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KOMATSU PW180-10 SHOP MANUAL VENBM63001 – PDF DOWNLOAD
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Description
KOMATSU PW180-10 SHOP MANUAL VENBM63001 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PW180-10 SHOP MANUAL VENBM63001 – PDF DOWNLOAD
Language : English
Pages : 1159
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PW180-10 SHOP MANUAL VENBM63001 – PDF DOWNLOAD
VENBM63001 PW180-10.................................................................................................. 1 FOREWORD............................................................................................................. 5 Safety........................................................................................................... 5 Important safety notice...................................................................................... 5 General precautions.......................................................................................... 5 Preparations for work........................................................................................ 5 Precautions during work...................................................................................... 6 General.......................................................................................................... 7 General...................................................................................................... 7 Structure and function....................................................................................... 7 Testing, adjusting and troubleshooting....................................................................... 7 Disassembly and assembly..................................................................................... 7 Maintenance standard......................................................................................... 7 How to read the shop manual...................................................................................... 8 Volumes...................................................................................................... 8 Distribution and updating................................................................................ 8 Filing method................................................................................................ 8 Revised edition mark......................................................................................... 8 Revisions.................................................................................................... 8 Symbols...................................................................................................... 8 Hoisting instructions............................................................................................ 9 Hoisting..................................................................................................... 9 Wire Ropes............................................................................................... 9 Coating materials................................................................................................ 10 Standard tightening torque....................................................................................... 12 Standard tightening torque of bolts and nuts................................................................. 12 Tightening torque of hose nuts............................................................................... 13 Tightening torque of split flange bolts...................................................................... 13 Tightening torques for hoses (taper seal type and face seal type)............................................ 13 Tightening torque for 107 engine series (bolts and nuts)..................................................... 14 Tightening torque for 107 engine series (eye joints)......................................................... 14 Tightening torque for 107 engine series (tapered screws)..................................................... 14 Electric wire code............................................................................................... 15 Classification by thickness.................................................................................. 15 Classification by color and code............................................................................. 15 Conversion tables................................................................................................ 16 Method of using the conversion table......................................................................... 16 Units............................................................................................................ 22 GENERAL.............................................................................................................. 23 Specification dimension drawings................................................................................. 24 Dimensions................................................................................................... 24 Working ranges................................................................................................... 26 Working range: 1-piece boom.................................................................................. 26 Working range: 2-piece boom.................................................................................. 27 Weight table..................................................................................................... 31 1-piece boom................................................................................................. 32 2-piece boom................................................................................................. 33 Fuel, coolant and lubricants..................................................................................... 34 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD......................................................................... 35 Engine related parts............................................................................................. 38 KVGT......................................................................................................... 40 EGR system piping drawing.................................................................................... 46 EGR system circuit diagram................................................................................... 48 EGR valve.................................................................................................... 49 EGR cooler................................................................................................... 51 KCCV layout drawing.......................................................................................... 52 KCCV ventilator.............................................................................................. 54 KDPF......................................................................................................... 56 Cooling system............................................................................................... 60 Power train...................................................................................................... 62 Swing circle................................................................................................. 64 Specifications........................................................................................... 64 Swing machinery & motor.......................................................................................... 65 Specification................................................................................................ 66 Operation of swing lock...................................................................................... 67 Relief valve portion......................................................................................... 68 Operation................................................................................................ 68 Undercarriage.................................................................................................... 70 Transmission..................................................................................................... 72 Specifications............................................................................................... 72 Function..................................................................................................... 74 ATT EPC valve assembly........................................................................................... 75 Hydraulic quick coupler.......................................................................................... 76 Schematic.................................................................................................... 76 Operation.................................................................................................... 77 Hydraulic quick coupler solenoid valve....................................................................... 77 Specification................................................................................................ 77 Quick coupler error logic.................................................................................... 78 Travel motor..................................................................................................... 80 Function..................................................................................................... 81 Operation of travel motor.................................................................................... 82 Clutch control circuit........................................................................................... 84 Function..................................................................................................... 85 Axle............................................................................................................. 86 Outline...................................................................................................... 86 Suspension lock cylinder......................................................................................... 90 Specifications............................................................................................... 90 Structure and function....................................................................................... 90 Circuit...................................................................................................... 91 Axle oscillation............................................................................................. 91 Braking system................................................................................................... 92 Structure and function....................................................................................... 93 Gear pump........................................................................................................ 94 Specifications............................................................................................... 94 Function..................................................................................................... 94 Priority valve................................................................................................... 96 Specification................................................................................................ 96 Function..................................................................................................... 96 Power brake valve................................................................................................ 98 Specifications............................................................................................... 99 Function..................................................................................................... 99 Accumulator for brake valve...................................................................................... 100 Specifications............................................................................................... 100 Structure and function....................................................................................... 100 Steering system.................................................................................................. 101 Structure and function....................................................................................... 101 Steering column.................................................................................................. 102 Orbitrol valve................................................................................................... 103 Specifications............................................................................................... 103 Structure and function....................................................................................... 103 Hydraulic equipment layout drawings.............................................................................. 104 Hydraulic circuit diagram........................................................................................ 106 Hydraulic tank................................................................................................... 107 Specifications............................................................................................... 107 Hydraulic pump................................................................................................... 108 Function..................................................................................................... 110 Structure.................................................................................................... 110 Operation.................................................................................................... 111 LS valve..................................................................................................... 113 PC valve..................................................................................................... 114 Function................................................................................................. 115 Operation................................................................................................ 116 1. LS valve.............................................................................................. 116 2. PC valve.............................................................................................. 120 LS(PC)-EPC valve............................................................................................. 127 Function................................................................................................. 128 Operation................................................................................................ 128 Pilot pressure control (PPC) system.............................................................................. 130 Function..................................................................................................... 131 Operation.................................................................................................... 131 Control valve.................................................................................................... 132 Outline...................................................................................................... 132 CLSS............................................................................................................. 143 Outline of CLSS.............................................................................................. 143 Features................................................................................................. 143 Structure................................................................................................ 143 Basic Principle.............................................................................................. 144 Operation for each function and valve........................................................................ 146 Hydraulic circuit diagram and name of valves............................................................. 146 1. Unload valve.............................................................................................. 148 Function................................................................................................. 148 Operation................................................................................................ 148 Operation................................................................................................ 149 Operation................................................................................................ 150 2. Introduction of LS pressure............................................................................... 151 Work equipment valve..................................................................................... 151 Function................................................................................................. 151 Operation................................................................................................ 151 3. LS bypass plug............................................................................................ 152 Outline.................................................................................................. 152 Operation................................................................................................ 152 4. Pressure compensation valve............................................................................... 153 Function................................................................................................. 153 Operation................................................................................................ 154 5. Area ratio of pressure compensation valve................................................................. 155 Function................................................................................................. 155 6. Boom regeneration circuit................................................................................. 156 Function................................................................................................. 156 Operation................................................................................................ 156 Function................................................................................................. 157 Operation................................................................................................ 157 7. Arm regeneration circuit.................................................................................. 158 Function................................................................................................. 158 Operation................................................................................................ 158 Function................................................................................................. 159 Operation................................................................................................ 159 8. Swing bleeding valve...................................................................................... 160 Function................................................................................................. 160 Operation (In fine control operation).................................................................... 160 9. Variable type pressure compensation valve (for service)................................................... 161 Function................................................................................................. 161 Simultaneous operation with work equipment under heavy load (boom RAISE, etc.)........................... 161 10. LS select valve.......................................................................................... 162 Function................................................................................................. 162 Operation................................................................................................ 162 Centre swivel joint.............................................................................................. 163 Travel PPC pedal................................................................................................. 164 Work equipment – Swing PPC valve................................................................................. 166 Operation.................................................................................................... 168 Solenoid valve block............................................................................................. 170 ON / OFF Solenoid valves (3 way valve)....................................................................... 172 Operation................................................................................................ 172 ON / OFF Solenoid valves (4 way valve)................................................................... 174 Operation................................................................................................ 174 Hi/ Lo Solenoid valve (4 way valve)...................................................................... 176 Operation................................................................................................ 176 Attachment PPC valve......................................................................................... 178 Function................................................................................................. 179 Operation................................................................................................ 179 Boom safety valve................................................................................................ 182 Operation.................................................................................................... 183 Hydraulic cylinder............................................................................................... 184 Boom cylinder................................................................................................ 184 Arm cylinder................................................................................................. 184 Bucket cylinder.............................................................................................. 184 Adjust cylinder.............................................................................................. 185 Outrigger cylinder........................................................................................... 186 Dozer cylinder............................................................................................... 188 Function................................................................................................. 189 Work equipment................................................................................................... 190 Work equipment............................................................................................... 191 1. Dimension of arm.......................................................................................... 192 2. Dimension of bucket....................................................................................... 194 Air conditioner.................................................................................................. 196 Air conditioner piping....................................................................................... 196 Electrical wiring diagram........................................................................................ 197 Electrical system................................................................................................ 198 Engine control............................................................................................... 198 1. Operation of System................................................................................... 198 2. Component............................................................................................. 199 Engine controller................................................................................................ 200 Pump controller.................................................................................................. 204 Electrical control system........................................................................................ 207 Machine control system diagram................................................................................... 208 1. Engine and pump control function.......................................................................... 209 Function..................................................................................................... 210 Function..................................................................................................... 214 Function..................................................................................................... 216 Function..................................................................................................... 218 Operation.................................................................................................... 219 Function..................................................................................................... 220 Function..................................................................................................... 224 Function..................................................................................................... 226 Function..................................................................................................... 229 Specifications............................................................................................... 230 Function..................................................................................................... 230 Function..................................................................................................... 231 Operation.................................................................................................... 231 Machine monitor system........................................................................................... 234 Monitor panel................................................................................................ 236 Monitor display.............................................................................................. 240 Monitor items and display.................................................................................... 242 Caution monitor.............................................................................................. 244 Pilot monitor................................................................................................ 247 Monitor switches............................................................................................. 249 Declaration of switch function on keypad................................................................. 250 Guidance icon and function switch........................................................................ 252 Operator mode function................................................................................... 255 Service mode function.................................................................................... 256 KOMTRAX system................................................................................................... 257 KOMTRAX terminal............................................................................................. 258 Overload warning device.......................................................................................... 260 Outline...................................................................................................... 260 Function................................................................................................. 260 Structure................................................................................................ 260 Sensor........................................................................................................... 261 Ambient pressure sensor...................................................................................... 262 Charge (boost) pressure and temperature sensor............................................................... 263 Coolant temperature sensor................................................................................... 264 Ne (crankshaft) speed sensor................................................................................. 264 Bkup (camshaft) speed sensor................................................................................. 265 Common rail pressure sensor.................................................................................. 265 Exhaust manifold pressure sensor............................................................................. 266 EGR orifice temperature sensor............................................................................... 266 EGR valve lift sensor........................................................................................ 267 KVGT speed sensor............................................................................................ 268 KVGT position sensor......................................................................................... 269 Mass air flow and temperature sensor......................................................................... 270 KDPF differential pressure and outlet pressure sensor........................................................ 271 KDOC inlet temperature sensor................................................................................ 272 KDOC outlet temperature sensor............................................................................... 272 KDPF outlet temperature sensor............................................................................... 273 Crankcase pressure sensor.................................................................................... 273 Engine oil level sensor...................................................................................... 274 Fuel level sensor............................................................................................ 275 WIF (Water-In-Fuel detection) sensor......................................................................... 276 Coolant level sensor......................................................................................... 277 Hydraulic oil temperature sensor......................................................................... 278 Air cleaner clogging sensor.................................................................................. 278 Overload Caution sensor...................................................................................... 279 Swing proximity sensor....................................................................................... 280 Travel PPC sensor............................................................................................ 280 PPC pressure sensor.......................................................................................... 280 Park brake pressure sensor................................................................................... 281 Brake accumulator low pressure sensor.................................................................... 281 Brake stop light sensor.................................................................................. 281 PPC levers....................................................................................................... 282 LH PPC lever................................................................................................. 282 RH PPC lever................................................................................................. 283 1st attachment circuit hydraulic performance (main valve bypassed)............................................... 284 Travel system.................................................................................................... 285 Travel circuit............................................................................................... 285 Travel Motor Performance................................................................................. 286 Auto-grease pump............................................................................................. 288 Overview................................................................................................. 289 Display and control unit................................................................................. 289 LED-display.............................................................................................. 290 Push buttons............................................................................................. 290 Three-digit LED display.................................................................................. 291 Check central lubrication system, fill up grease......................................................... 292 Lubrication diagrams............................................................................................. 293 Auto-grease pump with one-piece boom......................................................................... 293 Auto-grease pump with two-piece boom......................................................................... 294 Two point system one-piece boom.............................................................................. 295 Two point system two-piece boom.............................................................................. 296 Standard value table for engine related parts.................................................................... 298 Standard value table for chassis related parts................................................................... 299 Flow control characteristic of PC valve (STD)................................................................ 312 PM clinic service................................................................................................ 313 Check sheet.................................................................................................. 314 STANDARD VALUE TABLE................................................................................................. 297 TESTING AND ADJUSTING................................................................................................ 321 Measuring engine speed........................................................................................... 322 Measuring intake air pressure (boost pressure)................................................................... 323 Checking exhaust gas colour...................................................................................... 325 Measuring and adjusting valve clearance.......................................................................... 327 Testing...................................................................................................... 327 Adjusting.................................................................................................... 329 Testing compression pressure..................................................................................... 330 Testing...................................................................................................... 330 Measuring blow-by pressure....................................................................................... 335 Measuring engine oil pressure.................................................................................... 337 Handling fuel system parts....................................................................................... 338 Releasing residual pressure from fuel system..................................................................... 339 Measuring fuel pressure.......................................................................................... 340 Measuring fuel delivery, return and leakage...................................................................... 343 Bleeding air from fuel circuit................................................................................... 348 Checking fuel circuit for leakage............................................................................ 350 Checking and adjusting air conditioner compressor belt tension................................................... 351 Checking..................................................................................................... 351 Adjusting.................................................................................................... 351 Replacing the fan belt........................................................................................... 352 Measurement of clearance in swing circle bearing................................................................. 353 Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel.... 354 Measurement.................................................................................................. 354 Adjustment................................................................................................... 355 Inspection and adjustment of control circuit oil pressure........................................................ 357 Measurement.................................................................................................. 357 Procedure for pressure reducing adjustment................................................................... 358 Inspection and adjustment of pump PC (valve inlet) control oil pressure.......................................... 359 Measurement.................................................................................................. 359 Adjustment................................................................................................... 361 Inspection and adjustment of pump LS differential pressure....................................................... 362 Measurement.................................................................................................. 362 Adjustment................................................................................................... 364 Measurement of solenoid valve output pressure.................................................................... 365 Checking Proportional Control PPC Circuit.................................................................... 367 Adjustment of work equipment and swing PPC valve................................................................. 368 Measuring and adjusting quick coupler control valve output pressure.............................................. 369 Testing travel motor relief pressure............................................................................. 370 Measuring travel motor relief pressure....................................................................... 370 Testing propshaft speed.......................................................................................... 371 Measuring rotating speed of propshaft........................................................................ 371 Testing transmission clutch control circuit...................................................................... 372 Description.................................................................................................. 372 Inspection of locations of hydraulic drift of work equipment..................................................... 374 Release of remaining pressure in hydraulic circuit............................................................... 376 Measurement of oil leakage....................................................................................... 378 Air bleeding of various parts.................................................................................... 381 Inspection procedures for diode.................................................................................. 384 Special function of monitor panel................................................................................ 385 TROUBLESHOOTING...................................................................................................... 463 Troubleshooting.................................................................................................. 463 General information on troubleshooting........................................................................... 464 Troubleshooting points....................................................................................... 464 Sequence of events in troubleshooting........................................................................ 465 1. Points to remember when handling electric equipment................................................... 468 2. Points to remember when troubleshooting electric circuits............................................. 474 3. Points to remember when handling hydraulic equipment.................................................. 475 Checks before troubleshooting................................................................................ 477 How to read electric wire code............................................................................... 478 Connector location chart and circuit diagram by system........................................................... 482 Connector table.............................................................................................. 483 Connection table for connector pin numbers....................................................................... 496 T-boxes and T-adapters table................................................................................. 532 Before carrying out troubleshooting when failure code is displayed............................................... 542 Information contained in troubleshooting table................................................................... 544 Troubleshooting by failure code (Display of code)................................................................ 546 Failure code [879AKA] – A/C inner sensor open circuit............................................................ 546 Failure code [879AKB] – A/C inner sensor short circuit........................................................... 546 Failure code [879BKA] – A/C outer sensor open circuit............................................................ 546 Failure code [879BKB] – A/C outer sensor short circuit........................................................... 546 Failure code [879CKA] – Ventilating sensor open circuit.......................................................... 546 Failure code [879CKB] – Ventilating sensor short circuit......................................................... 547 Failure code [879DKZ] – Sunlight sensor open or short circuit.................................................... 547 Failure code [879EMC] – Ventilation damper abnormality........................................................... 547 Failure code [879FMC] – Air mix damper abnormality............................................................... 547 Failure code [879GKX] – Refrigerant abnormality.................................................................. 547 Failure code [2G00MA] – Brake oil pressure abnormality........................................................... 548 Failure code [6B2JMA] – Travel hydraulic abnormality............................................................. 550 Failure code [989L00] – Engine controller lock caution 1......................................................... 551 Failure code [989M00] – Engine controller lock caution 2......................................................... 552 Failure code [989N00] – Engine controller lock caution 3......................................................... 553 Failure code [AA10NX] – Air cleaner clogging..................................................................... 554 Failure code [A1U0N3] – HC Desorb Request 1...................................................................... 556 Failure code [A1U0N4] – HC Desorb Request 2...................................................................... 557 Failure code [AB00KE] – Charge voltage low....................................................................... 558 Failure code [B@BAZG] – Engine oil pressure low.................................................................. 560 Failure code [B@BAZK] – Engine oil level low..................................................................... 561 Circuit diagram related to engine oil level.................................................................. 561 Failure code [B@BCNS] – Engine coolant overheat.................................................................. 562 Failure code [B@BCZK] – Engine coolant level low................................................................. 563 Circuit diagram related to radiator coolant level switch..................................................... 563 Failure code [B@HANS] – Hydraulic oil overheat................................................................... 564 Failure code [CA111] – EMC critical internal failure............................................................. 564 Failure code [CA115] – Engine neutral and backup speed sensor error.............................................. 565 Failure code [CA122] – Charge air press sensor high error........................................................ 566 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 567 Failure code [CA123] – Charge air press sensor low error......................................................... 568 Failure code [CA131] – Throttle sensor high error................................................................ 570 Circuit diagram related to fuel control dial................................................................. 571 Failure code [CA132] – Throttle sensor low error................................................................. 572 Circuit diagram related to fuel control dial................................................................. 573 Failure code [CA144] – Coolant temperature sensor high error..................................................... 574 Failure code [CA145] – Coolant temp sensor low error............................................................. 576 Circuit diagram related to coolant temperature sensor........................................................ 577 Failure code [CA153] – Charge air temperature sensor high error.................................................. 578 Failure code [CA154] – Charge air temperature sensor low error................................................... 580 Circuit diagram related to boost pressure/temperature sensor (combination sensor)............................ 581 Failure code [CA155] – Charge air temperature high speed derate.................................................. 582 Failure code [CA187] – Sensor supply 2 voltage low error......................................................... 584 Failure code [CA221] – Ambient press sensor high error........................................................... 586 Circuit diagram related to ambient pressure sensor........................................................... 587 Failure code [CA222] – Ambient press sensor low error............................................................ 588 Circuit diagram related to ambient pressure sensor........................................................... 589 Failure code [CA227] – Sensor supply 2 volt high error........................................................... 590 Failure code [CA234] – Engine overspeed.......................................................................... 591 Failure code [CA238] – NE speed sensor supply voltage error...................................................... 592 Failure code [CA239] – Ne speed sens supply volt high error...................................................... 594 Circuit diagram related to Ne speed sensor................................................................... 595 Failure code [CA271] – IMV/PCV1 short circuit error.............................................................. 596 Failure code [CA272] – IMV/PCV1 open error....................................................................... 598 Failure code [CA295] – Ambient press sens in range error......................................................... 599 Failure code [CA322] – Injector #1 (L#1) open/short circuit error................................................ 600 Circuit diagram related to no. 1 injector.................................................................... 601 Failure code [CA323] – Injector #5(L#5) open/short circuit error................................................. 602 Circuit diagram related to injector #5....................................................................... 603 Failure code [CA324] – Injector #3 (L#3) open/short circuit Error................................................ 604 Circuit diagram related to no. 3 injector.................................................................... 605 Failure code [CA325] – Injector #6 (L#6) open/short circuit error................................................ 606 Circuit diagram related to injector #6....................................................................... 607 Failure code [CA331] – Injector #2 (L#2) open/short circuit error................................................ 608 Circuit diagram related to no. 2 injector.................................................................... 609 Failure code [CA332] – Injector #4 (L#4) open/short circuit error................................................ 610 Circuit diagram related to no. 4 injector.................................................................... 611 Failure code [CA343] – ECM critical internal failure............................................................. 612 Failure code [CA351] – Injectors drive circuit error............................................................. 613 Failure code [CA352] – Sensor 1 supply voltage low error......................................................... 614 Failure code [CA356] – Mass air flow sensor high error........................................................... 616 Failure code [CA357] – Mass air flow sensor low error............................................................ 618 Failure code [CA386] – Sensor 1 supply voltage high error........................................................ 620 Failure code [CA428] – Water-in-fuel sensor high error........................................................... 622 Failure code [CA429] – Water-in-fuel sensor low error............................................................ 624 Failure code [CA435] – Engine oil pressure switch error.......................................................... 626 Failure code [CA441] – Battery voltage low error................................................................. 628 Failure code [CA442] – Battery voltage high error................................................................ 630 Failure code [CA449] – Common rail pressure very high error...................................................... 632 Failure code [CA451] – Rail pressure sensor high error........................................................... 634 Failure code [CA452] – Rail pressure sensor low error............................................................ 636 Failure code [CA488] – Charge air temperature high torque derate................................................. 638 Failure code [CA515] – Rail press sens sup volt high error....................................................... 640 Failure code [CA516] – Rail press sens sup volt low error........................................................ 642 Failure code [CA553] – Common rail pressure high error........................................................... 644 Failure code [CA555] – Crankcase press high error 1.............................................................. 645 Failure code [CA556] – Crankcase press high error 2.............................................................. 646 Failure code [CA559] – Rail pressure low error................................................................... 648 Failure code [CA595] – Turbo speed high error 2.................................................................. 650 Failure code [CA687] – Turbo speed low error..................................................................... 652 Failure code [CA689] – Engine ne speed sensor error.............................................................. 654 Failure code [CA691] – Intake air temp sens high error........................................................... 656 Failure code [CA692] – Intake air temp sens low error............................................................ 658 Failure code [CA697] – ECM int temp sensor high error............................................................ 660 Failure code [CA698] – ECM int temp sensor low error............................................................. 661 Failure code [CA731] – Engine Bkup speed sensor phase error...................................................... 662 Failure code [CA778] – Engine Bkup speed sensor error............................................................ 664 Failure code [CA1117] – Persistent data lost error............................................................... 668 Failure code [CA1664] – KDOC malfunction......................................................................... 670 Failure code [CA1691] – Regeneration ineffective................................................................. 672 Failure code [CA1695] – Sensor 5 supply volt high error.......................................................... 674 Failure code [CA1696] – Sensor 5 supply volt low error........................................................... 676 Failure code [CA1843] – Crankcase press sens high error.......................................................... 678 Failure code [CA1844] – Crankcase press sens low error........................................................... 680 Failure code [CA1879] – KDPF delta P sensor high error........................................................... 682 Failure code [CA1881] – KDPF delta P sensor low error............................................................ 684 Failure code [CA1883] – KDPF delta P sens in range error......................................................... 686 Failure code [CA1921] – KDPF soot load high error 1.............................................................. 690 Failure code [CA1922] – KDPF soot load high error 2.............................................................. 692 Failure code [CA1942] – Crankcase press sens in range error...................................................... 696 Failure code [CA1993] – KDPF delta pressure low error............................................................ 697 Failure code [CA2185] – Throt sensor sup volt high error......................................................... 700 Failure code [CA2186] – Throt sensor sup volt low error.......................................................... 702 Failure code [CA2249] – Rail pressure very low error............................................................. 704 Failure code [CA2271] – EGR valve pos sens high error............................................................ 706 Failure code [CA2272] – EGR valve pos sens low error............................................................. 708 Failure code [CA2288] – Turbo speed high error 1................................................................. 710 Failure code [CA2311] – IMV solenoid error....................................................................... 711 Failure code [CA2349] – EGR valve solenoid open error............................................................ 712 Failure code [CA2353] – EGR valve solenoid short error........................................................... 714 Failure code [CA2357] – EGR valve servo error.................................................................... 716 Failure code [CA2373] – Exhaust manifold press sens high error................................................... 718 Failure code [CA2374] – Exhaust manifold press sens low error.................................................... 720 Failure code [CA2375] – EGR orifice temp sens high error......................................................... 722 Failure code [CA2376] – EGR orifice temp sens low error.......................................................... 724 Failure code [CA2381] – KVGT pos sens high error................................................................. 726 Failure code [CA2382] – KVGT pos sens low error.................................................................. 728 Failure code [CA2383] – KVGT solenoid open error................................................................. 730 Failure code [CA2386] – KVGT solenoid short error................................................................ 732 Failure code [CA2387] – KVGT servo error......................................................................... 734 Failure code [CA2554] – Exh manifold press sens in range error................................................... 735 Failure code [CA2555] – Grid heater relay volt low error......................................................... 736 Failure code [CA2556] – Grid heater relay volt high error........................................................ 738 Failure code [CA2637] – KDOC face plugging....................................................................... 740 Failure code [CA2639] – Manual stationary regeneration request................................................... 742 Failure code [CA2961] – EGR orifice temperature high error 1..................................................... 744 Failure code [CA2973] – Chg air press sensor in range error...................................................... 745 Failure code [CA3133] – KDPF outlet press sens high error........................................................ 746 Failure code [CA3134] – KDPF outlet press sens low error......................................................... 748 Failure code [CA3135] – KDPF outlet press sens in range error.................................................... 750 Failure code [CA3251] – KDOC inlet temp high error............................................................... 754 Failure code [CA3253] – KDOC temp error - non regeneration....................................................... 756 Failure code [CA3254] – KDOC outlet temp high error 1............................................................ 758 Failure code [CA3255] – KDPF temp error - non regeneration....................................................... 761 Failure code [CA3256] – KDPF outlet temp high error 1............................................................ 764 Failure code [CA3311] – KDOC outlet temp high error 2............................................................ 767 Failure code [CA3312] – KDPF outlet temp high error 2............................................................ 770 Failure code [CA3313] – KDOC inlet temp sensor low error......................................................... 773 Failure code [CA3314] – KDOC inlet temp sens high error.......................................................... 776 Failure code [CA3315] – KDOC inlet temp sens in range error...................................................... 780 Failure code [CA3316] – KDOC outlet temp sens low error.......................................................... 784 Failure code [CA3317] – KDOC outlet temp sens high error......................................................... 786 Failure code [CA3318] – KDOC outlet temp sens in range error..................................................... 790 Failure code [CA3319] – KDPF outlet temp sens high error......................................................... 794 Failure code [CA3321] – KDPF outlet temp sens low error.......................................................... 797 Failure code [CA3322] – KDPF outlet temp sens in range error..................................................... 800 Failure code [CA3419] – Mass air flow sensor sup volt high error................................................. 804 Failure code [CA3421] – Mass air flow sensor sup volt low error.................................................. 806 Failure code [CA3741] – Rail press valve trip error.............................................................. 808 Failure code [D110KB] – Battery relay output voltage............................................................. 810 Failure code [D161KA] – Backup alarm relay open circuit.......................................................... 812 Failure code [D161KB] – Backup alarm relay short circuit......................................................... 814 Failure code [D19JKZ] – Personal code relay abnormality.......................................................... 816 Failure code [D19QKB] – Refuel pump relay short circuit.......................................................... 818 Failure code [D1EMKA] – Parking brake relay open circuit......................................................... 820 Failure code [D1EMKB] – Parking brake relay short circuit........................................................ 822 Failure code [D811MC] – KOMTRAX error............................................................................ 824 Failure code [D862KA] – GPS antenna open circuit................................................................. 825 Failure code [D8ALKA] – System operating lamp disconnection (KOMTRAX)............................................ 826 Failure code [D8ALKB] – System operating lamp short circuit (KOMTRAX)............................................ 828 Failure code [D8AQKR] – CAN2 discon (KOMTRAX).................................................................... 830 Failure code [DA20MC] – Pump controller.......................................................................... 831 Failure code [DA22KK] – Pump solenoid power low error............................................................ 832 Failure code [DA25KP] – 5V sensor 1 power abnormality............................................................ 834 Failure code [DA26KP] – 5V sensor 2 power abnormality............................................................ 836 Failure code [DA29KQ] – Model selection abnormality.............................................................. 838 Failure code [DA2LKA] – System operating lamp disconnection (pump con)........................................... 840 Failure code [DA2LKB] – System operating lamp short circuit (pump con)........................................... 842 Failure code [DA2QKR] – CAN2 discon (pump con)................................................................... 844 Failure code [DA2RKR] – CAN1 discon (pump con)................................................................... 846 Failure code [DAB0KT] – Internal flash memory error.............................................................. 847 Failure code [DAC3KB] – Cruise control system power supply short circuit......................................... 848 Failure code [DAF0MB] – Monitor ROM abnormality.................................................................. 850 Failure code [DAF0MC] – Monitor error............................................................................ 851 Failure code [DAF8KB] – Camera power supply short circuit........................................................ 852 Failure code [DAF9KQ] – Model selection abnormality.............................................................. 854 Failure code [DAFGMC] – GPS module operation error............................................................... 855 Failure code [DAFLKA] – Operating lamp open circuit (monitor).................................................... 856 Failure code [DAFLKB] – System operating lamp short circuit (monitor)............................................ 858 Failure code [DAFQKR] – CAN2 discon (monitor).................................................................... 860 Failure code [DAZ9KQ] – A/C model selection abnormality.......................................................... 861 Failure code [DAZQKR] – CAN2 discon (AC)......................................................................... 862 Failure code [DB2QKR] – CAN2 discon (engine con)................................................................. 866 Failure code [DB2RKR] – CAN1 discon (engine con)................................................................. 870 Failure code [DDK8KA] – SUSLock forced sw open circuit........................................................... 874 Failure code [DDK8KB] – SUSLock forced sw short circuit.......................................................... 876 Failure code [DDP4KX] – Disconnection in travel PPC pressure switch.............................................. 878 Failure code [DDP6L5] – Service brake press sw abnormality....................................................... 880 Failure code [DDQ1KA] – SUSLock mode selection sw open circuit................................................... 882 Failure code [DDQ1KB] – SUSLock mode selection sw short circuit.................................................. 884 Failure code [DDWCKZ] – Direction switch abnormality............................................................. 886 Failure code [DFB1KZ] – Service lever potentio 1 abnormality..................................................... 888 Failure code [DFB2KZ] – Service lever potentio 2 abnormality..................................................... 890 Failure code [DFB3L8] – Service lever 1 potentio error........................................................... 892 Failure code [DFB4L8] – Service lever 2 potentio error........................................................... 893 Failure code [DFB5KZ] – Service lever sub potentio 1 abnormality................................................. 894 Failure code [DFB6KZ] – Service lever sub potentio 2 abnormality................................................. 896 Failure code [DGH2KB] – Hydraulic oil temperature sensor short circuit........................................... 898 Failure code [DH10KP] – 24V sensor power abnormality............................................................. 900 Failure code [DHA4KA] – Air cleaner clog sensor open circuit..................................................... 902 Failure code [DHH2MA] – Return line filter press sensor abnormally............................................... 904 Failure code [DHPAMA] – F pump press sensor abnormality.......................................................... 906 Failure code [DHS5KX] – Abnormality in travel PPC sensor......................................................... 908 Failure code [DHU1KA] – Brake accumulator press sensor open circuit.............................................. 910 Failure code [DHU1KY] – Brake accumulator press sensor short circuit............................................. 912 Failure code [DHUCKA] – Parking brake press sensor open circuit.................................................. 914 Failure code [DHUCKY] – Parking brake press sensor short circuit................................................. 916 Failure code [DHUGKA] – Service brake press sensor open circuit.................................................. 918 Failure code [DHUGKY] – Service brake press sensor short circuit................................................. 920 Failure code [DHX1MA] – Overload sensor abnormality (analog)..................................................... 922 Failure code [DLT4KA] – Disconnection in transmission speed sensor............................................... 924 Failure code [DR21KX] – Camera 2 picture rev. drive abnormality.................................................. 926 Failure code [DR31KX] – Camera 3 picture rev. drive abnormality.................................................. 928 Failure code [DW27KA] – Disconnection in transmission clutch solenoid............................................ 930 Failure code [DW27KB] – Short circuit in transmission clutch solenoid............................................ 932 Failure code [DW27KY] – T/M clutch sol hot short circuit......................................................... 934 Failure code [DW4AKA] – Disconnection in suspension lock solenoid................................................ 936 Failure code [DW4AKB] – Short circuit in suspension lock solenoid................................................ 938 Failure code [DW4AKY] – SUSLock sol hot short circuit............................................................ 940 Failure code [DW4CKA] – Disconnection in PPC lock solenoid....................................................... 942 Failure code [DW4CKB] – PPC lock sol. short circuit.............................................................. 944 Failure code [DW4MKA] – Disconnection in creep solenoid.......................................................... 946 Failure code [DW4MKB] – Short circuit in creep solenoid.......................................................... 947 Failure code [DW44KA] – Disconnection in travel F/R solenoid..................................................... 948 Failure code [DW44KB] – Short circuit in travel F/R solenoid..................................................... 950 Failure code [DW44KY] – Travel F/R sol hot short circuit......................................................... 952 Failure code [DW45KA] – Disconnection in swing holding brake solenoid............................................ 954 Failure code [DW45KB] – Swing holding brake solenoid short circuit............................................... 956 Failure code [DW91KA] – Disconnection in travel neutral solenoid................................................. 958 Failure code [DW91KB] – Short circuit in travel neutral solenoid................................................. 960 Failure code [DWB1KA] – Disconnection in outrigger operation solenoid............................................ 962 Failure code [DWB1KB] – Short circuit in outrigger operation solenoid............................................ 964 Failure code [DWB2KA] – Disconnection in 1st outrigger solenoid.................................................. 966 Failure code [DWB2KB] – Short circuit in 1st outrigger solenoid.................................................. 968 Failure code [DWB3KA] – Disconnection in 2nd outrigger solenoid.................................................. 970 Failure code [DWB3KB] – Short circuit in 2nd outrigger solenoid.................................................. 972 Failure code [DWB4KA] – Disconnection in 3rd outrigger solenoid.................................................. 974 Failure code [DWB4KB] – Short circuit in 3rd outrigger solenoid.................................................. 976 Failure code [DWB5KA] – Disconnection in 4th outrigger solenoid.................................................. 978 Failure code [DWB5KB] – Short circuit in 4th outrigger solenoid.................................................. 980 Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid................................................. 982 Failure code [DWK0KB] – Short circuit in 2-stage relief solenoid................................................. 983 Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid.......................................... 984 Failure code [DWK2KB] – Short circuit in 2-stage back pressure solenoid.......................................... 985 Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system.............................................. 986 Failure code [DXA8KB] – Short circuit in PC-EPC (F) solenoid..................................................... 988 Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system.................................................. 990 Failure code [DXE0KB] – Short circuit in LS-EPC solenoid......................................................... 991 Failure code [DXE7KA] – Service current EPC2 solenoid disconnection (right hand)................................. 992 Failure code [DXE7KB] – Service current EPC solenoid short (right hand).......................................... 994 Failure code [DXE8KA] – Service current EPC solenoid disconnection (left hand)................................... 996 Failure code [DXE8KB] – Service current EPC3 solenoid short (left hand).......................................... 998 Failure code [DXE9KA] – Service current EPC solenoid disconnection (right hand)..................................1000 Failure code [DXE9KB] – Service current EPC solenoid short (right hand)..........................................1002 Failure code [DXEAKA] – Service Current EPC1 open circuit (left hand)............................................1004 Failure code [DXEAKB] – Service current EPC1 solenoid short (left hand)..........................................1006 Failure code [DXK3KA] – Travel pedal throttle EPC solenoid open circuit..........................................1008 Failure code [DXK3KB] – Travel pedal throttle EPC solenoid short circuit.........................................1009 Failure code [DY20KA] – Wiper working abnormality................................................................1010 Failure code [DY20MA] – Wiper parking abnormality................................................................1012 Failure code [DY2CKA] – Window washer drive system disconnection.................................................1014 Failure code [DY2CKB] – Washer drive short circuit...............................................................1016 Failure code [DY2DKB] – Wiper drive (fwd) short circuit..........................................................1018 Failure code [DY2EKB] – Wiper drive (rev) short circuit..........................................................1020 Troubleshooting of central lubrication system (CLS)..............................................................1023 Trouble......................................................................................................1023 Troubleshooting during grease pump operation.................................................................1025 Pump element.................................................................................................1026 Check power supply...........................................................................................1027 Changing the control unit....................................................................................1027 Troubleshooting – grease system faults.......................................................................1028 Venting of the system........................................................................................1029 General assembly advice......................................................................................1030 TROUBLESHOOTING...................................................................................................... 537 Troubleshooting when failure code is indicated................................................................... 537 Appendix.............................................................................................................1031 Table of contents................................................................................................1031 Air conditioner components.......................................................................................1032 Precautions for refrigerant..................................................................................1032 Air conditioner component....................................................................................1033 Configuration and function of refrigeration cycle............................................................1036 Outline of refrigeration cycle...............................................................................1037 Air conditioner unit.........................................................................................1039 Function.....................................................................................................1040 Functions of major components................................................................................1041 Servomotor...................................................................................................1042 Expansion valve..............................................................................................1043 Dual pressure switch.........................................................................................1045 Function.....................................................................................................1045 Air conditioner controller...................................................................................1046 Compressor...................................................................................................1047 Function.....................................................................................................1047 Air conditioner condenser....................................................................................1048 Function.....................................................................................................1048 Sunlight sensor..............................................................................................1050 Function.....................................................................................................1050 Procedure for testing and troubleshooting....................................................................1051 Circuit diagram and arrangement of connector pins............................................................1053 System diagram...............................................................................................1055 Input and output signals of the air conditioner controller...................................................1056 Function.....................................................................................................1057 Parts and connectors layout..................................................................................1058 Details......................................................................................................1059 Testing with self-diagnosis function.........................................................................1062 Testing outline..............................................................................................1062 How to open the electrical system abnormality record screen in service mode of the machine monitor...........1063 Testing vent (mode) changeover...............................................................................1065 Testing......................................................................................................1065 Testing FRESH/RECIRC air changeover..........................................................................1067 Testing......................................................................................................1067 Testing sunlight sensor......................................................................................1068 Testing......................................................................................................1068 Testing (dual) pressure switch for refrigerant...............................................................1069 Testing......................................................................................................1069 Testing relays...............................................................................................1070 Testing......................................................................................................1070 Troubleshooting chart 1......................................................................................1071 Troubleshooting chart 2......................................................................................1072 Information in troubleshooting table.........................................................................1075 Information in troubleshooting table.........................................................................1075 Failure code list related to air conditioner.................................................................1076 Failure code [879AKA] A/C Inner Sensor Open Circuit..........................................................1077 Failure code [879AKB] A/C Inner Sensor Short Circuit.........................................................1078 Failure code [879CKA] Ventilating Sensor Open Circuit........................................................1079 Failure code [879CKB] Ventilating Sensor Short Circuit.......................................................1080 Failure code [879DKZ] Sunlight sensor Open or Short Circuit..................................................1081 Circuit diagram related to sunlight sensor...................................................................1082 Failure code [879EMC] Ventilation Damper Abnormality.........................................................1083 Failure code [879FMC] Air Mix Damper Abnormality.............................................................1084 Failure code [879GKX] Refrigerant Abnormality................................................................1085 Troubleshooting for power supply system (Air conditioner does not operate)...................................1087 Circuit diagram related to blower motor system...............................................................1096 Troubleshooting with gauge pressure..........................................................................1097 Connection of service tool...................................................................................1100 Precautions for disconnecting and connecting air conditioner piping..........................................1102 Handling of compressor oil...................................................................................1104 Desiccant replacement........................................................................................1106 Tool control system..............................................................................................1109 System overview..............................................................................................1109 Operation....................................................................................................1109 System delivery condition....................................................................................1110 Adjusting and testing........................................................................................1111 Required equipment.......................................................................................1111 Software installation....................................................................................1112 Initial program start....................................................................................1114 Connect to tool control monitor/controller...............................................................1115 Analog inputs setup and calibration......................................................................1118 Tool parameters..........................................................................................1121 1st attachment pressure control..........................................................................1122 2nd attachment pressure control..........................................................................1123 1st attachment proportional switch flow control..........................................................1124 2nd attachment proportional switch flow control..........................................................1126 Additional software functionality........................................................................1128 Troubleshooting of tool control system.......................................................................1130 Software errors..........................................................................................1130 System error codes (displayed on the tool control monitor)...............................................1130 Tool control current [%] reference value table (1/2).........................................................1132 Tool control current [%] reference value table (2/2).........................................................1134 OTHER................................................................................................................1137 Hydraulic circuit diagram (1/3)..................................................................................1139 Hydraulic circuit diagram (2/3)..................................................................................1140 Hydraulic circuit diagram (3/3)..................................................................................1141 Circuit diagram (cabin 1/5)......................................................................................1142 Circuit diagram (cabin 2/5)......................................................................................1143 Circuit diagram (cabin 3/5)......................................................................................1144 Circuit diagram (cabin 4/5)......................................................................................1145 Circuit diagram (cabin 5/5)......................................................................................1146 Circuit diagram (machine 1/5)....................................................................................1147 Circuit diagram (machine 2/5)....................................................................................1148 Circuit diagram (machine 3/5)....................................................................................1149 Circuit diagram (machine 4/5)....................................................................................1150 Circuit diagram (machine 5/5)....................................................................................1151 Connector diagram 1/8............................................................................................1152 Connector table for revolving frame harness..................................................................1152 Connector diagram 2/8............................................................................................1153 Connector table for operator‘s cab wiring harness (Part 1/2).................................................1153 Connector diagram 3/8............................................................................................1154 Connector table for operators cab wiring harness (Part 2/2)..................................................1154 Connector diagram (4/8)..........................................................................................1155 Connector table various wiring harness (Part 1/3)............................................................1155 Connector diagram (5/8)..........................................................................................1156 Connector table various wiring harness (Part 2/3)............................................................1156 Connector diagram (6/8)..........................................................................................1157 Connector table various wiring harness (Part 3/3)............................................................1157 Connector diagram (7/8)..........................................................................................1158 Connector table optionally wiring harness....................................................................1158 Connector diagram (8/8)..........................................................................................1159
DESCRIPTION:
KOMATSU PW180-10 SHOP MANUAL VENBM63001 – PDF DOWNLOAD
General precautions
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
S.S 26/12/24
