Komatsu 80001 - Page 2

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Table of Contents

Table of Contents6
Safety Notice16
How to Read the Shop Manual21
Explanation of Terms for Maintenance Standard23
Handling of Electric Equipment and Hydraulic Component25
Handling of Connectors Newly Used for Engines34
How to Read Electric Wire Code37
Precautions When Carrying out Operation40
Method of Disassembling and Connecting Push-Pull Type Coupler43
Standard Tightening Torque Table46
Conversion Table50
Specification57
- Specification Dimension Drawings58
- Working Range Diagram59
- Specifications60
- List of Weights64
- List of Lubricant and Coolant to be Filled66
Structure, Function and Maintenance Standard69
- Engine and Cooling System SEN03770-0169
- Power Train SEN03771-0175
- Hydraulic System, Part 193
- Hydraulic System, Part 2129
- Hydraulic System, Part 3175
- Work Equipment SEN03776-00229
  - Work Equipment229
  - Dimensions of Components232
- Cab and Its Attachments SEN03777-00237
Standard Value Table299
- Standard Value Table for Engine Related Parts300
- Standard Value Table for Chassis Related Parts301
Testing and Adjusting Testing and Adjusting, Part311
- Tools for Testing, Adjusting, and Troubleshooting313
- Sketches of Special Tools318
- Testing Engine Speed319
- Testing Exhaust Temperature320
- Checking Exhaust Gas Color321
- Adjusting Valve Clearance322
- Testing Compression Pressure324
- Testing Blow-By Pressure326
- Testing Engine Oil Pressure327
- Reduced Cylinder Mode Operation328
- No-Injection Cranking328
- Handling Fuel System Parts329
- Releasing Residual Pressure from Fuel System329
- Testing Fuel Pressure330
- Testing Fuel Return Rate and Fuel Leakage331
- Bleeding Air from Fuel Circuit333
- Checking Fuel Circuit for Leakage334
- Testing and Adjusting Alternator Belt Tension335
- Checking and Adjusting Air Conditioner Compressor Belt Tension336
- Testing Swing Circle Bearing Clearance337
- Checking and Adjusting Track Shoe Tension338
- Testing and Adjusting Oil Pressure in Work Equipment, Swing, and Travel Circuits340
- Testing Control Circuit Basic Pressure343
- Testing and Adjusting Oil Pressure in Pump PC Control Circuit344
- Testing and Adjusting Oil Pressure in Pump LS Control Circuit347
- Testing Solenoid Valve Output Pressure350
- Testing PPC Valve Output Pressure354
- Adjusting Play of Work Equipment and Swing PPC Valves355
- Checking Parts Which Cause Hydraulic Drift of Work Equipment356
- Testing and Adjusting Travel Deviation358
- Releasing Residual Pressure from Hydraulic Circuit360
- Testing Oil Leakage363
- Bleeding Air from each Part366
- Checking Cab Tipping Stopper368
- Installation and Adjustment of Mirrors and Camera369
- Inspection of Air Conditioner Recirc/Fresh Air Filter380
- Testing and Adjusting, Part 2383
  - Special Functions of Machine Monitor384
- Testing and Adjusting, Part 3435
  - Handling Voltage Circuit of Engine Controller436
  - Testing and Adjusting436
  - Preparation Work for Troubleshooting of Electrical System437
  - Procedure for Testing Diodes442
  - Pm Clinic Service443
Troubleshooting449
- Failure Code Table450
- Fuse Locations454
- Points to Remember When Troubleshooting458
- Troubleshooting458
- Sequence of Events in Troubleshooting459
- Checks before Troubleshooting460
- Classification and Procedures for Troubleshooting461
- Information in Troubleshooting Table462
- Phenomena Looking Like Troubles and Troubleshooting Nos464
- Connection Table for Connector Pin Numbers467
- T- Branch Box and T- Branch Adapter Table503
- Troubleshooting by Failure Code, Part 1507
- Failure Code [CA272] IMV/PCV1 Open Error551
- Failure Code [CA322] Injector #1 (L #1) System Open/Short Error552
- Failure Code [CA324] Injector #3 (L #3) System Open/Short Error554
- Failure Code [CA331] Injector #2 (L #2) System Open/Short Error556
- Failure Code [CA332] Injector #4 (L #4) System Open/Short Error558
Troubleshooting by Failure Code, Part 2561
- Failure Code [CA342] Calibration Code Incompatibility563
- Troubleshooting563
- Failure Code [CA351] Inj. Drive Circuit Error564
- Failure Code [CA352] Sensor Sup. 1 Volt. Low Error567
- Failure Code [CA386] Sensor Sup. 1 Volt. High Error568
- Failure Code [CA435] Abnormality in Engine Oil Pressure Switch570
- Failure Code [CA441] Battery Voltage Low Error571
- Failure Code [CA442] Battery Voltage High Error572
- Failure Code [CA449] Rail Press. very High Error573
- Failure Code [CA451] Rail Press. Sensor High Error574
- Failure Code [CA452] Rail Press. Sensor Low Error576
- Failure Code [CA488] Chg Air Temp High Torque Derate577
- Failure Code [CA553] Rail Press. High Error578
- Failure Code [CA559] Rail Press. Low Error579
- Failure Code [CA689] Eng. Ne Speed Sensor Error582
- Failure Code [CA731] Eng. Bkup Speed Sensor Phase Error584
- Failure Code [CA757] All Persistent Data Lost Error585
- Failure Code [CA778] Eng. Bkup Speed Sensor Error586
- Failure Code [CA1633] KOMNET Datalink Timeout Error588
- Failure Code [CA2185] Throttle Sens. Sup. Volt. High Error590
- Failure Code [CA2186] Throttle Sens. Sup. Volt. Low Error592
- Failure Code [CA2249] Rail Press. very Low Error592
- Failure Code [CA2311] Abnormality in IMV Solenoid593
- Failure Code [D110KB] Battery Relay Drive Short594
- Failure Code [D19JKZ] Personal Code Relay Abnormality596
- Failure Code [D862KA] GPS Antenna Discon598
- Failure Code [DA22KK] Pump Solenoid Power Low Error600
- Failure Code [DA25KP] 5V Sensor 1 Power Abnormality602
- Failure Code [DA26KP] 5V Sensor 2 Power Abnormality605
- Failure Code [DA29KQ] Model Selection Abnormality606
Troubleshooting by Failure Code, Part 3609
- Failure Code [DA2RMC] CAN Discon (Pump Controller Detected)612
- Troubleshooting612
- Failure Code [DAF8KB] Short Circuit in Camera Power Supply614
- Failure Code [DAFGMC] GPS Module Error616
- Failure Code [DAFRMC] CAN Discon (Monitor Detected)618
- Failure Code [DGH2KB] Hydr Oil Sensor Short620
- Failure Code [DHPAMA] Pump Press Sensor Abnormality622
- Failure Code [DHSFMA] Travel Left Forward PPC Press Sensor Abnormality624
- Failure Code [DHSGMA] Travel Right Forward PPC Press Sensor Abnormality626
- Failure Code [DHSHMA] Travel Left Reverse PPC Press Sensor Abnormality628
- Failure Code [DHSJMA] Travel Right Reverse PPC Press Sensor Abnormality630
- Failure Code [DHX1MA] Overload Sensor Abnormality (Analog)632
- Failure Code [DV20KB] Travel Alarm Short Circuit633
- Failure Code [DW43KA] Travel Speed Sol Discon634
- Failure Code [DW43KB] Travel Speed Sol Short635
- Failure Code [DW45KA] Swing Brake Sol Discon636
- Failure Code [DW45KB] Swing Brake Sol Short638
- Failure Code [DW91KA] Travel Junction Sol Discon640
- Failure Code [DW91KB] Travel Junction Sol Short642
- Failure Code [DWJ0KA] Merge-Divider Sol Discon644
- Failure Code [DWJ0KB] Merge-Divider Sol Short646
- Failure Code [DWK0KA] 2-Stage Relief Sol Discon648
  - Failure Code [DWK0KB] 2-Stage Relief Sol Short650
- Troubleshooting by Failure Code, Part 4653
  - Failure Code [DXA8KA] PC-EPC Sol Discon654
  - Troubleshooting654
  - Failure Code [DXA8KB] PC-EPC Sol Short656
  - Failure Code [DXE4KA] Service Current EPC Discon658
  - Failure Code [DXE4KB] Service Current EPC Short660
  - Failure Code [DY20KA] Wiper Working Abnormality662
  - Failure Code [DY20MA] Wiper Parking Abnormality664
  - Failure Code [DY2CKA] Washer Drive Discon666
  - Failure Code [DY2CKB] Washer Drive Short668
  - Failure Code [DY2DKB] Wiper Drive (For) Short670
  - Failure Code [DY2EKB] Wiper Drive (Rev) Short672
  - Before Carrying out Troubleshooting of Electrical System677
  - Troubleshooting677
  - Information in Troubleshooting Table679
  - When Starting Switch Turned ON, Machine Monitor Displays Nothing680
  - When Starting Switch Turned on (before Starting Engine), Basic Check Item Lights up682
  - Engine Does Not Start (Engine Does Not Turn)685
  - Preheater Does Not Operate688
  - Automatic Warm-Up System Does Not Operate (in Cold Season)690
  - All Work Equipment, Swing, and Travel Mechanism Do Not Move or Cannot be Locked692
  - Precaution Lights up While Engine Is Running694
  - Emergency Stop Item Lights up While Engine Is Running699
  - Engine Coolant Temperature Gauge Does Not Indicate Normally700
  - Hydraulic Oil Temperature Gauge Does Not Indicate Normally701
  - Fuel Level Gauge Does Not Indicate Normally703
  - Contents of Display by Machine Monitor Are Different from Applicable Machine705
  - Function Switch Does Not Work705
  - Machine Monitor Does Not Display some Items705
  - Auto-Decelerator Does Not Operate Normally706
  - Working Mode Does Not Change707
  - Travel Speed Does Not Change708
  - Alarm Buzzer Cannot be Stopped709
  - Windshield Wiper and Window Washer Do Not Operate710
  - Power Maximizing Function Does Not Operate Normally714
  - Swing Holding Brake Does Not Operate Normally716
  - Travel Alarm Does Not Sound or Does Not Stop Sounding718
  - Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)719
  - Machine Monitor Cannot be Set in Service Mode731
  - While Starting Switch Is in off Position, Service Meter Is Not Displayed731
  - Monitoring Function Does Not Display Lever Control Signal Normally732
  - KOMTRAX System Does Not Operate Normally748
  - Information Contained in Troubleshooting Table753
  - System Chart for Hydraulic and Mechanical Systems754
  - Speed or Power of All Work Equipment, Swing, and Travel Are Low756
  - Engine Speed Sharply Drops or Engine Stalls757
  - Abnormal Noise Is Heard from Around Hydraulic Pump758
  - No Work Equipment, Travel and Swing Move758
  - Fine Control Mode Does Not Function759
  - Speed or Power of Boom Is Low760
  - Speed or Power of Arm Is Low761
  - Speed or Power of Bucket Is Low762
  - Work Equipment Does Not Move in Its Single Operation763
  - Hydraulic Drift of Work Equipment Is Large764
  - Power Maximizing Function Does Not Operate Normally765
  - Time Lag of Work Equipment Is Large765
- Work Equipment Loaded more Is Slower During Compound Operation766
- Boom RAISE Speed Is Low in Compound Operation of Swing + Boom RAISE766
- Travel Speed Lowers Largely During Compound Operation of Work Equipment/Swing + Travel767
- Machine Deviates During Travel768
- Travel Speed Is Low769
- Machine Cannot be Steered Easily or Steering Power Is Low770
- Travel Speed Does Not Change or It Is Kept Low or High771
- Track Does Not Move (Only Either Side)771
- Machine Does Not Swing772
- Swing Acceleration or Swing Speed Is Low773
- Excessive Overrun When Stopping Swing774
- When Upper Structure Stops Swinging, It Makes Large Shock775
- When Upper Structure Stops Swinging, It Makes Large Sound775
- Hydraulic Drift of Swing Is Large776
- Flow Rate in Attachment Circuit Cannot be Adjusted777
- Method of Using Troubleshooting Chart782
- Starting Performance Is Poor786
- Engine Does Not Start787
- Engine Does Not Pick up Smoothly790
- Engine Stops During Operations791
- Engine Does Not Rotate Smoothly792
- Engine Lacks Output (or Lacks Power)793
- Exhaust Smoke Is Black (Incomplete Combustion)794
- Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)795
- Oil Becomes Contaminated Quickly796
- Fuel Consumption Is Excessive797
- Oil Is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)798
- Oil Pressure Drops799
- Oil Level Rises (Entry of Coolant or Fuel)800
- Coolant Temperature Becomes too High (Overheating)801
- Abnormal Noise Is Made802
- Vibration Is Excessive803
Disassembly and Assembly806
- How to Read this Manual806
- Coating Materials List808
- Special Tool List811
- Sketch of Special Tool815
- Removal and Installation of Fuel Supply Pump Assembly822
- Removal and Installation of Fuel Injector Assembly825
- Removal and Installation of Front Oil Seal828
- Removal and Installation of Rear Oil Seal830
- Removal and Installation of Cylinder Head Assembly833
- Removal and Installation of Radiator Assembly843
- Removal and Installation of Aftercooler Assembly845
- Removal and Installation of Work Equipment Oil Cooler Assembly847
- Removal and Installation of Engine and Work Equipment Pump Assembly849
- Removal and Installation of Fuel Tank Assembly857
- Removal and Installation of Travel Motor and Final Drive Assembly862
- Disassembly and Assembly of Travel Motor and Final Drive Assembly864
- Removal and Installation of Swing Motor and Swing Machinery Assembly901
- Disassembly and Assembly of Swing Machinery Assembly903
Diagrams and Drawings1027
- Hydraulic Circuit Diagram (1/2)1029
- Hydraulic Circuit Diagram1030

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