Komatsu Wheeled Excavator PW148 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheeled Excavator PW148-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheeled Excavator PW148-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,158 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
VEBM720100 - Wheeled Excavator PW148-8 Shop Manual.pdf
MAIN SECTIONS
VEBM720100 PW148-8.....1
CONTENTS.....3
FOREWORD.....5
Safety.....5
Important safety notice.....5
General precautions.....5
Preparations for work.....5
Precautions during work.....6
General.....7
General.....7
Structure and function.....7
Testing, adjusting and troubleshooting.....7
Disassembly and assembly.....7
Maintenance standard.....7
How to read the shop manual.....8
Volumes.....8
Distribution and updating.....8
Filing method.....8
Revised edition mark.....8
Revisions.....8
Symbols.....8
Hoisting instructions.....9
Hoisting.....9
Wire Ropes.....9
Coating materials.....10
Standard tightening torque.....12
Standard tightening torque of bolts and nuts.....12
Tightening torque of hose nuts.....13
Tightening torque of split flange bolts.....13
Tightening torques for hoses (taper seal type and face seal type).....13
Tightening torque for 107 engine series (bolts and nuts).....14
Tightening torque for 107 engine series (eye joints).....14
Tightening torque for 107 engine series (tapered screws).....14
Electric wire code.....15
Classification by thickness.....15
Classification by color and code.....15
Conversion tables.....16
Method of using the conversion table.....16
Units.....22
GENERAL.....23
Specification dimension drawings.....24
Dimensions.....24
Working ranges.....26
Working range: 1 piece boom.....26
Working range: 2 piece boom.....27
Specifications.....29
Weight table.....31
1 piece boom.....32
2 piece boom.....33
Fuel, coolant and lubricants.....34
STRUCTURE AND FUNCTION.....35
KOMTRAX terminal system.....269
Service brake and suspension system.....264
Braking system.....264
Operation.....267
Steering system.....251
Operating principles.....251
Dynamic Steering.....251
2 - stage principle.....251
1. Condition 1.....252
2. Condition 2.....253
3. Condition 3.....254
4. Condition 4.....255
5. Condition 5.....256
6. Condition 6.....257
7. OLS priority valve.....258
8. Load sensing steering unit.....259
Travel system.....231
Travel circuit.....231
1. Travel motor.....232
2. Travel pedal.....241
3. Forward / Neutral / Reverse switch (F-N-R).....242
4. Forward / Reverse travel solenoid.....243
5. Travel / neutral solenoid.....244
6. Travel creep solenoid.....245
Operational and control features.....246
Operational and Control features (1).....246
Operational and Control features (2).....246
Operational and Control features (3).....247
7. 2-Stage relief solenoid.....248
8. Transmission clutch control valve.....250
1st attachment circuit hydraulic performance (main valve bypassed).....230
Sensor.....221
Coolant temperature sensor.....222
Oil pressure switch.....222
Rotation sensor.....223
Boost pressure and temperature sensor.....223
WIF (Water-In-Fuel detection) sensor.....224
Engine oil level sensor.....224
Coolant level sensor.....225
Coolant temperature sensor.....226
Hydraulic oil temperature sensor.....226
Fuel level sensor.....226
Air cleaner clogging sensor.....227
Overload Caution sensor.....227
Swing proximity sensor.....228
Travel PPC sensor.....228
PPC pressure sensor.....228
Park brake pressure sensor.....229
Brake accumulator low pressure sensor.....229
Brake stop light sensor.....229
Overload warning device.....220
Outline.....220
Function.....220
Structure.....220
Machine monitor system.....204
Monitor panel.....205
Outline.....205
Monitor control, display portion.....208
Monitor gauge displays.....212
Keypad layout.....217
Declaration of switch function on keypad.....218
Electrical control system.....181
Machine control system diagram.....182
1. Engine and pump control function.....183
Function.....184
Function.....188
Function.....190
Function.....192
Operation.....193
Function.....194
Function.....196
Function.....198
Function.....201
Specifications.....202
Function.....202
Function.....203
Operation.....203
Electrical system.....174
Engine control.....174
1. Operation of System.....174
2. Component.....175
Engine controller.....176
Pump controller.....178
Electrical wiring diagramm.....173
Air conditioner.....172
Air conditioner piping.....172
Work equipment.....166
Work equipment.....167
1. Dimension of arm.....168
2. Dimension of bucket.....170
Dozer cylinder.....164
Function.....165
Outrigger cylinder.....162
Function.....163
Hydraulic cylinder.....160
Boom cylinder.....160
Arm cylinder.....160
Bucket cylinder.....160
Adjust cylinder.....161
Boom safety valve.....158
Operation.....159
Solenoid valve block.....146
ON / OFF Solenoid valves (3 way valve).....148
Operation.....148
ON / OFF Solenoid valves (4 way valve).....150
Operation.....150
Hi/ Lo Solenoid valve (4 way valve).....152
Operation.....152
Attachment PPC valve.....154
Function.....155
Operation.....155
Work equipment - Swing PPC valve.....142
Operation.....144
Travel PPC pedal.....140
Centre swivel joint.....139
CLSS.....117
Outline of CLSS.....117
Features.....117
Structure.....117
Basic Principle.....118
Operation for each function and valve.....120
Hydraulic circuit diagram and name of valves.....120
1. Unload valve.....122
Function.....122
Operation.....122
Operation.....123
Operation.....124
2. Introduction of LS pressure.....125
Work equipment valve.....125
Function.....125
Operation.....125
3. LS bypass plug.....126
Outline.....126
Operation.....126
4. Pressure compensation valve.....128
Function.....128
Operation.....129
5. Area ratio of pressure compensation valve.....130
Function.....130
6. Boom regeneration circuit.....132
Function.....132
Operation.....132
Function.....133
Operation.....133
7. Arm regeneration circuit.....134
Function.....134
Operation.....134
Function.....135
Operation.....135
8. Swing bleeding valve.....136
Function.....136
Operation (In fine control operation).....136
9. Variable type pressure compensation valve (for service).....137
Function.....137
Simultaneous operation with work equipment under heavy load (boom RAISE, etc.).....137
10. LS select valve.....138
Function.....138
Operation.....138
Control valve.....106
Outline.....106
Pilot pressure control (PPC) system.....104
Function.....105
Operation.....105
Hydraulic pump.....81
Function.....83
Structure.....83
Operation.....84
LS valve.....86
PC valve.....87
Function.....88
Operation.....90
1. LS valve.....90
2. PC valve.....94
LS(PC)-EPC valve.....101
Function.....102
Operation.....102
Hydraulic tank.....79
Specifications.....80
Hydraulic circuit diagram.....78
Hydraulic equipment layout drawings.....76
Orbitrol valve.....75
Specifications.....75
Structure and function.....75
Steering column.....74
Steering system.....73
Structure and function.....73
Accumulator for brake valve.....72
Specifications.....72
Structure ans function.....72
Power brake valve.....70
Specifications.....71
Function.....71
Priority valve.....69
Specification.....69
Function.....69
Brake/steer pump.....68
Specifications.....68
Function.....68
Braking system.....66
Structure and function.....67
Suspension lock cylinder.....64
Specifications.....64
Structure and function.....64
Circuit.....65
Axle oscillation.....65
Axle.....60
Outline.....60
Clutch control circuit.....58
Function.....59
Travel motor.....54
Function.....55
Operation of travel motor.....56
ATT EPC valve assembly.....53
Shematic.....52
Quick coupler control valve.....51
Specification.....51
Operation.....51
Transmission.....48
Specifications.....48
Function.....49
Undercarriage.....46
Swing machinery & motor.....41
Specification.....42
Operation of swing lock.....43
Relief valve portion.....44
Operation.....44
Swing circle.....40
Specifications.....40
Power train.....38
Radiator, oil cooler, aftercooler and fuel cooler.....37
Engine related parts.....36
Outline.....36
TESTING AND ADJUSTING.....271
Standard value table for engine related parts.....272
Standard value table for chassis related parts.....273
Flow control characteristic of PC valve (STD).....286
Checking fuel circuit for leakage.....308
Checking and adjusting air conditioner compressor belt tension.....309
Checking.....309
Adjusting.....309
Replacing the fan belt.....310
Measurement of clearance in swing circle bearing.....311
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel.....312
Measurement.....312
Adjustment.....313
Inspection and adjustment of control circuit oil pressure.....315
Measurement.....315
Procedure for pressure reducing adjustment.....316
Inspection and adjustment of pump PC (valve inlet) control oil pressure.....317
Measurement.....317
Adjustment.....319
Inspection and adjustment of pump LS valve control oil pressure.....320
Measurement.....320
Adjustment.....323
Measurement of solenoid valve output pressure.....324
Measurement of PPC valve output pressure.....329
Checking Proportional Control PPC Circuit.....330
Adjustment of work equipment and swing PPC valve.....331
TESTING AND ADJUSTING (100).....287
Measuring and adjusting quick coupler control valve output pressure.....332
Measuring engine speed.....288
Measuring intake air pressure (boost pressure).....289
Checking exhaust gas colour.....290
Adjusting valve clearance.....292
Measurement of compression pressure.....294
Measuring blow-by pressure.....296
Measuring engine oil pressure.....297
Handling fuel system parts.....298
Releasing residual pressure from fuel system.....299
Measuring fuel pressure.....300
Measuring fuel return rate and leakage.....302
Bleeding air from fuel circuit.....306
Solenoid valve block.....326
Testing travel motor relief pressure.....333
Measuring travel motor relief pressure.....333
Adjusting travel motor relief pressure.....334
Testing propshaft speed.....335
Measuring rotating speed of propshaft.....335
Testing transmission clutch control circuit.....336
Description.....336
Inspection of locations of hydraulic drift of work equipment.....338
Release of remaining pressure in hydraulic circuit.....340
Measurement of oil leakage.....341
Air bleeding of various parts.....344
Inspection procedures for diode.....347
Special function of monitor panel.....348
TESTING AND ADJUSTING (220).....403
Troubleshooting.....403
Points to remember when troubleshooting.....404
Sequence of events in troubleshooting.....405
Points to remember when carrying out maintenance.....406
1. Points to remember when handling electric equipment.....406
2. Points to remember when troubleshooting electric circuits.....412
3. Points to remember when handling hydraulic equipment.....413
Checks before troubleshooting.....415
Classification and steps for troubleshooting.....416
Classification of troubleshooting.....416
Steps for troubleshooting.....416
Failure-looking phenomenon and troubleshooting no.....417
How to read electric wire code.....420
Connector location chart and electrical circuit diagram by system.....424
Connector table for revolving frame harness.....425
Connector table for operators cab wiring harness (Part 1/2).....428
Connector table for operators cab wiring harness (Part 2/2).....430
Connector table various wiring harness (Part 1/2).....432
Connector table various wiring harness (Part 2/2).....434
Connection table for connector pin numbers.....436
T-boxes and T-adapters table.....464
TESTING AND ADJUSTING (300).....469
Troubleshooting when failure code is indicated.....469
Before carrying out troubleshooting when failure code is displayed.....472
Information contained in troubleshooting table.....473
Relative electrical circuit diagram.....474
Failure code [6B2JMA] - Travel hydraulic abnormality.....475
Failure code [989L00] - Engine controller lock caution 1.....476
Failure code [989M00] - Engine controller lock caution 2.....477
Failure code [989N00] - Engine controller lock caution 3.....478
Failure code [AA10NX] - Air cleaner clogging.....479
Failure code [AB00KE] - Charge voltage low.....480
Failure code [B@BAZG] - Eng oil press. low.....481
Failure code [B@BAZK] - Eng oil level low.....482
Failure code [B@BCNS] - Eng water overheat.....483
Failure code [B@BCZK] - Eng water level low.....484
Failure code [B@HANS] - Hydr oil overheat.....485
Failure code [CA111] - EMC critical internal failure.....486
Failure code [CA115] - Engine neutral and backup speed sensor error.....487
Failure code [CA122] - Chg air press sensor high error.....488
Circuit diagram related to boost pressure/temperature sensor (combination sensor).....489
Failure code [CA123] - Chg air press sensor low error.....490
Circuit diagram related to boost pressure/temperature sensor (combination sensor).....491
Failure code [CA131] - Throttle sensor high error.....492
Circuit diagram related to fuel control dial.....493
Failure code [CA132] - Throttle sensor low error.....494
Circuit diagram related to fuel control dial.....495
Failure code [CA144] - Coolant temp sens high error.....496
Circuit diagram related to coolant temperature sensor.....497
Failure code [CA145] - Coolant temp sens low error.....498
Circuit diagram related to coolant temperature sensor.....499
Failure code [CA153] - Chg air temp sensor high error.....500
Circuit diagram related to boost pressure/temperature sensor (combination sensor).....501
Failure code [CA154] - Chg air temp sensor low error.....502
Circuit diagram related to boost pressure/temperature sensor (combination sensor).....503
Failure code [CA155] - Chg air temp high speed derate.....504
Failure code [CA187] - Sens supply 2 volt low error.....506
Circuit diagram related to sensor power supply 2.....507
Failure code [CA221] - Ambient press sens high error.....508
Circuit diagram related to ambient pressure sensor.....509
Failure code [CA222] - Ambient press sens low error.....510
Circuit diagram related to ambient pressure sensor.....511
Failure code [CA227] - Sens supply 2 volt high error.....512
Circuit diagram related to sensor power supply 2.....512
Failure code [CA234] - Eng overspeed.....513
Failure code [CA238] - Ne speed sens supply volt error.....514
Circuit diagram related to engine Ne speed sensor.....514
Failure code [CA271] - IMV/PCV1 short error.....515
Circuit diagram related to supply pump actuator (metering unit).....515
Failure code [CA272] - IMV/PCV1 open error.....516
Circuit diagram related to supply pump actuator (metering unit).....516
Failure code [CA322] - Inj #1 (L#1) open/short error.....518
Circuit diagram related to no. 1 injector.....519
Failure code [CA324] - Inj #3 (L#3) open/short error.....520
Failure code [CA331] - Inj #2 (L#2) open/short error.....522
Circuit diagram related to no. 2 injector.....523
Failure code [CA332] - Inj #4 (L#4) open/short error.....524
Circuit diagram related to no. 4 injector.....525
Failure code [CA342] - Calibration code incompatibility.....526
Failure code [CA351] - Injectors drive circuit error.....528
Circuit diagram related to engine controller.....529
Failure code [CA352] - Sens supply 1 volt low error.....530
Circuit diagram related to sensor power supply 1.....531
Failure code [CA386] - Sens supply 1 volt high error.....532
Circuit diagram related to sensor power supply 1.....532
Failure code [CA428] - Water in fuel sensor high error.....534
Circuit diagram related to water-in-fuel sensor.....535
Failure code [CA429] - Water in fuel sensor low error.....536
Circuit diagram related to water-in-fuel sensor.....537
Failure code [CA435] - Eng oil press sw error.....538
Circuit diagram related to engine oil pressure switch.....538
Failure code [CA441] - Battery voltage low error.....539
Circuit diagram related to engine controller power supply.....541
Failure code [CA442] - Battery voltage high error.....542
Circuit diagram related to engine controller power supply.....543
Failure code [CA449] - Rail press very high error.....544
Failure code [CA451] - Rail press sensor high error.....546
Circuit diagram related to common rail pressure sensor.....547
Failure code [CA452] - Rail press sensor low error.....548
Circuit diagram related to common rail pressure sensor.....549
Failure code [CA488] - Chg air temp high torque derate.....550
Failure code [CA553] - Rail press high error.....551
Failure code [CA559] - Rail press low error.....552
Failure code [CA689] - Eng Ne speed sensor error.....554
Circuit diagram related to engine Ne speed sensor.....555
Failure code [CA731] - Eng bkup speed sens phase error.....556
Failure code [CA757] - All continuous data lost error.....558
Circuit diagram related to engine controller power supply.....559
Failure code [CA778] - Eng bkup speed sensor error.....560
Circuit diagram related to engine G speed sensor.....561
Failure code [CA1633] - KOMNET datalink timeout error.....562
Circuit diagram related to CAN communication.....563
Failure code [CA2185] - Throttle sensor supply voltage high error.....564
Circuit diagram related to fuel control dial.....564
Failure code [CA2186] - Throttle sensor supply voltage low error.....565
Circuit diagram related to fuel control dial.....565
Failure code [CA2249] - Rail press very low error.....566
Failure code [CA2311] - IMV solenoid error.....568
Circuit diagram related to supply pump actuator (metering unit).....569
Failure code [CA2555] - Grid htr relay volt high error.....570
Circuit diagram related to engine preheater/starting motor/charging system.....571
Failure code [CA2556] - Grid heater relay volt low error.....572
Circuit diagram related to engine preheater/starting motor/charging system.....573
Failure code [D110KB] - Short-circuiting in battery relay.....574
Electrical circuit diagram for battery relay - Pump controller.....575
Failure code [D19JKZ] - Personal code relay abnormality.....576
Circuit diagram related to engine preheater/starting motor/charging system.....577
Failure code [D862KA] - GPS antenna disconnection.....578
Configuration diagram of KOMTRAX system.....578
Circuit diagram related to no. 3 injector.....521
Failure code [DA25KP] - 5V sensor 1 power abnormality.....580
Circuit diagram related to pressure sensor power supply of pump controller.....581
Failure code [DA2RMC] - CAN discon (pump con detected).....582
Circuit diagram related to CAN communication.....583
Failure code [DAFRMC] - GPS module error.....584
Failure code [DAFRMC] - CAN discon (monitor detected).....586
Circuit diagram related to CAN communication.....587
Failure code [DDP4KX] - Abnormality in travel PPC pressure switch.....588
Electrical circuit diagram for travel PPC pressure switch.....589
Failure code [DDWCKZ] - Abnormality in travel direction control switch.....590
Electrical circuit diagram for travel direction control switch.....591
Failure code [DFB1KZ] - 1st ATT service lever main potentio 1 abnormality.....592
Failure code [DFB2KZ] - 2nd ATT service lever main potentio 2 abnormality.....594
Failure code [DFB3L8] - 1st ATT service lever Potentio 1 error.....596
Failure code [DFB4L8] - 2nd ATT service lever potentio 2 error.....597
Failure code [DFB5KZ] - 1st ATT service lever main potentio 1 abnormality.....598
Failure code [DFB6KZ] - Service lever potentio 2 abnormality.....600
Failure code [DGH2KB] - Hydr oil sensor short.....602
Circuit diagram related to hydraulic oil temperature sensor.....603
Failure code [DH10KS] - Abnormality in 24V sensor power source.....604
Electrical circuit diagram for 24V sensor power source.....605
Failure code [DHPAMA] - F pump press sensor abnormality.....606
Circuit diagram related to pump pressure sensor of pump controller.....607
Failure code [DHS5KX] - Abnormality in travel PPC sensor.....608
Failure code [DHX1MA] - Abnormality in overload caution sensor.....610
Electrical Circuit Diagram for Overload Caution.....611
Failure code [DLT4KA] - Disconnection in transmission speed sensor in pump controller system.....612
Electrical circuit diagram for monitor panel power source.....613
Failure code [DW27KA] - Disconnection in transmission clutch solenoid.....614
Electrical circuit diagram for transmission clutch solenoid in pump controller.....615
Failure code [DW27KB] - Short-circuiting in transmission clutch solenoid.....616
Electrical circuit diagram for transmission clutch solenoid.....617
Failure code [DW4AKA] - Disconnection in suspension lock solenoid.....618
Electrical circuit diagram for suspension lock solenoid in pump controller.....619
Failure code [DW4AKB] - Short circuiting in suspension lock solenoid.....620
Electrical circuit diagram for suspension lock solenoid in pump controller.....621
Failure code [DW4CKA] - Disconnection in PPC lock solenoid.....622
Electrical circuit diagram for ppc lock solenoid in pump controller.....623
Failure code [DW4CKB] - PPC lock sol. S/C.....624
Circuit diagram related to swing holding brake solenoid of pump controller.....625
Failure code [DW4MKA] - Disconnection in creep solenoid.....626
Electrical circuit diagram for creep solenoid in pump controller.....627
Failure code [DW4MKB] - Short-circuiting in creep solenoid.....628
Electrical circuit diagram for creep solenoid in pump controller.....629
Failure code [DW44KA] - Disconnection of travel F/R solenoid.....630
Electrical circuit diagram for travel F/R solenoid.....631
Failure code [DW44KB] - Short-circuiting of travel F/R solenoid.....632
Electrical circuit for travel F/R solenoid in pump controller.....633
Failure code [DW45KA] - Disconnection in swing parking brake solenoid.....634
Electrical circuit diagram for swing and parking brake solenoid in pump controller.....635
Failure code [DW45KB] - Swing brake sol. S/C.....636
Circuit diagram related to swing holding brake solenoid of pump controller.....637
Failure code [DW91KA] - Disconnection in travel neutral solenoid.....638
Electrical circuit diagram for travel neutral solenoid.....639
Failure code [DW91KB] - Short-circuiting in travel neutral solenoid.....640
Electrical circuit diagram for travel neutral solenoid.....641
Failure code [DWK0KA] - Disconnection in 2-stage relief solenoid.....642
Electrical circuit diagram for 2-stage relief solenoid in pump controller.....643
Failure code [DWK0KB] - Short-circuiting in 2-stage relief solenoid.....644
Electric circuit diagram for 2-stage relief solenoid in pump controller.....645
Failure code [DWK2KA] - Disconnection in 2-stage back pressure solenoid.....646
Electrical circuit diagram for 2-stage back pressure solenoid in pump controller.....647
Failure code [DWK2KB] - Short circuiting in 2-stage back pressure solenoid.....648
Electrical circuit diagram for 2-stage back pressure solenoid in pump controller.....649
Failure code [DXA8KA] - Disconnection in PC-EPC (F) solenoid system.....650
Electrical circuit diagram for PC-EPC solenoid in pump controller.....651
Failure code [DXA8KB] - Short-circuiting in PC-EPC (F) solenoid.....652
Electrical circuit diagram for PC-EPC solenoid in pump controller.....653
Failure code [DXE0KA] - Disconnection in LS-EPC solenoid system.....654
Electrical circuit diagram for LS-EPC solenoid in pump controller.....654
Failure code [DXE0KB] - Short-circuiting in LS-EPC solenoid.....655
Electrical circuit diagram for LS-EPC solenoid in pump controller.....655
Failure code [DXE4KA] - 1st service current EPC discon (left hand).....656
Circuit diagram related to the 1st and 2 nd service EPC solenoids.....657
Failure code [DXE4KB] - 1st service current EPC short (left hand).....658
Circuit diagram related to the 1st and 2nd service EPC solenoids.....659
Failure code [DXE7KA] - 1st service current EPC discon (right hand).....660
Circuit diagram related to the 1st and 2nd service EPC solenoids.....661
Failure code [DXE7KB] - 1st service current EPC short (right hand).....662
Circuit diagram related to the 1st and 2nd service EPC solenoids.....663
Failure code [DXE8KA] - 2nd service current EPC discon (left hand).....664
Circuit diagram related to the 1st and 2nd service EPC solenoids.....665
Failure code [DXE8KB] - 2nd service current EPC short (left hand).....666
Circuit diagram related to the 1st and 2nd service EPC solenoids.....667
Failure code [DXE9KA] - 2nd service current EPC discon (right hand).....668
Circuit diagram related to the 1st and 2nd service EPC solenoids.....669
Failure code [DXE9KB] - 2nd service current EPC short (right hand).....670
Circuit diagram related to the 1st and 2nd service EPC solenoids.....671
Failure code [DY20KA] - Wiper working abnormality.....672
Circuit diagram related to wiper motor of machine monitor.....673
Failure code [DY20MA] - Wiper parking abnormality.....674
Circuit diagram related to wiper motor of machine monitor.....675
Failure code [DY2CKA] - Washer drive discon.....676
Circuit diagram related to wiper motor of machine monitor.....677
Failure code [DY2CKB] - Washer drive short.....678
Circuit diagram related to window washer motor of machine monitor.....679
Failure code [DY2DKB] - Wiper drive (for) short.....680
Circuit diagram related to wiper motor of machine monitor.....681
Failure code [DY2EKB] - Wiper drive (rev) short.....682
Circuit diagram related to wiper motor of machine monitor.....683
TESTING AND ADJUSTING (520).....685
Troubleshooting of electrical system (E-Mode).....685
Preparations for troubleshooting of electrical system.....686
Troubleshooting of electrical system (E-mode).....690
Before carrying out troubleshooting of electrical system.....690
Location of fusible links.....692
Location of fuse box and fuse numbers.....692
Information contained in troubleshooting table.....693
E-1 When starting switch turned ON, machine monitor displays nothing.....694
Circuit diagramm related to machine monitor power supply.....695
E-2 When starting switch turned ON (before starting engine), basic check item lights up.....696
Circuit diagram related to radiator coolant level switch.....697
Circuit diagram related to engine oil level switch.....698
E-3 Engine does not start (engine does not rotate).....699
Electrical circuit diagram for engine start, stop and battery charging.....701
E-4 Preheater does not operate.....702
Circuit diagram related to engine preheater.....703
E-5 Automatic warm-up system does not operate (in cold season).....704
E-6 All work equipment, swing and travel mechanism do not move or cannot be locked.....705
Electrical circuit diagram for PPC lock solenoid.....706
E-7 Precaution lights up while engine is running.....707
Circuit diagram related to engine preheater/starting motor/charging system.....708
Circuit diagram related to air cleaner clogging switch.....710
E-8 Emergency stop item lights up while engine is running.....712
Circuit diagram related to 2-stage relief solenoid.....713
E-9 Engine coolant temperature gauge does not indicate normally.....714
E-10 Hydraulic oil temperature gauge does not indicate normally.....715
E-11 Fuel level gauge does not indicate normally.....717
Circuit diagram related to fuel level sensor.....718
E-12 Contents of display by machine monitor are different from applicable machine.....720
E-13 Machine monitor does not display some items.....720
E-14 Function switch does not work.....720
E-15 Auto-decelerator does not operate normally.....721
E-16 Working mode does not change.....722
E-17 Travel speed does not change.....723
Circuit diagram related to travel speed shifting solenoid.....723
E-18 Alarm buzzer cannot be stopped.....724
Circuit diagram for Quick Coupler system.....725
E-19 Windshield wiper and window washer do not operate.....726
Circuit diagram related to windshield and window washer.....727
E-20 Power maximising function does not operate normally.....728
E-21 Swing holding brake does not operate normally.....729
Electrical circuit diagram for Swing Lock switch.....730
E-21 - "Boom/Stabiliser RAISE" is not correctly displayed in monitor function.....731
Electrical circuit diagram for boom RAISE PPC hydraulic switch.....731
E-22 Travel alarm does not sound or does not stop sounding.....732
Electrical circuit diagram for travel PPC hydraulic switch and travel alarm.....733
E-23 Air conditioner does not operate normally (including air conditioner abnormality record).....734
Circuit diagram related to air conditioner.....744
E-24 When starting switch is turned OFF, service meter is not displayed.....745
E-25 Machine monitor cannot be set in service mode.....745
E-26 Monitoring function does not display lever control signal normally.....746
Electrical circuit diagram for boom RAISE PPC hydraulic switch.....746
Electrical circuit diagram for boom LOWER PPC hydraulic switch.....747
Electrical circuit diagram for arm DIGGING PPC hydraulic switch.....748
Electrical circuit diagram for arm DUMPING PPC hydraulic switch.....749
Electrical circuit diagram for bucket DIGGING PPC hydraulic switch.....750
Electrical circuit diagram for bucket DUMPING PPC hydraulic switch.....751
Electrical circuit diagram for right and left swing PPC hydraulic switches.....753
Electrical circuit diagram for travel PPC hydraulic switch and travel alarm.....755
Electrical circuit diagram for 2 piece boom PPC hydraulic switch.....757
E-27 KOMTRAX system does not operate normally.....758
TESTING AND ADJUSTING (600).....759
Troubleshooting of electrical system (Error checking of items without monitor codes).....759
Swing lock proximity switch.....864
Brake and swing lock proximity switches.....865
Hazard warning lights contd (A).....861
Circuit diagram for indicators & hazard warning.....862
Hazard warning lights.....860
Indicators - Left hand.....858
Circuit diagram for indicators & hazard warning.....859
Indicators - Right hand.....856
Circuit diagram for indicators & hazard warning.....857
Driving lights - Position lights.....852
Driving lights - Position lights contd (1) and (2).....853
Circuit diagram for driving lights.....854
Driving lights - Main beam dipped.....850
Circuit diagram for driving lights.....851
Driving lights - Main beam flash.....848
Circuit diagram for driving lights.....849
Driving lights - Main beam.....846
Circuit diagram for driving lights.....847
Emergency travel control - Reverse.....844
Circuit diagram for travel direction control.....845
Emergency travel control - Neutral.....842
Circuit diagram for travel direction control.....843
Emergency travel control - Forward.....840
Circuit diagram for travel direction control.....841
Neutral start (engine) contd (C).....838
Circuit diagram for neutral start (engine).....839
Neutral start (engine) contd (B).....836
Circuit diagram for neutral start (engine).....837
Neutral start (engine) contd (A).....834
Circuit diagram for neutral start (engine).....835
Neutral start (engine).....832
Circuit diagram for neutral start (engine).....833
Swing lock - Emergency operation.....830
Circuit diagram for swing lock.....831
Swing lock - Normal operation.....828
Circuit diagram for swing lock.....829
Horns.....826
Circuit diagram for horn.....827
RH PPC Lever clamshell roller switch pushed to the RH or LH.....824
Circuit diagram for clamshell control.....825
RH PPC Lever clamshell roller switch pushed to the RH position.....822
Circuit diagram for clamshell control.....823
Park brake (displayed symbol).....820
Circuit diagram for park brake.....821
Park brake (not activating).....818
Circuit diagram for park brake.....819
Cigarette lighter.....816
Circuit diagram for cigarette lighter.....817
Operator cab interior light.....814
Circuit diagram for operator cab interior light.....815
Air seat compressor (option - air suspension seat).....812
Circuit diagram for air seat compressor (option - air suspension seat).....813
Flashing beacon (Fuel tank mount).....810
Circuit diagram for cab, counterweight & fuel tank beacon light.....811
Flashing beacon (Counterweight mount).....808
Circuit diagram for cab, counterweight & fuel tank beacon light.....809
Flashing beacon (Operators cabin mount).....806
Circuit diagram for cab, counterweight & fuel tank beacon light.....807
Worklights (Oil tank - side mount).....804
Circuit diagram for worklights - worklight switch (2).....805
Worklights (Counterweight - right hand).....802
Circuit diagram for worklights - worklight switch (2).....803
Worklights (Counterweight - left hand).....800
Circuit diagram for worklights - worklight switch (2).....801
Worklights (Revolving frame - right hand).....798
Circuit diagram for worklights - Worklight switch (1).....799
Worklights (Revolving frame - left hand).....796
Circuit diagram for worklights - Worklight switch (1).....797
Worklights (Boom - right hand).....794
Circuit diagram for worklights - Worklight switch (1).....795
Worklights (Boom - left hand).....792
Circuit diagram for worklights - Worklight switch (1).....793
Work lights (operator cab rear).....790
Circuit diagram for worklights - worklight switch (2).....791
Work lights (operator cab front right).....788
Circuit diagram for worklights - Worklight switch (1).....789
Work lights (operator cab front left).....786
Circuit diagram for worklights - Worklight switch (1).....787
Lower wiper does not work (optional fitment).....784
Circuit diagram for lower wiper.....785
Suspension lock.....782
Circuit diagram for suspension lock.....783
Heated seat does not warm up.....780
Circuit diagram for the heated seat.....781
Undercarriage attachments - Rear right outrigger.....778
Circuit diagram for undercarriage attachments - Mode selection.....779
Undercarriage attachments - Rear left outrigger.....776
Circuit diagram for undercarriage attachments - Mode selection.....777
Undercarriage attachments - Front right outrigger.....774
Circuit diagram for undercarriage attachments - Mode selection.....775
Undercarriage attachments - Front left outrigger.....772
Circuit diagram for undercarriage attachments - Mode selection.....773
Undercarriage attachments - Mode activation.....770
Circuit diagram for undercarriage attachments - Mode activation.....771
Undercarriage attachments - Mode selection.....768
Circuit diagram for undercarriage attachments - Mode selection.....769
Brake light circuit.....766
Circuit diagram for brake light circuit.....767
PPC lock circuit.....764
Circuit diagram for PPC lock circuit.....765
Radio cassette & telephone socket.....762
Electrical circuit diagram for radio cassette & telephone socket.....763
Information in troubleshooting table.....761
TESTING AND ADJUSTING (710).....867
Troubleshooting of engine (S-MODE).....894
S-1 - Starting performance is poor.....897
S-2 - Engine does not start.....898
S-3 - Engine does not pick up smoothly.....901
S-4 - Engine stops during operations.....902
S-5 - Engine does not rotate smoothly.....903
S-6 - Engine lacks output (or lacks power).....904
S-7 - Exhaust smoke is black (incomplete combustion).....905
S-8 - Oil consumption is excessive (or exhaust smoke is blue).....906
S-9 - Oil becomes contaminated quickly.....907
S-10 - Fuel consumption is excessive.....908
S-11 - Oil is in coolant (or coolant spurts back or coolant level goes down).....909
S-12 - Oil pressure drops.....910
S-13 - Oil level rises (Entry of coolant/fuel).....911
S-14 - Coolant temperature becomes too high (overheating).....912
S-15 - Abnormal noise is made.....913
S-16 - Vibration is excessive.....914
Method of using troubleshooting chart.....894
Troubleshooting of hydraulic and mechanical system (H-MODE).....867
System chart for hydraulic and mechanical systems.....869
Information contained in troubleshooting table.....873
H-1 - All work equipment lacks power, or travel and swing speeds are slow.....874
H-2 - Engine speed sharply drops or engine stalls.....875
H-3 - No work equipment, travel or swing move.....876
H-4 - Abnormal noise is heard from around hydraulic pump.....876
H-5 - Auto-decelerator does not work.....877
H-6 - Fine control mode does not function.....877
H-7 - Boom moves slowly or lacks power.....878
H-8 - Arm moves slowly or lacks power.....879
H-9 - Bucket moves slowly or lacks power.....880
H-10 - Work equipment does not move in its single operation.....880
H-11 - Work equipment hydraulic drift is too fast.....881
H-12 - Work equipment has big time lag.....882
H-13 - Other work equipment moves when relieving single circuit.....882
H-14 - One-touch power max. switch does not operate.....883
H-15 - In compound operation, work equipment with larger load moves slowly.....883
H-16 - In swing + boom RAISE operation, boom moves slowly.....883
H-17 - In swing + travel, travel speed drops sharply.....884
H-18 - Travel speed does not switch.....885
H-19 - Travel speed does not shift, or it is too slow or fast.....886
H-20 - Machine does not swing.....887
H-21 - Swing acceleration is poor, or swing speed is slow.....888
H-22 - Excessive overrun when stopping swing.....889
H-23 - There is big shock when stopping swing.....890
H-24 - There is loud abnormal noise caused when stopping swing.....890
H-25 - Swing natural drift is too big.....891
H-26 - Swing speed is faster than specified swing speed.....891
Quick coupler.....892
DISASSEMBLY AND ASSEMBLY.....915
How to read this manual.....920
Removal and installation of assemblies.....920
Special tools.....920
Removal of parts.....920
Installation of parts.....920
Sketches of special tools.....920
Coating material lists.....921
Special tools list.....924
Sketches of special tools.....926
List of tools.....928
Precautions when performing operation.....929
Removal and installation of fuel supply pump assembly.....931
Removal.....931
Installation.....932
Removal and installation of fuel injector assembly.....934
Special tools.....934
Removal.....934
Installation.....936
Removal and installation of front oil seal.....939
Special tools.....939
Removal.....939
Installation.....939
Removal and installation of rear oil seal.....941
Special tools.....941
Removal.....941
Installation.....942
Removal and installation of cylinder head assembly.....944
Special tools.....944
Removal.....944
Installation.....949
Removal and installation of fuel cooler assembly.....954
Removal and installation of combination cooler assembly.....955
Removal.....955
Installation.....957
Removal and installation of engine and hydraulic pump assembly.....958
Special tools.....958
Removal.....958
Installation.....963
Removal and installation of engine hood assembly.....965
Removal.....965
Installation.....965
Removal and installation of travel motor.....967
Removal.....967
Installation.....968
Disassembly and assembly of travel motor assembly.....970
Disassembly.....970
Assembly.....972
Removal and installation of swing motor and swing machinery.....974
Removal.....974
Installation.....975
Removal of swing motor assembly.....976
Removal.....976
Installation.....977
Disassembly and assembly of swing motor and swing machinery.....978
Disassembly.....978
Assembly.....980
Removal and installation of front axle assembly.....984
Removal.....984
Installation.....985
Disassembly and assembly of front axle.....986
Disassembly of steering cylinder.....986
Assembly of steering cylinder.....988
Disassembly of epicyclic reduction gear and brake.....992
Assembly of epicylic reduction gear and brake.....996
Disassembly of joint box.....1002
Assembly of joint box.....1006
Disassembly of beam trumpet and differential unit.....1011
Assembly of beam trumpet and differential unit.....1014
Disassembly of pinion group.....1020
Assembly of pinion group.....1022
Toe-in adjustment.....1028
Steering angle adjustment.....1029
Removal and installation of rear axle and transmission.....1030
Removal.....1030
Installation.....1031
Disassembly and assembly of rear axle assembly.....1032
Special tools.....1032
Removal of epicyclic reduction gear and brake.....1032
Installation of epicylic reduction gear and brake.....1036
Disassembly of beam trumpet and differential unit.....1043
Installation of beam trumpet and differential unit.....1047
Disassembly of pinion group.....1053
Installation of pinion group.....1056
Disassembly and assembly of transmission.....1062
Special tools.....1062
Removal of travel motor and flange.....1062
Installation of travel motor.....1063
Removal of transmission box.....1066
Installation of transmission box.....1074
Removal and installation of propshaft assembly.....1085
Removal.....1085
Installation.....1085
Removal and installation of wheel.....1086
Removal.....1086
Installation.....1086
Removal and installation of suspension lock cylinder assembly.....1087
Removal.....1087
Installation.....1087
Disassembly and assembly of suspension lock cylinders.....1088
Change Rod Seal.....1088
Removal and installation of outrigger assembly.....1089
Removal.....1089
Installation.....1089
Disassembly and assembly of outriggers.....1090
Disassembly.....1090
Assembly.....1090
Removal and installation of dozer blade assembly.....1091
Removal.....1091
Installation.....1091
Disassembly and assembly of dozer blade.....1092
Disassembly.....1092
Assembly.....1092
Removal and installation of swing circle assembly.....1093
Removal.....1093
Installation.....1093
Removal and installation of revolving frame assembly.....1094
Removal.....1094
Installation.....1096
Removal and installation of centre swivel joint.....1097
Removal.....1097
Installation.....1099
Disassembly and assembly of centre swivel joint assembly.....1100
Special tools.....1100
Disassembly.....1100
Assembly.....1101
Removal and installation of fuel tank assembly.....1102
Removal.....1102
Installation.....1103
Removal and installation of hydraulic tank assembly.....1104
Removal.....1104
Installation.....1106
Removal and installation of control valve assembly.....1107
Removal.....1107
Installation.....1109
Removal and installation of LS separation valve assembly.....1110
Removal.....1110
Installation.....1110
Removal and installation of pressure compensation valve assembly.....1111
Removal.....1111
Installation.....1111
Removal and installation of main relief valve assembly.....1112
Removal.....1112
Installation.....1112
Removal and installation of LS control EPC valve.....1113
Removal.....1113
Installation.....1113
Removal and installation of PC EPC valve assembly.....1114
Removal.....1114
Installation.....1114
Removal and installation of PPC valve block assembly.....1115
Removal.....1115
Installation.....1115
Removal and installation of oil seal in hydraulic pump input shaft.....1116
Special tools.....1116
Removal.....1116
Installation.....1116
Disassembly and assembly of work equipment PPC valve.....1117
Assembly.....1117
Disassembly and assembly of hydraulic cylinder.....1118
Special tools.....1118
Disassembly.....1118
Assembly.....1120
Removal and installation of monoboom work equipment.....1124
Special tools.....1124
Removal.....1124
Installation.....1125
Removal and installation of 2 piece boom work equipment.....1126
Special tools.....1126
Removal.....1126
Installation.....1127
Removal and installation of air conditioner unit.....1128
Special tools.....1128
Removal.....1128
Installation.....1131
Removal and installation of counterweight.....1132
Removal.....1132
Installation.....1133
Removal and installation of operator cab assembly.....1134
Removal.....1134
Installation.....1135
Removal and installation of monitor assembly.....1136
Removal.....1136
Installation.....1136
Removal and installation of pump controller assembly.....1137
Removal.....1137
Installation.....1137
Removal and installation of engine controller assembly.....1138
Removal.....1138
Installation.....1139
Removal and Installation of KOMTRAX terminal.....1140
Removal.....1140
Installation.....1140
OTHER.....1141
Hydraulic circuit diagram (1/3).....1143
Hydraulic circuit diagram (2/3).....1144
Hydraulic circuit diagram (3/3).....1145
Electrical circuit diagram (cabin 1/4).....1146
Electrical circuit diagram (cabin 2/4).....1147
Electrical circuit diagram (cabin 3/4).....1148
Electrical circuit diagram (cabin 4/4).....1149
Electrical circuit diagram (machine 1/4)).....1150
Electrical circuit diagram (machine 2/4)).....1151
Electrical circuit diagram (machine 3/4)).....1152
Electrical circuit diagram (machine 4/4)).....1153
Connector diagramm 1/5.....1154
Connector table for revolving frame harness.....1154
Connector diagram 2/5.....1155
Connector table for operators cab wiring harness (Part 1/2).....1155
Connector diagram 3/5.....1156
Connector table for operators cab wiring harness (Part 2/2).....1156
Connector diagram (4/5).....1157
Connector table various wiring harness (Part 1/2).....1157
Connector diagram (5/5).....1158
Connector table various wiring harness (Part 2/2).....1158
