE CODE [CA1664] ......................40-410 FAILURE CODE [CA1669] ......................40-413...
  • Page 11 00 INDEX AND FOREWORD INDEX FAILURE CODE [CA2382] ......................40-515 FAILURE CODE [CA2383] ......................40-517 FAILURE CODE [CA2386] ......................40-519 FAILURE CODE [CA2387] ......................40-521 FAILURE CODE [CA2555] ......................40-523 FAILURE CODE [CA2556] ......................40-525 FAILURE CODE [CA2637] ......................40-527 FAILURE CODE [CA2639] ......................40-529 FAILURE CODE [CA2732] ......................40-531 FAILURE CODE [CA2733] ......................40-533 FAILURE CODE [CA2741] ......................40-535 FAILURE CODE [CA2765] ......................40-536...
  • Page 12 INDEX 00 INDEX AND FOREWORD FAILURE CODE [CA3547] ......................40-660 FAILURE CODE [CA3558] ......................40-661 FAILURE CODE [CA3559] ......................40-663 FAILURE CODE [CA3562] ......................40-665 FAILURE CODE [CA3563] ......................40-667 FAILURE CODE [CA3567] ......................40-670 FAILURE CODE [CA3568] ......................40-674 FAILURE CODE [CA3571] ......................40-678 FAILURE CODE [CA3572] ......................40-680 FAILURE CODE [CA3574] ......................40-682 FAILURE CODE [CA3575] ......................40-685 FAILURE CODE [CA3577] ......................40-687...
  • Page 13 00 INDEX AND FOREWORD INDEX FAILURE CODE [CA4281] ......................40-826 FAILURE CODE [CA4459] ......................40-830 FAILURE CODE [CA4461] ......................40-832 FAILURE CODE [CA4658] ......................40-835 FAILURE CODE [CA4731] ......................40-839 FAILURE CODE [CA4732] ......................40-840 FAILURE CODE [CA4739] ......................40-841 FAILURE CODE [CA4768] ......................40-842 FAILURE CODE [CA4769] ......................40-844 FAILURE CODE [CA4842] ......................40-847 FAILURE CODE [CA4952] ......................40-850 FAILURE CODE [CA5115] ......................40-852...
  • Page 14 INDEX 00 INDEX AND FOREWORD FAILURE CODE [DAQ4KB] ......................40-941 FAILURE CODE [DAQ9KQ] ......................40-943 FAILURE CODE [DAQLKA] ......................40-944 FAILURE CODE [DAQLKB] ......................40-946 FAILURE CODE [DAQQKR] ......................40-948 FAILURE CODE [DAQRKR]......................40-949 FAILURE CODE [DAQRMA] ......................40-950 FAILURE CODE [DAZ9KQ]......................40-951 FAILURE CODE [DAZQKR] ......................40-952 FAILURE CODE [DB2QKR] ......................40-953 FAILURE CODE [DB2RKR] ......................40-958 FAILURE CODE [DB90KK] ......................40-964 FAILURE CODE [DB90KT] ......................40-967...
  • Page 15 00 INDEX AND FOREWORD INDEX FAILURE CODE [DGT1KB]......................40-1063 FAILURE CODE [DH21KA] ......................40-1065 FAILURE CODE [DH21KB] ......................40-1068 FAILURE CODE [DHA4KA]......................40-1070 FAILURE CODE [DHAAMA]......................40-1072 FAILURE CODE [DHACMA] .......................40-1074 FAILURE CODE [DHPCKX] ......................40-1076 FAILURE CODE [DHPDKX] ......................40-1079 FAILURE CODE [DHQ2KX] ......................40-1082 FAILURE CODE [DHT1KX]......................40-1084 FAILURE CODE [DHT2L6]......................40-1087 FAILURE CODE [DHT5KX]......................40-1089 FAILURE CODE [DHT7KX]......................40-1092...
  • Page 16 INDEX 00 INDEX AND FOREWORD FAILURE CODE [DPQ3KR] ......................40-1225 FAILURE CODE [DSJ0KR] ......................40-1228 FAILURE CODE [DT20KB] ......................40-1231 FAILURE CODE [DT22KB] ......................40-1233 FAILURE CODE [DT23KB] ......................40-1235 FAILURE CODE [DV00KB] ......................40-1237 FAILURE CODE [DW2BKA]......................40-1239 FAILURE CODE [DW2BKB]......................40-1240 FAILURE CODE [DW2BKY]......................40-1241 FAILURE CODE [DW2BL1]......................40-1242 FAILURE CODE [DW2BLH] ......................40-1244 FAILURE CODE [DW4PKA]......................40-1246 FAILURE CODE [DW4PKB]......................40-1248...
  • Page 17 00 INDEX AND FOREWORD INDEX FAILURE CODE [DXH7KY]......................40-1339 FAILURE CODE [DXH8KA]......................40-1341 FAILURE CODE [DXH8KB]......................40-1343 FAILURE CODE [DXH8KY]......................40-1345 FAILURE CODE [DXHHKA] ......................40-1347 FAILURE CODE [DXHHKB] ......................40-1349 FAILURE CODE [DXHHKY] ......................40-1351 FAILURE CODE [DXHJKA]......................40-1353 FAILURE CODE [DXHJKB]......................40-1355 FAILURE CODE [DXHJKY]......................40-1357 FAILURE CODE [DXHKKA] ......................40-1359 FAILURE CODE [DXHKKB] ......................40-1361 FAILURE CODE [DXHKKY] ......................40-1363 FAILURE CODE [DXHLKA]......................40-1365...
  • Page 18 INDEX 00 INDEX AND FOREWORD E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL ..........40-1453 E-29 ALARM BUZZER DOES NOT SOUND ................40-1455 E-30 ALARM BUZZER DOES NOT STOP SOUNDING ..............40-1457 E-31 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON ....40-1458 E-32 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED ..........40-1460 E-33 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED............40-1462...
  • Page 19 00 INDEX AND FOREWORD INDEX H-1 MACHINE DOES NOT START .....................40-1604 H-2 LOCKUP IS NOT RELEASED....................40-1607 H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE ........40-1608 H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT ..................40-1609 H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED ...40-1612 H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED ..40-1615 H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH ..........40-1618...
  • Page 20 INDEX 00 INDEX AND FOREWORD S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) ......................40-1674 S-4 ENGINE STARTABILITY IS POOR..................40-1675 S-5 ENGINE DOES NOT PICK UP SMOOTHLY ................40-1677 S-6 ENGINE STOPS DURING OPERATION ................40-1679 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ................40-1681 S-8 ENGINE LACKS POWER.....................40-1682 S-9 KDPF GETS CLOGGED IN A SHORT TIME ................40-1684...
  • Page 21 00 INDEX AND FOREWORD INDEX DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY ..............................50-217 REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..............50-219 REMOVE AND INSTALL ENGINE REAR OIL SEAL..............50-224 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY ..............50-232 REMOVE AND INSTALL FUEL TANK ASSEMBLY ...............50-240 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............50-246 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY......50-263 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ..............50-267...
  • Page 22 INDEX 00 INDEX AND FOREWORD DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY......50-649 CAB AND ITS ATTACHMENTS ......................50-656 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ............50-656 REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS) .........50-676 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY ..........50-686 REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY............50-697 REMOVE AND INSTALL SEAT BELT ...................50-701 ELECTRICAL SYSTEM ........................50-703...
  • Page 23 00 INDEX AND FOREWORD INDEX MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN....60-69 HYDRAULIC SYSTEM.......................... 60-74 MAINTENANCE STANDARD OF HYDRAULIC TANK ..............60-74 MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP............60-75 MAINTENANCE STANDARD OF POWER TRAIN CHARGE DUPLEX PUMP....... 60-77 MAINTENANCE STANDARD OF CONTROL VALVE..............
  • Page 24 INDEX 00 INDEX AND FOREWORD FAILURE CODE [879EMC] ........................80-74 FAILURE CODE [879FMC] ........................80-77 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)................................80-80 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)................................80-83 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .............................
  • Page 25 00 INDEX AND FOREWORD INDEX INDEX..................................1 WA500-8 00-23...
  • Page 26 ABBREVIATION LIST 00 INDEX AND FOREWORD ABBREVIATION LIST • This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo- nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
  • Page 27 00 INDEX AND FOREWORD ABBREVIATION LIST Purpose of use (major ap- Abbrevia- Actual word spelled out plicable machine (*1), or Explanation tion component/system) Electronic control device uses the signals from Electronic Control Mod- the sensors on the machine. These signals indi- Electronic control system cate the optimum actuation to the actuators.
  • Page 28 Inlet Metering Valve Engine discharged volume of supply pump. (Same as IMA) This mechanism separates oil in blowby gas and Komatsu Closed Crank- KCCV Engine returns it to the intake side to combust it there. It case Ventilation primarily consists of filters.
  • Page 29 00 INDEX AND FOREWORD ABBREVIATION LIST Purpose of use (major ap- Abbrevia- Actual word spelled out plicable machine (*1), or Explanation tion component/system) Characteristics of electrical or hydraulic circuits. Electrical system, Hydraul- Normally Open Circuit is normally open if it is not actuated, and it ic system closes when it is actuated.
  • Page 30 ABBREVIATION LIST 00 INDEX AND FOREWORD Purpose of use (major ap- Abbrevia- Actual word spelled out plicable machine (*1), or Explanation tion component/system) Variable Geometry Tur- The turbocharger on which the cross-section Engine bocharger area of the exhaust passage is made variable. *1: Code for applicable machine model D: Bulldozer HD: Dump truck...
  • Page 31 00 INDEX AND FOREWORD ABBREVIATION LIST Abbreviation Actual word spelled out Torque Converter Transmission WA500-8 00-29...
  • Page 32 REMARK • Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor. • The materials and specifications are subject to change without notice. • Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.
  • Page 33 00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL Symbols Important safety and quality portions are marked with the following symbols so that shop manual is used effec- tively. Symbol Item Remark This signal indicates an extremely hazardous situation which will result in Danger death or serious injury if it is not avoided.
  • Page 34 Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...
  • Page 35 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION • Always wear the protective eyeglasses when hitting parts with a hammer. • Always wear the protective eyeglasses when grinding parts with a grinder, etc. • When performing any operation with multiple workers, al- ways agree on the operating procedure before starting.
  • Page 36 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD • Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.
  • Page 37 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION • Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not be damaged by contact with other parts when the machine is operated.
  • Page 38 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD REMARK When slinging a load with 2 or more ropes, the force sub- jected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} ...
  • Page 39 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION REMARK Weight of component whose weight is heavier than 25 kg is shown with symbol in "DISASSEMBLY AND ASSEMBLY". • Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz- ing caution lamp, and check the following safety items.
  • Page 40 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD Precautions for disconnecting air conditioner piping NOTICE When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.
  • Page 41 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION REMARK • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping".
  • Page 42 Fire around the machine due to highly heated exhaust gas Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 43 00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE • When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa- ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused by KDPF regeneration.
  • Page 44 ACTIONS IF FIRE OCCURS 00 INDEX AND FOREWORD ACTIONS IF FIRE OCCURS • Turn the starting switch to OFF position to stop the engine. • Use the handrails and steps to get off the machine. • Do not jump off the machine. You may fall and suffer serious injury. •...
  • Page 45 00 INDEX AND FOREWORD PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials. • Always drain the oil from your machine in containers. Nev- er drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.
  • Page 46 This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
  • Page 47 00 INDEX AND FOREWORD PRECAUTIONS FOR DEF PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
  • Page 48 STORE AdBlue/DEF 00 INDEX AND FOREWORD STORE AdBlue/DEF • If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage. Only open containers in a well-ventilated area. • Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of AdBlue/DEF with another one.
  • Page 49 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.
  • Page 50 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD Preventing intrusion of foreign materials during refilling • During refilling with the hydraulic oil, do not let water enter the electrical components. • Clean the oil filler port and its around, refilling pump, oil jug, or etc.
  • Page 51 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT REMARK The oil cleaning equipment can remove the ultra fine (approxi- mately 3 μm) particles that the filter built in the hydraulic equip- ment cannot remove. So, it is very effective device. WA500-8 00-49...
  • Page 52 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- INGS 00 INDEX AND FOREWORD PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and as- sembly" of the components, observe the following precautions. Precautions for removal and disassembling work •...
  • Page 53 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- 00 INDEX AND FOREWORD INGS Introduction of parts for the disconnection of the taper seal type hoses and tubes Hose side Pipe joint side Nominal No. Plug (1) Nut (2) 07376-50210 07222-00210 07376-50315 07222-00312 07376-50422 07222-00414...
  • Page 54 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- INGS 00 INDEX AND FOREWORD Bolt pitch (mm) Hose side Tube side Nomi O-ring (4) Bolt (5) Washer (6) Split flange Sleeve head Flange (1) 58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032 66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232...
  • Page 55 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- 00 INDEX AND FOREWORD INGS Introduction of parts for the removal of taper pipe thread type joint Plug (1) Nominal Nominal No. thread size Square head type (A) Hexagonal socket head (B) 07042-00108 07043-00108 07042-00211 07043-00211...
  • Page 56 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 57 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- 00 INDEX AND FOREWORD INGS Fuel system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion. If there is any looseness, damage, or fuel leak, retighten or repair the part. Check the exhaust equipment and its installation portion for looseness and damage.
  • Page 58 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at im- proving the quality of repairs.
  • Page 59 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT Disconnection in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the sol- dering, or break the wiring harness.
  • Page 60 If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
  • Page 61 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure.
  • Page 62 To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor. 00-60 WA500-8...
  • Page 63 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER REMARK • Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank. • Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.
  • Page 64 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition. REMARK When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a prob- lem.
  • Page 65 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER Disconnection Hold the tightening adapter part and push body (2) straight...
  • Page 66 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. 00-64 WA500-8...
  • Page 67 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- 00 INDEX AND FOREWORD NECTORS PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC- TORS Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, always hold the con- necting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel.
  • Page 68 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- NECTORS 00 INDEX AND FOREWORD • Check that there is no deformation, defective contact, corrosion, or damage on the connector pins. • Check that there is no damage or crack on the external surfaces of the connectors. NOTICE •...
  • Page 69 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- 00 INDEX AND FOREWORD NECTORS Disconnect the connector and wipe off the water with a dry cloth. NOTICE If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defec- tive contact, remove oil and water in the air before starting air blow.
  • Page 70 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- NECTORS 00 INDEX AND FOREWORD NOTICE • Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine. •...
  • Page 71 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH 00 INDEX AND FOREWORD CONNECTOR METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC- Method for disconnecting Deutsch connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2). Method for connecting Deutsch connector Push in female connector (2) horizontally, and insert it straight until it clicks.
  • Page 72 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00 INDEX AND FOREWORD METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA- TOME-2) Slide lock (L1) to the right. While pressing lock (L2), pull out connector (1) toward you. REMARK If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward...
  • Page 73 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK 00 INDEX AND FOREWORD TYPE CONNECTOR While pressing lock (L2), pull out connector (1). REMARK Lock (L2) is located behind connector (1) in the figure. Method for connecting slide lock type connector (FRAMATOME-24) Insert it straight until it clicks.
  • Page 74 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00 INDEX AND FOREWORD METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL Method for disconnecting connector with lock to pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
  • Page 75 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR 00 INDEX AND FOREWORD WITH LOCK TO PUSH METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH Method for disconnecting connector with lock to push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow. •...
  • Page 76 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 INDEX AND FOREWORD Method for disconnecting connector with lock to push (AMP-3) While pressing lock (E), pull out connector (5) in the direction of the arrow. Method for connecting connector with lock to push (AMP-3) Insert it straight until it clicks.
  • Page 77 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR 00 INDEX AND FOREWORD WITH HOUSING TO ROTATE METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE Method for disconnecting connector with housing to rotate Turn housing (H1) to the left, and pull it out. REMARK Housing (H1) is left on the wiring harness side.
  • Page 78 HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electrical wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No.
  • Page 79 00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands Diameter of 0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32 strand Conductor Cross-sec- tional area 0.51 0.56...
  • Page 80 HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD Nominal No. 0.5f 0.75f 0.85 1.25f 1.25 CAVS Standard REMARK “f” of nominal No. denotes "flexible". Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green and White Brown...
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Wa500-8