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KOMATSU PW180-7 PLUS SHOP MANUAL VENBM64000 – PDF DOWNLOAD
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Description
KOMATSU PW180-7 PLUS SHOP MANUAL VENBM64000 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PW180-7 PLUS SHOP MANUAL VENBM64000 – PDF DOWNLOAD
Language : English
Pages : 1242
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PW180-7 PLUS SHOP MANUAL VENBM64000 – PDF DOWNLOAD
VENBM64000 PW180-7 Plus.............................................................................................. 1 FOREWORD............................................................................................................. 5 Safety notice.................................................................................................... 5 Important safety notice...................................................................................... 5 General precautions.......................................................................................... 5 Preparations for work........................................................................................ 5 Precautions during work...................................................................................... 6 Foreword......................................................................................................... 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 1 Piece boom............................................................................................. 24 Dimensions................................................................................................... 26 2 Piece boom............................................................................................. 26 Working ranges................................................................................................... 28 1 Piece boom................................................................................................. 28 2 Piece boom................................................................................................. 29 Specifications................................................................................................... 30 Weight table..................................................................................................... 32 1 Piece boom................................................................................................. 33 2 Piece boom................................................................................................. 34 Fuel, coolant and lubricants..................................................................................... 35 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD......................................................................... 37 Engine related parts............................................................................................. 38 Outline...................................................................................................... 38 Radiator – oil cooler – charge air cooler........................................................................ 39 Specifications............................................................................................... 39 Power train...................................................................................................... 40 Swing circle..................................................................................................... 42 Specifications............................................................................................... 42 Swing machinery & motor.......................................................................................... 43 Swing motor...................................................................................................... 46 Specifications............................................................................................... 46 Operation of swing lock...................................................................................... 50 Relief valve portion......................................................................................... 51 Operation................................................................................................ 51 Undercarriage.................................................................................................... 52 Transmission..................................................................................................... 54 Specifications............................................................................................... 54 Function..................................................................................................... 55 Quick coupler control valve...................................................................................... 58 Specification................................................................................................ 58 Operation.................................................................................................... 58 Shematic..................................................................................................... 59 ATT EPC valve assembly........................................................................................... 60 Travel motor..................................................................................................... 61 Specifications............................................................................................... 61 Function..................................................................................................... 62 Operation of travel motor.................................................................................... 63 Clutch control circuit........................................................................................... 66 Function..................................................................................................... 67 Axle............................................................................................................. 68 Outline...................................................................................................... 68 Suspension lock cylinder......................................................................................... 72 Specifications............................................................................................... 72 Structure and function....................................................................................... 72 Circuit...................................................................................................... 73 Braking system................................................................................................... 74 Structure and function....................................................................................... 75 Brake/steer pump................................................................................................. 76 Specifications............................................................................................... 76 Function..................................................................................................... 76 Priority valve................................................................................................... 77 Specification................................................................................................ 77 Function..................................................................................................... 77 Power brake valve................................................................................................ 78 Specifications............................................................................................... 78 Function..................................................................................................... 79 Accumulator for brake valve...................................................................................... 80 Specifications............................................................................................... 80 Structure and function....................................................................................... 80 Steering system.................................................................................................. 81 Structure and function....................................................................................... 81 Steering column.................................................................................................. 82 Orbitrol valve................................................................................................... 83 Specifications............................................................................................... 83 Structure and function....................................................................................... 83 Hydraulic equipment layout drawings.............................................................................. 84 Hydraulic circuit diagram........................................................................................ 86 Hydraulic tank................................................................................................... 87 Specifications............................................................................................... 87 Hydraulic pump................................................................................................... 88 HPV125....................................................................................................... 88 Function..................................................................................................... 90 Structure.................................................................................................... 90 Operation.................................................................................................... 91 LS valve..................................................................................................... 93 PC valve..................................................................................................... 94 Function................................................................................................. 95 Operation................................................................................................ 96 LS(PC)-EPC Valve............................................................................................. 107 Function................................................................................................. 108 Operation................................................................................................ 108 Pilot pressure control (PPC) system.............................................................................. 110 Function..................................................................................................... 111 Operation.................................................................................................... 111 Control valve.................................................................................................... 112 Outline...................................................................................................... 112 CLSS............................................................................................................. 123 Outline of CLSS.............................................................................................. 123 Features................................................................................................. 123 Structure................................................................................................ 123 Basic principle.............................................................................................. 124 Operation for each function and valve........................................................................ 126 Hydraulic circuit diagram and name of valves............................................................. 126 1. Unload valve.............................................................................................. 128 Function................................................................................................. 128 Operation................................................................................................ 128 Operation................................................................................................ 129 Operation................................................................................................ 130 2. Introduction of LS pressure............................................................................... 131 Work equipment valve..................................................................................... 131 Function................................................................................................. 131 Operation................................................................................................ 131 3. LS bypass plug............................................................................................ 132 Outline.................................................................................................. 132 Operation................................................................................................ 132 4. Pressure compensation valve............................................................................... 134 Function................................................................................................. 134 Operation................................................................................................ 135 5. Area ratio of pressure compensation valve................................................................. 136 Function................................................................................................. 136 6. Boom regeneration circuit................................................................................. 138 Function................................................................................................. 138 Operation................................................................................................ 138 Function................................................................................................. 139 Operation................................................................................................ 139 7. Arm regeneration circuit.................................................................................. 140 Function................................................................................................. 140 Operation................................................................................................ 140 Function................................................................................................. 141 Operation................................................................................................ 141 8. Swing bleeding valve...................................................................................... 142 Function................................................................................................. 142 Operation (In fine control operation).................................................................... 142 9. Variable type pressure compensation valve (for service)................................................... 143 Function................................................................................................. 143 Simultaneous operation with work equipment under heavy load (boom RAISE, etc.)........................... 143 10. LS select valve.......................................................................................... 144 Function................................................................................................. 144 Operation................................................................................................ 144 Centre swivel joint.............................................................................................. 145 Travel PPC pedal................................................................................................. 146 Work equipment – swing PPC valve................................................................................. 148 Operation.................................................................................................... 150 Solenoid valve block............................................................................................. 152 ON / OFF Solenoid valves (3 way valve)....................................................................... 154 Operation................................................................................................ 154 ON / OFF Solenoid valves (4 way valve)....................................................................... 156 Operation................................................................................................ 156 Hi/ Lo Solenoid valve (4 way valve)...................................................................... 158 Operation................................................................................................ 158 Attachment EPC valve......................................................................................... 160 Function................................................................................................. 161 Operation................................................................................................ 161 Boom safety valve................................................................................................ 164 Operation.................................................................................................... 165 Hydraulic cylinder............................................................................................... 166 Boom cylinder................................................................................................ 166 Arm cylinder................................................................................................. 166 Bucket cylinder.............................................................................................. 166 Adjust cylinder.............................................................................................. 167 Outrigger cylinder............................................................................................... 168 Function..................................................................................................... 169 Important – Depressurising the cylinder...................................................................... 169 Depressurise the cylinder before opening..................................................................... 169 Dozer cylinder................................................................................................... 170 Function..................................................................................................... 171 Important – Depressurising the cylinder...................................................................... 171 Depressurise the cylinder before opening..................................................................... 171 Work equipment................................................................................................... 172 Work Equipment............................................................................................... 173 1. Dimension of arm.......................................................................................... 174 2. Dimension of bucket....................................................................................... 176 Air conditioner.................................................................................................. 178 Air conditioner piping....................................................................................... 178 Electrical wiring diagram........................................................................................ 179 Electrical system................................................................................................ 180 Engine Control............................................................................................... 180 Function................................................................................................. 181 Engine controller............................................................................................ 182 CN-CE01.................................................................................................. 182 CN-CE01.................................................................................................. 183 CN-CE02.................................................................................................. 183 CN-CE03.................................................................................................. 183 Pump controller.............................................................................................. 184 Input signals............................................................................................ 185 Output signals........................................................................................... 186 Electronic control system........................................................................................ 187 Machine control system diagram............................................................................... 188 1. Engine and pump control function...................................................................... 189 Function................................................................................................. 190 2. Pump/Valve control function........................................................................... 194 Function................................................................................................. 194 3. One-touch power maximizing function................................................................... 196 Function................................................................................................. 196 4. Auto-deceleration function............................................................................ 198 Function................................................................................................. 198 Operation................................................................................................ 199 5 Auto-warm-up/Overheat and White Smoke prevention function.............................................. 200 Function................................................................................................. 200 6. Swing control function................................................................................ 202 Function................................................................................................. 202 7. Travel control function............................................................................... 204 Function................................................................................................. 204 8. ATT flow control, ATT direction control............................................................... 206 9. System component parts................................................................................ 207 Function................................................................................................. 207 Specifications........................................................................................... 208 Function................................................................................................. 208 Function................................................................................................. 209 Operation................................................................................................ 209 Machine monitor system........................................................................................... 210 Monitor panel................................................................................................ 211 Outline.................................................................................................. 211 Input and output signals................................................................................. 212 Monitor control, display portion......................................................................... 214 Monitor items and display................................................................................ 216 Monitor Gauge Displays................................................................................... 218 Keypad layout............................................................................................ 223 Declaration of switch function on keypad................................................................. 224 Overload warning device.......................................................................................... 226 Outline...................................................................................................... 226 Function................................................................................................. 226 Structure................................................................................................ 226 Sensor........................................................................................................... 227 Coolant temperature sensor................................................................................... 228 Oil pressure switch.......................................................................................... 228 Rotation sensor.............................................................................................. 229 Boost pressure and temperature sensor........................................................................ 229 WIF (Water-In-Fuel detection) sensor......................................................................... 230 Engine oil level sensor...................................................................................... 230 Coolant level sensor......................................................................................... 231 Coolant temperature sensor................................................................................... 232 Fuel level sensor............................................................................................ 232 Air cleaner clogging sensor.................................................................................. 233 Overload Caution sensor...................................................................................... 233 Swing proximity sensor....................................................................................... 234 Travel PPC sensor............................................................................................ 234 PPC pressure sensor.......................................................................................... 234 Park brake pressure sensor................................................................................... 235 Brake accumulator low pressure sensor........................................................................ 235 Brake stop light sensor...................................................................................... 235 1st Attachment circuit hydraulic performance (main valve bypassed)............................................... 236 Travel system.................................................................................................... 237 Travel circuit............................................................................................... 237 1. Travel motor.......................................................................................... 238 2. Travel pedal.......................................................................................... 247 3. Forward / Neutral / Reverse switch (F-N-R)............................................................ 248 4. Forward / Reverse travel solenoid..................................................................... 249 5. Travel / Neutral solenoid............................................................................. 250 6. Travel creep solenoid................................................................................. 251 7. 2-Stage relief solenoid............................................................................... 252 8. Transmission clutch control valve..................................................................... 254 Steering system.................................................................................................. 255 Operating principles......................................................................................... 255 Dynamic steering......................................................................................... 255 2 - Stage principle...................................................................................... 255 1. Condition 1........................................................................................... 256 2. Condition 2........................................................................................... 257 3. Condition 3........................................................................................... 258 4. Condition 4........................................................................................... 259 5. Condition 5........................................................................................... 260 6. Condition 6........................................................................................... 261 7. OLS Priority valve.................................................................................... 262 8. Load sensing steering unit............................................................................ 263 Service brake and suspension system.............................................................................. 268 Braking system............................................................................................... 268 Operation.................................................................................................... 271 Komtrax terminal system.......................................................................................... 273 Central lubrication system (CLS)................................................................................. 275 Auto-grease pump............................................................................................. 275 Overview..................................................................................................... 276 Display and control unit..................................................................................... 276 LED-display.................................................................................................. 277 Push buttons................................................................................................. 277 Three-digit LED display...................................................................................... 278 Check central lubrication system, fill up grease............................................................. 279 Lubrication diagram.............................................................................................. 280 Standard value table for engine related parts.................................................................... 282 Standard value table for chassis related parts................................................................... 283 Flow control characteristic of PC valve (STD).................................................................... 295 STANDARD VALUE TABLE................................................................................................. 281 Measuring engine speed........................................................................................... 298 Measuring intake air pressure (boost pressure)................................................................... 299 Measurement of exhaust gas colour................................................................................ 300 Adjusting valve clearance........................................................................................ 302 Measuring compression pressure................................................................................... 304 Measuring blow-by pressure....................................................................................... 306 Measuring engine oil pressure.................................................................................... 307 Handling fuel system parts....................................................................................... 308 Releasing residual pressure from fuel system..................................................................... 309 Measuring fuel pressure.......................................................................................... 310 Measuring fuel return rate and leakage........................................................................... 312 Bleeding air from fuel circuit................................................................................... 314 Air bleeding route of fuel circuit........................................................................... 315 Checking fuel circuit for leakage............................................................................ 316 Checking and adjusting air conditioner compressor belt tension................................................... 317 Checking..................................................................................................... 317 Adjusting.................................................................................................... 317 Replacing the fan belt........................................................................................... 318 Measurement of clearance in swing circle bearings................................................................ 319 Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel.... 320 Measurement.................................................................................................. 320 Adjustment................................................................................................... 321 Inspection and adjustment of control circuit oil pressure........................................................ 323 Measurement.................................................................................................. 323 Procedure for pressure reducing adjustment................................................................... 324 Inspection and adjustment of pump PC (valve inlet) control oil pressure.......................................... 325 Measurement.................................................................................................. 325 Adjustment................................................................................................... 327 Inspection and adjustment of pump LS valve control oil pressure.................................................. 328 Measurement.................................................................................................. 328 Adjustment................................................................................................... 331 Measurement of solenoid valve output pressure.................................................................... 332 Solenoid valve block......................................................................................... 334 Measurement of PPC valve output pressure......................................................................... 336 Checking proportional control PPC circuit.................................................................... 337 Adjustment of work equipment and swing PPC valve................................................................. 338 Measuring and adjusting quick coupler control valve output pressure.............................................. 339 Testing travel motor relief pressure............................................................................. 340 Measuring travel motor relief pressure....................................................................... 340 Adjusting travel motor relief pressure........................................................................... 341 Testing propshaft speed.......................................................................................... 342 Measuring rotating speed of propshaft........................................................................ 342 Testing transmission clutch control circuit...................................................................... 344 Description.................................................................................................. 344 Inspection of locations of hydraulic drift of work equipment..................................................... 346 Release of remaining pressure in hydraulic circuit............................................................... 348 Measurement of oil leakage....................................................................................... 349 Air bleeding of various parts.................................................................................... 352 Inspection procedures for diode.................................................................................. 355 Special function of monitor panel................................................................................ 356 Changing the lubrication interval times.......................................................................... 414 TESTING AND ADJUSTING................................................................................................ 297 TROUBLESHOOTING...................................................................................................... 415 Troubleshooting.................................................................................................. 415 Points to remember when troubleshooting.......................................................................... 416 Sequence of events in troubleshooting............................................................................ 417 Points to remember when carrying out maintenance................................................................. 418 1. Points to remember when handling electric equipment....................................................... 418 2. Points to remember when troubleshooting electric circuits................................................. 424 3. Points to remember when handling hydraulic equipment...................................................... 425 Checks before troubleshooting.................................................................................... 427 Classification and steps for troubleshooting..................................................................... 428 Classification of troubleshooting............................................................................ 428 Steps for troubleshooting................................................................................ 428 Failure-looking phenomenon and troubleshooting no................................................................ 429 How to read electric wire code............................................................................... 432 Connector location chart and circuit diagram by system........................................................... 437 Connector table.............................................................................................. 438 Connection table for connector pin numbers....................................................................... 451 T-boxes and T-adapters table................................................................................. 479 Before carrying out troubleshooting when failure code is displayed............................................... 486 Information contained in troubleshooting table................................................................... 488 Relative circuit diagram..................................................................................... 489 Failure code [2G00MA] – Brake oil pressure abnormality........................................................... 490 Circuit diagram related to brake oil pressure switch......................................................... 490 Failure code [6B2JMA] – Travel hydraulic abnormality............................................................. 491 Failure code [989L00] – Engine controller lock caution 1......................................................... 491 Failure code [989M00] – Engine controller lock caution 2......................................................... 492 Failure code [989N00] – Engine controller lock caution 3......................................................... 492 Failure code [AA10NX] – Air cleaner clogging..................................................................... 493 Failure code [AB00KE] – Charge voltage low....................................................................... 494 Failure code [B@BAZG] – Engine oil pressure low.................................................................. 495 Failure code [B@BAZK] – Engine oil level low..................................................................... 495 Failure code [B@BCNS] – Engine water overheat.................................................................... 496 Failure code [B@BCZK] – Engine coolant level low................................................................. 496 Failure code [B@HANS] – Hydraulic oil overheat................................................................... 497 Failure code [CA111] – EMC critical internal failure............................................................. 497 Failure code [CA115] – Engine neutral and backup speed sensor error.............................................. 498 Failure code [CA122] – Charge air press sensor high error........................................................ 500 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 501 Failure code [CA123] – Charge air press sensor low error......................................................... 502 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 503 Failure code [CA131] – Throttle sensor high error................................................................ 504 Circuit diagram related to fuel control dial................................................................. 505 Failure code [CA132] – Throttle sensor low error................................................................. 506 Circuit diagram related to fuel control dial................................................................. 507 Failure code [CA144] – Coolant temperature sensor high error..................................................... 508 Circuit diagram related to coolant temperature sensor........................................................ 509 Failure code [CA145] – Coolant temp sensor low error............................................................. 510 Circuit diagram related to coolant temperature sensor........................................................ 511 Failure code [CA153] – Charge air temperature sensor high error.................................................. 512 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 513 Failure code [CA154] – Charge air temperature sensor low error................................................... 514 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 515 Failure code [CA155] – Charge air temperature high speed derate.................................................. 516 Failure code [CA187] – Sensor supply 2 voltage low error......................................................... 518 Circuit diagram related to sensor power supply 2............................................................. 519 Failure code [CA221] – Ambient press sensor high error........................................................... 520 Circuit diagram related to ambient pressure sensor........................................................... 521 Failure code [CA222] – Ambient press sensor low error............................................................ 522 Circuit diagram related to ambient pressure sensor........................................................... 523 Failure code [CA227] – Sensor supply 2 volt high error........................................................... 524 Circuit diagram related to sensor power supply 2............................................................. 524 Failure code [CA234] – Engine overspeed.......................................................................... 525 Failure code [CA238] – NE speed sensor supply voltage error...................................................... 526 Circuit diagram related to engine NE speed sensor............................................................ 526 Failure code [CA271] – IMV/PCV1 short circuit error.............................................................. 527 Circuit diagram related to supply pump actuator (metering unit).............................................. 527 Failure code [CA272] – IMV/PCV1 open error....................................................................... 528 Circuit diagram related to supply pump actuator (metering unit).............................................. 528 Failure code [CA322] – Injector #1 (L#1) open/short circuit error................................................ 530 Circuit diagram related to no. 1 injector.................................................................... 531 Failure code [CA324] – Injector #3 (L#3) open/short circuit error................................................ 532 Circuit diagram related to no. 3 injector.................................................................... 533 Failure code [CA331] – Injector #2 (L#2) open/short circuit error................................................ 534 Circuit diagram related to no. 4 injector.................................................................... 537 Failure code [CA342] – Calibration code incompatibility.......................................................... 538 Failure code [CA351] – Injectors drive circuit error............................................................. 540 Circuit diagram related to engine controller................................................................. 541 Failure code [CA352] – Sensor power supply 1 voltage low error................................................... 542 Circuit diagram related to sensor power supply 1............................................................. 543 Failure code [CA386] – Sensor power supply 1 voltage high error.................................................. 544 Circuit diagram related to sensor power supply 1............................................................. 544 Failure code [CA428] – Water-in-fuel sensor high error........................................................... 546 Circuit diagram related to water-in-fuel sensor.............................................................. 547 Failure code [CA429] – Water-in-fuel sensor low error............................................................ 548 Circuit diagram related to water-in-fuel sensor.............................................................. 549 Failure code [CA435] – Engine oil pressure switch error.......................................................... 550 Circuit diagram related to engine oil pressure switch........................................................ 550 Failure code [CA441] – Battery voltage low error................................................................. 551 Circuit diagram related to engine controller power supply.................................................... 553 Failure code [CA442] – Battery voltage high error................................................................ 554 Circuit diagram related to engine controller power supply.................................................... 555 Failure code [CA449] – Common rail pressure very high error...................................................... 556 Failure code [CA451] – Common rail pressure sensor high error.................................................... 558 Circuit diagram related to common rail pressure sensor....................................................... 559 Failure code [CA452] – Common rail pressure sensor low error..................................................... 560 Circuit diagram related to common rail pressure sensor....................................................... 561 Failure code [CA488] – Charge air temperature high torque derate................................................. 562 Failure code [CA553] – Common rail pressure high error........................................................... 562 Failure code [CA559] – Common rail pressure low error............................................................ 563 Failure code [CA689] – Engine Ne speed sensor error.............................................................. 564 Circuit diagram related to engine Ne speed sensor............................................................ 565 Failure code [CA731] – Engine G speed sensor phase error......................................................... 566 Failure code [CA757] – All continuous data lost error............................................................ 568 Circuit diagram related to engine controller power supply.................................................... 569 Failure code [CA778] – Engine G speed sensor error............................................................... 570 Circuit diagram related to engine G speed sensor............................................................. 571 Failure code [CA1633] – KOMNET Datalink timeout error............................................................ 572 Circuit diagram related to CAN communication................................................................. 573 Failure code [CA2185] – Throttle sensor supply voltage high error................................................ 574 Circuit diagram related to fuel control dial................................................................. 574 Failure code [CA2186] – Throttle sensor supply voltage low error................................................. 575 Circuit diagram related to fuel control dial................................................................. 575 Failure code [CA2249] – Common rail pressure very low error...................................................... 576 Failure code [CA2311] – IMV solenoid error....................................................................... 578 Circuit diagram related to supply pump actuator (metering unit).............................................. 579 Failure code [CA2555] – Grid heater relay volt high error........................................................ 580 Circuit diagram related to engine preheater/starting motor/charging system................................... 581 Failure code [CA2556] – Grid heater relay volt low error......................................................... 582 Circuit diagram related to engine preheater/starting motor/charging system................................... 583 Failure code [D110KB] – Short circuit in battery relay........................................................... 584 Circuit diagram for battery relay – Pump controller.......................................................... 585 Failure code [D19JKZ] – Personal code relay abnormality.......................................................... 586 Circuit diagram related to engine preheater/starting motor/charging system................................... 587 Failure code [D862KA] – GPS antenna disconnection................................................................ 588 Configuration diagram of KOMTRAX system...................................................................... 588 Failure code [DA22KK] – Pump solenoid power supply voltage low error............................................. 590 Circuit diagram related to solenoid power supply............................................................. 591 Failure code [DA25KP] – Pressure sensor power abnormality........................................................ 592 Circuit diagram related to pressure sensor power supply of pump controller................................... 593 Failure code [DA26KP] – 5V sensor 2 power abnormality............................................................ 594 Circuit diagram related to 5V sensor......................................................................... 594 Failure code [DA29KQ] – Model selection abnormality.............................................................. 596 Circuit diagram related to model selection abnormality....................................................... 597 Failure code [DA2RMC] – CAN disconnection (Pump controller detected.............................................. 598 Circuit diagram related to CAN communication................................................................. 599 Failure code [DAF8KB] – Short circuit in camera power supply..................................................... 600 Circuit diagram related to camera power supply............................................................... 601 Failure code [DAFGMC] – GPS module operation error............................................................... 602 Failure code [DAFRMC] – CAN disconnection (monitor detected...................................................... 604 Circuit diagram related to CAN communication................................................................. 605 Failure code [DDP4KX] – Disconnection in travel PPC pressure switch.............................................. 606 Circuit diagram for travel PPC pressure switch............................................................... 607 Failure code [DDWCKZ] – Disconnection in direction control switches.............................................. 608 Circuit diagram for travel direction control switch (S/N H60051 - H60103).................................... 609 Circuit diagram for travel direction control switch (S/N H60104 and up)...................................... 609 Failure code [DFB1KZ] – Service lever potentiometer 1 abnormality................................................ 610 Circuit diagram for PPC control switches..................................................................... 611 Failure code [DFB2KZ] – 2nd ATT service lever main potentio 2 abnormality........................................ 612 Circuit diagram for PPC control switches..................................................................... 613 Failure code [DFB3L8] – RH Lever potentiometer (for 1st ATT) has failure......................................... 614 Failure code [DFB4L8] – 2nd ATT service lever potentio 2 error................................................... 615 Failure code [DFB5KZ] – 1st ATT service lever main potentio 1 abnormality........................................ 616 Circuit diagram for PPC control switches..................................................................... 617 Failure code [DFB6KZ] – Service lever potentiometer 2 abnormality................................................ 618 Circuit diagram for PPC control switches..................................................................... 619 Failure code [DGH2KB] – Hydraulic oil temperature sensor short circuit........................................... 620 Circuit diagram related to hydraulic oil temperature sensor.................................................. 621 Failure code [DH10KS] – Abnormality in 24V sensor power source................................................... 622 Circuit diagram for 24V sensor power source.................................................................. 623 Failure code [DHPAMA] – F pump press sensor abnormality.......................................................... 624 Circuit diagram related to pump pressure sensor of pump controller........................................... 625 Failure code [DHS5KX] – Abnormality in travel PPC sensor......................................................... 626 Circuit diagram related to Travel PPC sensor................................................................. 627 Failure code [DHX1MA] – Overload sensor abnormality (analog)..................................................... 628 Circuit diagram for overload caution......................................................................... 629 Failure code [DLT4KA] – Disconnection in transmission speed sensor............................................... 630 Circuit diagram for transmission speed sensor power source................................................... 631 Failure code [DW27KA] – Disconnection in transmission clutch solenoid............................................ 632 Circuit diagram for transmission clutch solenoid in pump controller.......................................... 633 Failure code [DW27KB] – Short circuit in transmission clutch solenoid............................................ 634 Circuit diagram for transmission clutch solenoid............................................................. 635 Failure code [DW4AKA] – Disconnection in suspension lock solenoid................................................ 636 Circuit diagram for suspension lock solenoid in pump controller.............................................. 637 Failure code [DW4AKB] – Short circuit in suspension lock solenoid................................................ 638 Circuit diagram for suspension lock solenoid in pump controller.............................................. 639 Failure code [DW4CKA] – Disconnection in PPC lock solenoid....................................................... 640 Circuit diagram for PPC lock solenoid in pump controller..................................................... 641 Failure code [DW4CKB] – PPC lock sol. S/C........................................................................ 642 Circuit diagram related to swing holding brake solenoid of pump controller................................... 643 Failure code [DW4MKA] – Disconnection in creep solenoid.......................................................... 644 Circuit diagram for creep solenoid in pump controller........................................................ 644 Failure code [DW4MKB] – Short circuit in creep solenoid.......................................................... 645 Circuit diagram for creep solenoid in pump controller........................................................ 645 Failure code [DW44KA] – Disconnection in travel F/R solenoid..................................................... 646 Circuit diagram for travel F/R solenoid...................................................................... 647 Failure code [DW44KB] – Short circuit in travel F/R solenoid..................................................... 648 Circuit for travel F/R solenoid in pump controller........................................................... 649 Failure code [DW45KA] – Disconnection in swing parking brake solenoid............................................ 650 Circuit diagram for swing and parking brake solenoid in pump controller...................................... 651 Failure code [DW45KB] – Swing holding brake solenoid short circuit............................................... 652 Circuit diagram related to swing holding brake solenoid of pump controller................................... 653 Failure code [DW91KA] – Disconnection in travel neutral solenoid................................................. 654 Circuit diagram for travel neutral solenoid.................................................................. 655 Failure code [DW91KB] – Short circuit in travel neutral solenoid................................................. 656 Circuit diagram for travel neutral solenoid.................................................................. 657 Failure code [DWB1KA] – Disconnection in outrigger operation solenoid............................................ 658 Circuit diagram for outrigger operation solenoid............................................................. 659 Failure code [DWB1KB] – Short circuit in outrigger operation solenoid............................................ 660 Circuit diagram for outrigger operation solenoid............................................................. 661 Failure code [DWB2KA] – Disconnection in 1st outrigger solenoid.................................................. 662 Circuit diagram for outrigger solenoid....................................................................... 663 Failure code [DWB2KB] – Short circuit in 1st outrigger solenoid.................................................. 664 Circuit diagram for outrigger solenoid....................................................................... 665 Failure code [DWB3KA] – Disconnection in 2nd outrigger solenoid.................................................. 666 Circuit diagram for outrigger solenoid....................................................................... 667 Failure code [DWB3KB] – Short circuit in 2nd outrigger solenoid.................................................. 668 Circuit diagram for outrigger solenoid....................................................................... 669 Failure code [DWB4KA] – Disconnection in 3rd outrigger solenoid.................................................. 670 Circuit diagram for outrigger solenoid....................................................................... 671 Failure code [DWB4KB] – Short circuit in 3rd outrigger solenoid.................................................. 672 Circuit diagram for outrigger solenoid....................................................................... 673 Failure code [DWB5KA] – Disconnection in 4th outrigger solenoid.................................................. 674 Circuit diagram for outrigger solenoid....................................................................... 675 Failure code [DWB5KB] – Short circuit in 4th outrigger solenoid.................................................. 676 Circuit diagram for outrigger solenoid....................................................................... 677 Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid................................................. 678 Circuit diagram for 2-stage relief solenoid in pump controller............................................... 678 Failure code [DWK0KB] – Short circuit in 2-stage relief solenoid................................................. 679 Electric circuit diagram for 2-stage relief solenoid in pump controller...................................... 679 Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid.......................................... 680 Circuit diagram for 2-stage back pressure solenoid in pump controller........................................ 680 Failure code [DWK2KB] – Short circuit in 2-stage back pressure solenoid.......................................... 681 Circuit diagram for 2-stage back pressure solenoid in pump controller........................................ 681 Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system.............................................. 682 Circuit diagram for PC-EPC solenoid in pump controller....................................................... 683 Failure code [DXA8KB] – Short circuit in PC-EPC (F) solenoid..................................................... 684 Circuit diagram for PC-EPC solenoid in pump controller....................................................... 685 Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system.................................................. 686 Circuit diagram for LS-EPC solenoid in pump controller....................................................... 686 Failure code [DXE0KB] – Short circuit in LS-EPC solenoid......................................................... 687 Circuit diagram for LS-EPC solenoid in pump controller....................................................... 687 Failure code [DXEAKA] – Service Current EPC1 Open Circuit (left hand)............................................ 688 Circuit diagram related to the 1st and 2nd service EPC solenoids............................................. 689 Failure code [DXEAKB] – Service current EPC1 solenoid short (left hand).......................................... 690 Circuit diagram related to the 1st and 2nd service EPC solenoids............................................. 691 Failure code [DXE7KA] – Service current EPC2 solenoid disconnection (right hand)................................. 692 Circuit diagram related to the 1st and 2nd service EPC solenoids............................................. 693 Failure code [DXE7KB] – Service current EPC solenoid short (right hand).......................................... 694 Circuit diagram related to the 1st and 2nd service EPC solenoids............................................. 695 Failure code [DXE8KA] – Service current EPC solenoid disconnection (left hand)................................... 696 Circuit diagram related to the 1st and 2nd service EPC solenoids............................................. 697 Failure code [DXE8KB] – Service current EPC3 solenoid short (left hand).......................................... 698 Circuit diagram related to the 1st and 2nd service EPC solenoids............................................. 699 Failure code [DXE9KA] – Service current EPC solenoid disconnection (right hand).................................. 700 Circuit diagram related to the 1st and 2nd service EPC solenoids............................................. 701 Failure code [DXE9KB] – Service current EPC solenoid short (right hand).......................................... 702 Circuit diagram related to the 1st and 2nd service EPC solenoids............................................. 703 Failure code [DXK3KA] – Travel pedal throttle EPC solenoid open circuit.......................................... 704 Circuit diagram related to travel pedal EPC valve............................................................ 704 Failure code [DXK3KB] – Travel pedal throttle EPC solenoid short circuit......................................... 705 Circuit diagram related to travel pedal EPC valve............................................................ 705 Failure code [DY20KA] – Wiper working abnormality................................................................ 706 Circuit diagram related to wiper motor of machine monitor.................................................... 707 Failure code [DY20MA] – Wiper parking abnormality................................................................ 708 Circuit diagram related to wiper motor of machine monitor.................................................... 709 Failure code [DY2CKA] – Window washer drive system disconnection................................................. 710 Circuit diagram related to wiper motor of machine monitor.................................................... 711 Failure code [DY2CKB] – Washer drive short circuit............................................................... 712 Circuit diagram related to window washer motor of machine monitor............................................ 713 Failure code [DY2DKB] – Wiper drive (fwd) short circuit.......................................................... 714 Circuit diagram related to wiper motor of machine monitor.................................................... 715 Failure code [DY2EKB] – Wiper drive (rev) short circuit.......................................................... 716 Circuit diagram related to wiper motor of machine monitor.................................................... 717 TROUBLESHOOTING...................................................................................................... 483 Troubleshooting when failure code is indicated................................................................... 483 Circuit diagram related to no. 2 injector.................................................................... 535 Failure code [CA332] – Injector #4 (L#4) open/short circuit error................................................ 536 Preparations for troubleshooting of electrical system............................................................ 720 Troubleshooting of electrical system (E-mode).................................................................... 724 Before carrying out troubleshooting of electrical system..................................................... 724 Location of fusible links................................................................................ 726 Location of fuse box and fuse numbers.................................................................... 726 Information contained in troubleshooting table................................................................... 727 E-1 When starting switch turned ON, machine monitor displays nothing............................................. 728 Circuit diagram related to machine monitor power supply...................................................... 729 E-2 When starting switch turned ON (before starting engine), basic check item lights up.......................... 730 Circuit diagram related to radiator coolant level switch..................................................... 730 Circuit diagram related to engine oil level switch........................................................... 731 E-3 Engine does not start (engine does not rotate)............................................................... 732 Circuit diagram for engine start, stop and battery charging.................................................. 734 E-4 Preheater does not operate................................................................................... 736 Circuit diagram related to engine preheater.................................................................. 737 E-5 Automatic warm-up system does not operate (in cold season)................................................... 738 E-6 All work equipment, swing and travel mechanism do not move or cannot be locked............................... 740 Circuit diagram for PPC lock solenoid........................................................................ 741 E-7 Precaution lights up while engine is running................................................................. 742 Circuit diagram related to engine preheater/starting motor/charging system................................... 743 Circuit diagram related to air cleaner clogging switch....................................................... 745 E-8 Emergency stop item lights up while engine is running........................................................ 748 Circuit diagram related to 2-stage relief solenoid........................................................... 749 E-9 Engine coolant temperature gauge does not indicate normally.................................................. 750 E-10 Hydraulic oil temperature gauge does not indicate normally.................................................. 751 E-11 Fuel level gauge does not indicate normally................................................................. 754 Circuit diagram related to fuel level sensor................................................................. 754 E-12 Contents of display by machine monitor are different from applicable machine................................ 756 E-13 Machine monitor does not display some items................................................................. 756 E-14 Function switch does not work............................................................................... 756 E-15 Auto-decelerator does not operate normally.................................................................. 757 E-16 Working mode does not change................................................................................ 758 E-17 Travel speed does not change................................................................................ 759 Circuit diagram related to travel speed shifting solenoid.................................................... 759 E-18 Alarm buzzer cannot be stopped.............................................................................. 760 Circuit diagram for Quick Coupler system..................................................................... 761 E-19 Windshield wiper and window washer do not operate........................................................... 762 Circuit diagram related to windshield and window washer...................................................... 763 E-20 Power maximising function does not operate normally......................................................... 764 E-21 Swing holding brake does not operate normally............................................................... 765 Circuit diagram for Swing Lock switch........................................................................ 766 E-21 – "Boom/Stabiliser RAISE" is not correctly displayed in monitor function.................................... 767 Circuit diagram for boom RAISE PPC hydraulic switch.......................................................... 767 E-22 Travel alarm does not sound or does not stop sounding....................................................... 768 Circuit diagram for travel PPC hydraulic switch and travel alarm............................................. 769 E-23 Air conditioner does not operate normally (including air conditioner abnormality record).................... 770 Circuit diagram related to air conditioner................................................................... 780 E-24 When starting switch is turned OFF, service meter is not displayed.......................................... 781 E-25 Machine monitor cannot be set in service mode............................................................... 781 E-26 Monitoring function does not display lever control signal normally.......................................... 782 Circuit diagram for boom RAISE PPC hydraulic switch.......................................................... 782 Circuit diagram for boom LOWER PPC hydraulic switch.......................................................... 783 Circuit diagram for arm DIGGING PPC hydraulic switch......................................................... 784 Circuit diagram for arm DUMPING PPC hydraulic switch......................................................... 785 Circuit diagram for bucket DIGGING PPC hydraulic switch...................................................... 786 Circuit diagram for bucket DUMPING PPC hydraulic switch...................................................... 787 Circuit diagram for right and left swing PPC hydraulic switches.............................................. 789 Circuit diagram for travel PPC hydraulic switch and travel alarm............................................. 791 Circuit diagram for 2-piece boom PPC hydraulic switch........................................................ 793 E-27 KOMTRAX system does not operate normally.................................................................... 794 TROUBLESHOOTING...................................................................................................... 719 Troubleshooting of electrical system (E-Mode).................................................................... 719 Information in troubleshooting table............................................................................. 799 12V socket....................................................................................................... 800 Radio........................................................................................................ 801 PPC lock circuit................................................................................................. 802 Circuit diagram for PPC lock circuit......................................................................... 803 Brake light circuit.............................................................................................. 804 Circuit diagram for brake light circuit...................................................................... 805 Undercarriage attachments – Mode selection....................................................................... 806 Circuit diagram for undercarriage attachments – Mode selection............................................... 807 Undercarriage attachments - Mode activation...................................................................... 808 Circuit diagram for undercarriage attachments – Mode activation.............................................. 809 Undercarriage attachments – Front left outrigger................................................................. 810 Circuit diagram for undercarriage attachments – Mode selection............................................... 811 Undercarriage attachments – Front right outrigger................................................................ 812 Circuit diagram for undercarriage attachments – Mode selection............................................... 813 Undercarriage attachments – Rear left outrigger.................................................................. 814 Circuit diagram for undercarriage attachments – Mode selection............................................... 815 Undercarriage attachments – Rear right outrigger................................................................. 816 Circuit diagram for undercarriage attachments – Mode selection............................................... 817 Heated seat does not warm up..................................................................................... 818 Circuit diagram for the heated seat.......................................................................... 819 Suspension lock.................................................................................................. 820 Circuit diagram for suspension lock.......................................................................... 821 Lower wiper does not work (optional fitment)..................................................................... 822 Circuit diagram for lower wiper.............................................................................. 823 Work lights (operator cab front left)............................................................................ 824 Circuit diagram for work lights - Work light switch (1)...................................................... 825 Work lights (operator cab front right)........................................................................... 826 Circuit diagram for work lights - Work light switch (1)...................................................... 827 Work lights (operator cab rear).................................................................................. 828 Circuit diagram for work lights - work light switch (2)...................................................... 829 Work lights (Boom - left hand)................................................................................... 830 Circuit diagram for work lights - Work light switch (1)...................................................... 831 Work lights (Boom - right hand).................................................................................. 832 Circuit diagram for work lights - Work light switch (1)...................................................... 833 Work lights (Revolving frame - left hand)........................................................................ 834 Circuit diagram for work lights - Work light switch (1)...................................................... 835 Work lights (Revolving frame - right hand)....................................................................... 836 Circuit diagram for work lights - Work light switch (1)...................................................... 837 Work lights (Counterweight - left hand).......................................................................... 838 Circuit diagram for work lights - work light switch (2)...................................................... 839 Work Lights (Counterweight - right hand)......................................................................... 840 Circuit diagram for work lights - work light switch (2)...................................................... 841 Work Lights (Oil tank - side mount).............................................................................. 842 Circuit diagram for work lights - work light switch (2)...................................................... 843 Flashing beacon (operator’s cabin mount)......................................................................... 844 Circuit diagram for cabin, counterweight & fuel tank beacon light............................................ 845 Flashing beacon (Counterweight mount)............................................................................ 846 Circuit diagram for cab, counterweight & fuel tank beacon light.............................................. 847 Flashing beacon (Fuel tank mount)................................................................................ 848 Circuit diagram for cab, counterweight & fuel tank beacon light.............................................. 849 Air seat compressor (option – air suspension seat)............................................................... 850 Circuit diagram for air seat compressor (option – air suspension seat)....................................... 851 Operator’s cab interior light.................................................................................... 852 Circuit diagram for operator’s cab interior light............................................................ 853 Cigarette lighter................................................................................................ 854 Circuit diagram for cigarette lighter........................................................................ 855 Park brake (not activating)...................................................................................... 856 Circuit diagram for park brake............................................................................... 857 Park brake (displayed symbol).................................................................................... 858 Circuit diagram for park brake............................................................................... 859 RH PPC Lever clamshell roller switch pushed to the RH position................................................... 860 Circuit diagram for clamshell control........................................................................ 861 RH PPC Lever clamshell roller switch pushed to the RH or LH position............................................. 862 Circuit diagram for clamshell control........................................................................ 863 Horns............................................................................................................ 864 Circuit diagram for horn..................................................................................... 865 Swing lock – Normal operation.................................................................................... 866 Circuit diagram for swing lock............................................................................... 867 Swing lock – Emergency operation................................................................................. 868 Circuit diagram for swing lock............................................................................... 869 Neutral start (engine)........................................................................................... 870 Circuit diagram for neutral start (engine)................................................................... 871 Neutral start (engine) cont’d (A)................................................................................ 872 Circuit diagram for neutral start (engine)................................................................... 873 Neutral start (engine) cont’d (B)................................................................................ 874 Circuit diagram for neutral start (engine)................................................................... 875 Neutral start (engine) cont’d (C)................................................................................ 876 Circuit diagram for neutral start (engine)................................................................... 877 Emergency travel control – Forward............................................................................... 878 Circuit diagram for travel direction control................................................................. 879 Emergency travel control – Neutral............................................................................... 880 Circuit diagram for travel direction control................................................................. 881 Emergency travel control – Reverse............................................................................... 882 Circuit diagram for travel direction control................................................................. 883 Driving lights – Main beam....................................................................................... 884 Circuit diagram for driving lights........................................................................... 885 Driving lights – Main beam flash................................................................................. 886 Circuit diagram for driving lights........................................................................... 887 Driving lights – Main beam dipped................................................................................ 888 Circuit diagram for driving lights........................................................................... 889 Driving lights – Position lights................................................................................. 890 Driving lights - Position lights cont’d (1) and (2).......................................................... 891 Circuit diagram for driving lights........................................................................... 892 Indicators – Right hand.......................................................................................... 894 Circuit diagram for indicators & hazard warning.............................................................. 895 Indicators – Left hand........................................................................................... 896 Circuit diagram for indicators & hazard warning.............................................................. 897 Hazard warning lights............................................................................................ 898 Hazard warning lights cont’d (A)................................................................................. 899 Circuit diagram for indicators & hazard warning.............................................................. 900 Swing lock proximity switch...................................................................................... 902 Brake and swing lock proximity switches...................................................................... 903 TROUBLESHOOTING...................................................................................................... 797 Troubleshooting of electrical system (Error checking of items without monitor codes)............................. 797 System chart for hydraulic and mechanical systems................................................................ 906 Information contained in troubleshooting table................................................................... 910 H-1 – All work equipment lacks power, or travel and swing speeds are slow........................................ 911 H-2 – Engine speed sharply drops or engine stalls................................................................ 912 H-3 – No work equipment, travel or swing move.................................................................... 913 H-4 – Abnormal noise is heard from around hydraulic pump......................................................... 913 H-5 – Auto-decelerator does not work............................................................................. 914 H-6 – Fine control mode does not function........................................................................ 914 H-7 – Boom moves slowly or lacks power........................................................................... 915 H-8 – Arm moves slowly or lacks power............................................................................ 916 H-9 – Bucket moves slowly or lacks power......................................................................... 917 H-10 – Work equipment does not move in its single operation...................................................... 917 H-11 – Work equipment hydraulic drift is too fast................................................................ 918 H-12 – Work equipment has big time lag........................................................................... 919 H-13 – Other work equipment moves when relieving single circuit.................................................. 919 H-14 – One-touch power max. switch does not operate.............................................................. 920 H-15 – In compound operation, work equipment with larger load moves slowly....................................... 920 H-16 – In swing + boom RAISE operation, boom moves slowly........................................................ 920 H-17 – In swing + travel, travel speed drops sharply............................................................. 921 H-18 – Travel speed does not switch.............................................................................. 922 H-19 – Travel speed does not shift, or it is too slow or fast.................................................... 923 H-20 – Machine does not swing.................................................................................... 924 H-21 – Swing acceleration is poor, or swing speed is slow........................................................ 925 H-22 – Excessive overrun when stopping swing..................................................................... 926 H-23 – There is big shock when stopping swing.................................................................... 927 H-24 – There is loud abnormal noise caused when stopping swing................................................... 927 H-25 – Swing natural drift is too big............................................................................ 928 H-26 – Swing speed is faster than specified swing speed.......................................................... 928 Troubleshooting of engine (S-MODE)............................................................................... 931 Method of using troubleshooting chart........................................................................ 931 S-1 – Starting performance is poor............................................................................... 934 S-2 – Engine does not start...................................................................................... 935 S-3 – Engine does not pick up smoothly........................................................................... 938 S-4 – Engine stops during operations............................................................................. 939 S-5 – Engine does not rotate smoothly............................................................................ 940 S-6 – Engine lacks output (or lacks power)....................................................................... 941 S-7 – Exhaust smoke is black (incomplete combustion)............................................................. 942 S-8 – Oil consumption is excessive (or exhaust smoke is blue).................................................... 943 S-9 – Oil becomes contaminated quickly........................................................................... 944 S-10 – Fuel consumption is excessive............................................................................. 945 S-11 – Oil is in coolant (or coolant spurts back or coolant level goes down)..................................... 946 S-12 – Oil pressure drops........................................................................................ 947 S-13 – Oil level rises (Entry of coolant/fuel)................................................................... 948 S-14 – Coolant temperature becomes too high (overheating)........................................................ 949 S-15 – Abnormal noise is made.................................................................................... 950 S-16 – Vibration is excessive.................................................................................... 951 Troubleshooting of central lubrication system (CLS).............................................................. 952 Trouble...................................................................................................... 952 Troubleshooting during grease pump operation................................................................. 954 Pump element................................................................................................. 955 Check power supply........................................................................................... 956 Changing the control unit.................................................................................... 956 Troubleshooting – grease system faults....................................................................... 957 Venting of the system........................................................................................ 958 TROUBLESHOOTING...................................................................................................... 905 Troubleshooting of hydraulic, mechanical and central lubrication system.......................................... 905 Quick coupler.................................................................................................... 929 DISASSEMBLY AND ASSEMBLY............................................................................................. 963 How to read this manual.......................................................................................... 966 Removal and installation of assemblies....................................................................... 966 Special tools............................................................................................ 966 Removal of parts......................................................................................... 966 Installation of parts.................................................................................... 966 Coating materials list....................................................................................... 967 Special tools list........................................................................................... 970 Sketches of special tools.................................................................................... 973 List of tools................................................................................................ 974 Precautions when performing operation............................................................................ 976 Removal and installation of fuel supply pump assembly............................................................ 978 Removal...................................................................................................... 978 Installation................................................................................................. 979 Removal and installation of fuel injector assembly............................................................... 980 Special tools................................................................................................ 980 Removal...................................................................................................... 980 Installation................................................................................................. 984 Removal and installation of engine front seal.................................................................... 988 Special tools................................................................................................ 988 Removal...................................................................................................... 988 Installation................................................................................................. 989 Removal and installation of engine rear seal..................................................................... 990 Special tools................................................................................................ 990 Removal...................................................................................................... 990 Installation................................................................................................. 991 Removal and installation of cylinder head assembly............................................................... 994 Special tools................................................................................................ 994 Removal...................................................................................................... 994 Installation................................................................................................. 999 Removal and installation of combination cooler assembly..........................................................1006 Removal......................................................................................................1006 Installation.................................................................................................1008 Removal and installation of fuel cooler assembly.................................................................1009 Removal......................................................................................................1009 Installation.................................................................................................1009 Removal and installation of engine and hydraulic pump assemblies.................................................1010 Special tools................................................................................................1010 Removal......................................................................................................1010 Installation.................................................................................................1014 Removal and installation of engine hood assembly.................................................................1016 Removal......................................................................................................1016 Installation.................................................................................................1017 Removal and installation of travel motor assembly................................................................1018 Removal......................................................................................................1018 Installation.................................................................................................1019 Disassembly and assembly of travel motor assembly................................................................1020 Disassembly..................................................................................................1020 Assembly.....................................................................................................1022 Removal and installation of swing motor and swing machinery......................................................1024 Removal......................................................................................................1024 Installation.................................................................................................1025 Disassembly and assembly of swing machinery......................................................................1026 Special tools................................................................................................1026 Disassembly..................................................................................................1026 Assembly.....................................................................................................1029 Disassembly and assembly of swing motor assembly.................................................................1034 Special tools................................................................................................1034 Disassembly..................................................................................................1034 Assembly.....................................................................................................1037 Removal and installation of front axle assembly..................................................................1042 Removal......................................................................................................1042 Installation.................................................................................................1043 Disassembly and assembly of front axle...........................................................................1044 Disassembly of steering cylinder.............................................................................1044 Assembly of steering cylinder................................................................................1046 Disassembly of epicyclic reduction gear and brake............................................................1052 Assembly of epicylic reduction gear and brake................................................................1056 Disassembly of joint box.....................................................................................1064 Assembly of joint box........................................................................................1068 Disassembly of beam trumpet and differential unit............................................................1074 Assembly of beam trumpet and differential unit...............................................................1078 Disassembly of pinion group..................................................................................1084 Assembly of pinion group.....................................................................................1086 Toe-in adjustment............................................................................................1094 Steering angle adjustment....................................................................................1096 Removal and installation of rear axle and transmission...........................................................1098 Removal......................................................................................................1098 Installation.................................................................................................1100 Disassembly and assembly of rear axle assembly...................................................................1102 Special tools................................................................................................1102 Disassembly..................................................................................................1102 Removal of epicyclic reduction gear and brake................................................................1102 Installation of epicylic reduction gear and brake............................................................1106 Disassembly of beam trumpet and differential unit............................................................1114 Installation of beam trumpet and differential unit...........................................................1117 Disassembly of pinion group..................................................................................1118 Installation of pinion group.................................................................................1121 Disassembly and assembly of transmission.........................................................................1128 Special tools................................................................................................1128 Disassembly..................................................................................................1128 Removal and installation of propshaft assembly...................................................................1158 Removal......................................................................................................1158 Installation.................................................................................................1159 Removal and installation of wheel assembly.......................................................................1160 Removal......................................................................................................1160 Installation.................................................................................................1161 Removal and installation of suspension lock cylinder assembly....................................................1162 Removal......................................................................................................1162 Installation.................................................................................................1162 Disassembly and assembly of suspension lock cylinder.............................................................1163 Change rod seal..............................................................................................1163 Removal and installation of outrigger assembly...................................................................1164 Removal......................................................................................................1164 Installation.................................................................................................1165 Disassembly and assembly of outriggers...........................................................................1166 Disassembly..................................................................................................1166 Assembly.....................................................................................................1167 Removal and installation of dozer blade assembly.................................................................1168 Removal......................................................................................................1168 Installation.................................................................................................1168 Disassembly and assembly of dozer blade..........................................................................1170 Disassembly..................................................................................................1170 Assembly.....................................................................................................1171 Removal and installation of swing circle assembly................................................................1172 Removal......................................................................................................1172 Installation.................................................................................................1172 Removal and installation of revolving frame assembly.............................................................1174 Removal......................................................................................................1174 Installation.................................................................................................1176 Removal and installation of centre swivel joint..................................................................1178 Removal......................................................................................................1178 Installation.................................................................................................1180 Disassembly and assembly of centre swivel joint assembly.........................................................1182 Special tools................................................................................................1182 Disassembly..................................................................................................1182 Assembly.....................................................................................................1183 Removal and installation of fuel tank assembly...................................................................1184 Removal......................................................................................................1184 Installation.................................................................................................1185 Removal and installation of hydraulic tank assembly..............................................................1186 Removal......................................................................................................1186 Installation.................................................................................................1188 Removal and installation of control valve assembly...............................................................1190 Removal......................................................................................................1190 Installation.................................................................................................1193 Removal and installation of LS separation valve assembly.........................................................1194 Removal......................................................................................................1194 Installation.................................................................................................1194 Removal and installation of pressure compensation valve assembly.................................................1195 Removal......................................................................................................1195 Installation.................................................................................................1195 Removal and installation of main relief valve assembly...........................................................1196 Removal......................................................................................................1196 Installation.................................................................................................1196 Removal and installation of LS control EPC valve.................................................................1197 Removal......................................................................................................1197 Installation.................................................................................................1197 Removal and installation of EPC solenoid valve assembly..........................................................1198 Removal......................................................................................................1198 Installation.................................................................................................1198 Removal and installation of PPC solenoid valve block assembly....................................................1200 Removal......................................................................................................1200 Installation.................................................................................................1201 Removal and installation of oil seal in hydraulic pump input shaft...............................................1202 Special tools................................................................................................1202 Removal......................................................................................................1202 Installation.................................................................................................1202 Disassembly and assembly of work equipment PPC valve.............................................................1203 Assembly.....................................................................................................1203 Disassembly and assembly of hydraulic cylinder...................................................................1204 Special tools................................................................................................1204 Disassembly..................................................................................................1204 Assembly.....................................................................................................1206 Removal and installation of monoboom work equipment..............................................................1210 Special tools................................................................................................1210 Removal......................................................................................................1210 Installation.................................................................................................1211 Removal and installation of 2 piece boom work equipment..........................................................1214 Special tools................................................................................................1214 Removal......................................................................................................1214 Installation.................................................................................................1215 Removal and installation of air conditioner unit.................................................................1218 Special tools................................................................................................1218 Removal......................................................................................................1218 Installation.................................................................................................1220 Removal and installation of counterweight........................................................................1222 Removal......................................................................................................1222 Installation.................................................................................................1223 Removal and installation of operator cab assembly................................................................1224 Removal......................................................................................................1224 Installation.................................................................................................1225 Removal and installation of monitor assembly.....................................................................1226 Removal......................................................................................................1226 Installation.................................................................................................1226 Removal and installation of pump controller assembly.............................................................1227 Removal......................................................................................................1227 Installation.................................................................................................1227 OTHER................................................................................................................1229 Hydraulic circuit diagram (1/3...................................................................................1231 Hydraulic circuit diagram (2/3)..................................................................................1232 Hydraulic circuit diagram (3/3)..................................................................................1233 Circuit diagram (cabin 1/5)......................................................................................1234 Circuit diagram (cabin 2/5)......................................................................................1235 Circuit diagram (cabin 3/5)......................................................................................1236 Circuit diagram (cabin 4/5)......................................................................................1237 Circuit diagram (cabin 5/5)......................................................................................1238 Circuit diagram (machine 1/4))...................................................................................1239 Circuit diagram (machine 2/4))...................................................................................1240 Circuit diagram (machine 3/4))...................................................................................1241 Circuit diagram (machine 4/4))...................................................................................1242
DESCRIPTION:
KOMATSU PW180-7 PLUS SHOP MANUAL VENBM64000 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
General
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
Testing, adjusting and troubleshooting
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
Disassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
Maintenance standard
This section gives the judgement standards when inspecting disassembled parts.
S.S 31/12/24
