Komatsu MACHINE MODEL PW130ES-6K Service Repair Manual – PDF Download

Description

Komatsu MACHINE MODEL PW130ES-6K Service Repair Manual 

Description:

Komatsu MACHINE MODEL PW130ES-6K Service Repair Manual

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters: these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs , as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling eachr component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

Table of Contents:

Komatsu MACHINE MODEL PW130ES-6K Service Repair Manual

PW130ES- 6K PW130ES- 6K ....................................................................................................................................................................  1
CONTENTS ...................................................................................................................................................................................  2
	10 STRUCTURE AND FUNCTION........................................................Helvetica-Bold ........................................................................................  2
	20 TESTING AND ADJUSTING ............................................................. .................................................................................................  2
	30 DISASSEMBLY AND ASSEMBLY .................................................... .......................................................................................................  2
	40 MAINTENANCE STANDARD........................................................Helvetica-Bold ..........................................................................................  2
CONTENTS ...................................................................................................................................................................................  3
01 GENERAL.........................................................Helvetica-Bold ..........................................................................................................  3
10 STRUCTURE AND FUNCTION ..................................................................................................................................................................  3
20 TESTING AND ADJUSTING ...................................................................................................................................................................  3
30 DISASSEMBLY AND ASSEMBLY ................................................................................................................................................................  3
40 MAINTENANCE STANDARD.................................................. ..................................................................................................................  3
SAFETY .....................................................................................................................................................................................  7
	SAFETY NOTICE ..........................................................................................................................................................................  7
FOREWORD ...................................................................................................................................................................................  9
	GENERAL ................................................................................................................................................................................  9
HOW TO READ THE SHOP MANUAL ................................................................................................................................................................ 10
HOISTING INSTRUCTIONS ...................................................................................................................................................................... 11
COATING MATERIALS .......................................................................................................................................................................... 12
STANDARD TIGHTENING TORQUE ................................................................................................................................................................. 13
ELECTRIC WIRE CODE ......................................................................................................................................................................... 15
CONVERSION TABLE ........................................................................................................................................................................... 16
ENIGNE RELATED PARTS ....................................................................................................................................................................... 24
RADIATOR AND OIL COOLER .................................................................................................................................................................... 25
	SPECIFICATIONS ......................................................................................................................................................................... 25
PTO ( COUPLING) ............................................................................................................................................................................ 26
POWER TRAIN - 20 Km/ h TRAVEL SPEED SPEC. .................................................................................................................................................. 27
POWER TRAIN - 30 Km/ h TRAVEL SPEED SPEC. .................................................................................................................................................. 28
SWING CIRCLE ............................................................................................................................................................................... 29
SWING MACHINERY ............................................................................................................................................................................ 30
UNDERCARRIAGE .............................................................................................................................................................................. 31
TRANSMISSION - 20 Km/ h TRAVEL SPEED SPEC. ................................................................................................................................................. 33
CLUTCH ASS'Y - 30 Km/ h TRAVEL SPEED SPEC. ................................................................................................................................................. 34
TRANSMISSION - 30 Km/ h TRAVEL SPEED SPEC. ................................................................................................................................................. 34
CLUTCH CONTROL CIRCUIT ( 30 Km/ h SPEC. ONLY) .............................................................................................................................................. 35
AXLE ....................................................................................................................................................................................... 37
SUSPENSION LOCK CYLINDER ................................................................................................................................................................... 41
	CIRCUIT ................................................................................................................................................................................ 42
BRAKE & STEERING CIRCUIT ( ITALIAN SPECIFICATION) GEAR PUMP ( ITALIAN SPECIFICATION) BRAKING TRAIN BRAKE/ STEER PUMP ....................................................................... 48
BRAKE PEDAL INCORPORATING BRAKE VALVE ...................................................................................................................................................... 49
PRIORITY VALVE ............................................................................................................................................................................. 50
ACCUMULATOR FOR BRAKE SYSTEM ............................................................................................................................................................... 51
STEERING TRAIN ............................................................................................................................................................................. 52
ITEM ....................................................................................................................................................................................... 53
	POSITIONS .............................................................................................................................................................................. 53
	QUANTITIY OF STEERING TURNS ............................................................................................................................................................ 53
STEERING COLUMN ............................................................................................................................................................................ 55
ORBITROL VALVE ............................................................................................................................................................................. 56
FUEL / HYDRAULIC TANK ...................................................................................................................................................................... 59
FUEL / HYDRAULIC TANK ...................................................................................................................................................................... 60
HYDRAULIC PUMP ............................................................................................................................................................................. 62
	MAIN PUMP .............................................................................................................................................................................. 63
	LS VALVE ............................................................................................................................................................................... 68
	PC VALVE ............................................................................................................................................................................... 68
	FIXED THROTTLE VALVE ................................................................................................................................................................... 69
PPC PUMPLESS SYSTEM ........................................................................................................................................................................ 82
CONTROL VALVE .............................................................................................................................................................................. 84
	EXTERNAL VIEW .......................................................................................................................................................................... 85
CLSS ....................................................................................................................................................................................... 94
SWING MOTOR ................................................................................................................................................................................124
CENTER SWIVEL JOINT ........................................................................................................................................................................129
FRONT TRAVEL MOTOR ( 20 Km/ h TRAVEL SPEED SPEC.) ..........................................................................................................................................130
	HYDRAULIC SCHEMATIC ....................................................................................................................................................................130
FRONT TRAVEL MOTOR ( 30 Km/ h TRAVEL SPEED SPEC.) ..........................................................................................................................................131
	HYDRAULIC SCHEMATIC ....................................................................................................................................................................131
REAR TRAVEL MOTOR ( 20 Km/ h TRAVEL SPEED SPEC.) ...........................................................................................................................................132
	HYDRAULIC SCHEMATIC ....................................................................................................................................................................132
REAR TRAVEL MOTOR ( 30 Km/ h TRAVEL SPEED SPEC.) ...........................................................................................................................................133
OPERATION OF TRAVEL MOTORS ( 30 Km/ h TRAVEL SPEED SPEC.) ..................................................................................................................................134
WORK EQUIPMENT - SWING PPC VALVE ...........................................................................................................................................................136
TRAVEL PPC VALVE PEDAL .....................................................................................................................................................................140
SAFETY LOCK SWITCH PPC MANIFOLD BLOCK ......................................................................................................................................................144
PPC MANIFOLD BLOCK PRESSURE SWITCHES SOLENOID VALVE ........................................................................................................................................146
TRAVEL SPEED, SWING BRAKE, 2- STAGE RELIEF SUSPENSION LOCK SOLENOID VALVE ..................................................................................................................147
BOOM SAFETY VALVE ..........................................................................................................................................................................148
HYDRAULIC CYLINDERS ( Boom & Arm) ..........................................................................................................................................................151
	BOOM LIFT CYLINDER .....................................................................................................................................................................151
	ARM CYLINDER ...........................................................................................................................................................................151
	BUCKET CYLINDER ........................................................................................................................................................................151
	BOOM ADJUST CYLINDER ...................................................................................................................................................................152
OUTRIGGER CYLINDER DOZER BLADE CYLINDER WORK EQUIPMENT - ONE PIECE BOOM WORK EQUIPMENT - TWO PIECE BOOM ....................................................................................155
ENGINE CONTROL SYSTEM ......................................................................................................................................................................160
	FUNCTION ...............................................................................................................................................................................180
MACHINE MONITOR SYSTEM .....................................................................................................................................................................189
	DISPLAY MONITOR ........................................................................................................................................................................191
	MODE SELECTION SWITCHES ................................................................................................................................................................192
OVERLOAD WARNING DEVICE ....................................................................................................................................................................196
BREAKER MODE HYDRAULIC PERFORMANCE ( MAIN VALVE BYPASSED) ..................................................................................................................................197
BREAKER MODE HYDRAULIC PERFORMANCE ( VIA MAIN VALVE) .......................................................................................................................................198
TABLE OF JUDGEMENT STANDARD VALUE ..........................................................................................................................................................201
STANDARD VALUE TABLE FOR ELECTRICAL PARTS ..................................................................................................................................................211
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOUTING ..........................................................................................................................................220
CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR .........................................................................................................................221
ADJUSTING ENGINE SPEED SENSOR ..............................................................................................................................................................222
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE ..........................................................................................................................................223
TESTING CLEARANCE OF SWING CIRCLE BEARING ..................................................................................................................................................224
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT ..........................................................................................................225
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE ( SERVO PISTON INPUT PRESSURE) ..............................................................................................................228
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE ( SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE .................................................................................230
TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE ...........................................................................................................................................232
TESTING SOLENOID VALVE OUPUT PRESSURE ......................................................................................................................................................233
MEASURING PPC VALVE OUTPUT PRESURE .........................................................................................................................................................234
TESTING TRAVEL MOTOR RELIEF PRESSURE .......................................................................................................................................................235
ADJUSTING TRAVEL MOTOR RELIEF PRESSURE .....................................................................................................................................................236
TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT ................................................................................................................................................237
CLUTCH CONTROL CIRCUITS COMPONENTS .........................................................................................................................................................239
TESTING CLUTCH CONTROL CIRCUIT .............................................................................................................................................................240
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ................................................................................................................................242
MEASURING OIL LEAKAGE ......................................................................................................................................................................244
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ..........................................................................................................................................245
BLEEDING AIR ...............................................................................................................................................................................246
	ACCUMULATORS ...........................................................................................................................................................................248
POINTS TO REMEMBER WHEN TROUBLESHOOTING ....................................................................................................................................................253
SEQUENSE OF EVENTS IN TROUBLESHOOTING ......................................................................................................................................................254
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ...........................................................................................................................................255
CHECKS BEFORE TROUBLESHOOTING ..............................................................................................................................................................263
CONNECTOR TYPES AND MOUNTING LOCATIONS .....................................................................................................................................................264
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .................................................................................................................................................268
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM .....................................................................................................................................283
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL ......................................................................................................................................284
METHOD OF USING JUDGEMENT TABLE ............................................................................................................................................................294
METHOD OF USING TROUBLESHOOTING CHARTS .....................................................................................................................................................296
M- 9 When starting switch is turned ON ( engine stops), basis check items flash ............................................................................................................297
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE ...................................................................................................................................298
SERVICE CODE TABLE .........................................................................................................................................................................303
N- 1 Communications abnormality ............................................................................................................................................................305
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER ( GOVERNOR CONTROL SYSTEM) ........................................................................308
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE .................................................................................................................309
JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER ( GOVERNOR CONTROL SYSTEM), AND ENGINE RELATED PARTS ..................................................................................313
A3 OPNEMEN A3 OPNEMEN E- 1 Abnormality in governor, pump controller power source ( controller LED is OFF) ..................................................................................317
E- 2 [ E308] Abnormality in fuel control dial input value is displayed .....................................................................................................................318
E3 [ E317] Abnormality ( disconnection) in motor drive system is displayed .................................................................................................................319
E- 4 [ 318] Abnormality ( short circuit) in motor drive system is displayed ................................................................................................................320
E- 5 [ E306] Abnormality in feedback potentiometer system is displayed .....................................................................................................................321
E- 6 [ E315] Abnormality ( short circuit) in battery relay output system is displayed ......................................................................................................322
E- 7 [ E316] Abnormality ( step- out) in motor is displayed ................................................................................................................................323
E- 8 Engine does not start .................................................................................................................................................................325
	E- 9 Engine speed is irregular .........................................................................................................................................................327
	E- 10 Lack of output ( engine high idling speed is too low) ............................................................................................................................331
	E- 11 Engine does not stop .............................................................................................................................................................333
	E- 12 Defective operation of battery relay system ( engine does not stop) ..............................................................................................................335
METHOD OF USING TROUBLESHOOTING CHARTS .....................................................................................................................................................338
S- 1 Starting performance is poor ( starting always takes time) ............................................................................................................................342
S- 2 Engine does not start .................................................................................................................................................................343
S- 3 Engine does not pick up smoothly ( follow- up is poor) ................................................................................................................................346
S- 4 Engine stops during operations ........................................................................................................................................................347
S- 5 Engine does not rotate smoothly ( hunting) ............................................................................................................................................348
S- 6 Engine lacks output ( no power) .......................................................................................................................................................349
S- 7 Exhaust smoke is black ( incomplete combustion) .......................................................................................................................................350
S- 8 Oil consumption is excessive ( or exhaust smoke is blue) ..............................................................................................................................351
S- 9 Oil becomes contaminated quickly ......................................................................................................................................................352
S- 10 Fuel consumption is excessive ........................................................................................................................................................353
S- 11 Oil is in cooling water, or water spurts back, or water level goes down ..............................................................................................................354
S- 12 Oil pressure caution lamp lights up ( drop in oil pressure) ..........................................................................................................................355
S- 13 Oil level rises ( water, fuel in oil) ................................................................................................................................................356
S- 14 Water temperature becomes too high ( overheating) ....................................................................................................................................357
S- 15 Abnormal noise is made ...............................................................................................................................................................358
S- 16 Vibration is excessive ...............................................................................................................................................................359
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM .............................................................................................................................362
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE .................................................................................................................363
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS ............................................................................................................................371
A3 A3 C- 1 Abnormality in controller power source system ( controller LED is OFF) ..........................................................................................................375
C- 2 [ E232] Short circuit in pump PC- EPC solenoid system is displayed ....................................................................................................................376
C- 3 [ E233] Disconnection in PC- EPC solenoid system is displayed .........................................................................................................................378
C- 4 [ E203] Short circuit in swing holding brake solenoid system is displayed .............................................................................................................380
C- 5 [ E213] Disconnection in swing holding brake solenoid system is displayed .............................................................................................................382
C- 6 [ E205] Short circuit in 2- stage relief solenoid system is displayed .................................................................................................................384
C- 7 [ E215] Disconnection in 2- stage relief solenoid system is displayed .................................................................................................................385
C- 8 [ E206] Short circuit in travel speed solenoid system is displayed ....................................................................................................................386
C- 9 [ E216] Disconnection in travel speed solenoid system is displayed ....................................................................................................................387
C- 12 [ E217] Model selection input error is displayed .....................................................................................................................................388
C- 13 [ E222] Short circuit in LS- EPC solenoid system is displayed ........................................................................................................................389
C- 14 [ E223] Disconnection in LS- EPC solenoid system is displayed ........................................................................................................................390
C15 [ E224] Abnormality in pump pressure sensor system is displayed ........................................................................................................................391
C- 16 [ E226] Abnormality in pressure sensor power source system is displayed ..............................................................................................................392
C- 17 [ E227] Abnormality in engine speed sensor system is displayed .......................................................................................................................393
A3 A3 F- 1 BIT PATTERN 20- ( 1) Swing oil pressure switch does not light up ................................................................................................................397
F- 2 Bit pattern 20- ( 2) Travel oil pressure switch does not light up. ....................................................................................................................398
F- 3 Bit pattern 20-( 3) Boom LOWER oil pressure switch does not light up ..................................................................................................................399
F- 4 Bit pattern 20-( 4) Boom RAISE oil pressure switch does not light up ..................................................................................................................400
F- 5 Bit pattern 20-( 5) Arm IN oil pressure switch does not light up ......................................................................................................................401
F- 6 Bit pattern 20-( 6) Arm OUT oil pressure switch does not light up .....................................................................................................................402
F- 7 Bit pattern 21-( 1) Bucket CURL oil pressure switch does not light up .................................................................................................................403
F- 8 Bit pattern 21-( 2) Bucket DUMP oil pressure switch does not light up .................................................................................................................404
F- 9 Bit pattern 21-( 3) Swing lock switch does not light up ...............................................................................................................................405
F- 11 Bit pattern 22-( 6) L. H. knob switch does not light up ..............................................................................................................................406
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM ......................................................................................................................409
H- 1 Speeds of all work equipment, swing, travel are slow or lack power ....................................................................................................................411
H- 2 There is excessive drop in engine speed, or engine stalls .............................................................................................................................413
H- 3 No work equipment, travel, swing move .................................................................................................................................................414
H- 4 Abnormal noise generated ( around pump) H- 5 Auto deceleration does not work ..........................................................................................................415
H- 6 Fine control ability is poor or response is poor H- 7 Boom is slow or lacks power .....................................................................................................417
H- 8 Arm is slow or lacks power. ...........................................................................................................................................................419
H- 9 Bucket is slow or lacks power .........................................................................................................................................................421
H- 10 Work equipment ( boom, arm, bucket) does not move ( but travel and swing are normal) .................................................................................................422
H- 11 Excessive hydraulic drift ( boom, arm, bucket) .......................................................................................................................................422
H- 12 Excessive time lag ( engine at low idling) ...........................................................................................................................................423
H- 13 Other equipment moves when single circuit is relieved. ...............................................................................................................................423
H- 14 In F/ O modes, work equipment speed is faster than specified speed ...................................................................................................................424
H- 15 Lack of power when pressure rises H- 16 In compound operations, work equipment with larger load is slow ..............................................................................424
H- 17 Travel speed is slow .................................................................................................................................................................425
H- 18 Travel speed does not switch or is faster than specified speed. ......................................................................................................................427
H- 19 Does not swing .......................................................................................................................................................................428
H- 20 Swing acceleration is poor ...........................................................................................................................................................429
H- 21 Excessive overrun when stopping swing ................................................................................................................................................431
H- 22 Excessive shock when stopping swing ( one direction only) ............................................................................................................................432
H- 23 Excessive abnormal noise when stopping swing H- 24 Excessive hydraulic drift of swing. ...............................................................................................433
H- 25 Swing speed is faster than specified swing speed .....................................................................................................................................434
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE A3 A3 M- 1 [ E101] Abnormality in error data is displayed [ E102] Error in clock data is displayed ...........443
M- 2 [ E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed. .......................................................................444
M- 3 [ E104] Air clogging detected is displayed ............................................................................................................................................445
M- 4 [ E106] Drop in engine oil pressure detected is displayed .............................................................................................................................445
M- 5 [ E108] Engine water temperature 1050C detected is displayed ..........................................................................................................................446
M- 6 When starting switch is turned ON, none of the lamps on the monitor panel light up for 3 seconds ......................................................................................447
M- 7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out. .........................................................................................449
M- 8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine ( model) .......................................................................449
M- 9 When starting switch is turned ON ( engine stopped), basic check items flashes. .......................................................................................................450
M- 10 Preheating is not being used but ( preheating monitor) lights up .....................................................................................................................452
M- 11 When starting switch is turned ON and engine is started, basic check items flash. ....................................................................................................453
M- 12 When starting switch is turned ON ( engine stopped), caution items, emergency items flash ( battery, engine oil pressure lamps do not light up). .....................................455
M- 13 When starting switch is turned ON and engine is started, caution items, emergency items flash ( when there is no abnormality in engine or items to check before troubleshooting). ....457
M- 14 When starting switch is turned ON ( engine stopped), buzzer does not sound for 1 second. Caution item flashes but buzzer does not sound ..............................................460
M- 15 No abnormality is displayed on monitor but buzzer sounds. ............................................................................................................................460
M- 16 Night lighting on monitor panel does not light up ( liquid crystal display is normal) ................................................................................................461
M- 17 Coolant temperature gauge does not rise ..............................................................................................................................................462
M- 18 Coolant temperature gauge does not give any display ( none of gauge lamps light up during operation) .................................................................................462
M- 19 Fuel level gauge always displays FULL ................................................................................................................................................463
M- 20 Fuel level gauge does not give display ...............................................................................................................................................463
M- 21 Swing lock switch is turned ON ( LOCK ) but ( swing lock monitor) does not light up. .................................................................................................464
M- 22 Swing prolix switch is turned ON ( prolix), but ( swing lock monitor) does not flash. ................................................................................................464
M- 23 Service meter does not advance while engine is running. ..............................................................................................................................465
M- 24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed ..................................................................................465
M- 25 Defective fuel level sensor system. ..................................................................................................................................................466
M- 26 Defective coolant temperature sensor system. .........................................................................................................................................467
M- 27 Defective engine oil level sensor system. ............................................................................................................................................468
M- 28 Defective coolant level sensor system. ...............................................................................................................................................469
M- 30 Wiper does not work or switch is not being used but wiper is actuated ................................................................................................................470
METHOD OF USING MANUAL .....................................................................................................................................................................476
PRECAUTIONS WHEN CARRYING OUT OPERATION ....................................................................................................................................................477
SPECIAL TOOL LIST ..........................................................................................................................................................................479
REMOVAL OF GOVERNOR MOTOR ASSEMBLY .........................................................................................................................................................482
INSTALLATION OF GOVERNOR MOTOR ASSEMBLY ....................................................................................................................................................482
REMOVAL OF ENGINE, MAIN PUMP ASSEMBLY ......................................................................................................................................................483
INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY .................................................................................................................................................487
REMOVAL OF HYADRAULIC OIL COOLER ASSEMBLY ..................................................................................................................................................488
INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY ..............................................................................................................................................488
REMOVAL OF RADIATOR - HYDRAULIC OIL COOLER ASSEMBLY ........................................................................................................................................489
INSTALLATION OF RADIATOR - HYDRAULIC OIL COOLER ASSEMBLY ...................................................................................................................................490
REMOVAL OF FUEL TANK ASSEMBLY ..............................................................................................................................................................491
INSTALLATION OF FUEL TANK ASSEMBLY .........................................................................................................................................................491
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY ....................................................................................................................................................492
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY ...............................................................................................................................................492
REMOVAL OF TRAVEL MOTOR ASSEMBLY ...........................................................................................................................................................493
INSTALLATION OF TRAVEL MOTOR ASSEMBLY ......................................................................................................................................................493
REMOVAL OF SWING MACHINERY Ł SWING MOTOR ASSEMBLY ..........................................................................................................................................494
INSTALLATION OF SWING MACHINERY - SWING MOTOR ASSEMBLY .....................................................................................................................................494
DISASSEMBLY OF SWING MACHINERY ASSEMBLY ....................................................................................................................................................495
ASSEMBLY OF SWING MACHINERY ASSEMBLY .......................................................................................................................................................498
REMOVAL OF SWING MOTOR ASSEMBLY ............................................................................................................................................................502
INSTALLATION OF SWING MOTOR ASSEMBLY .......................................................................................................................................................502
REMOVAL OF REVOLVING FRAME ASSEMBLY ........................................................................................................................................................503
INSTALLATION OF REVOLVING FRAME ASSEMBLY ...................................................................................................................................................504
REMOVAL OF SWING CIRCLE ASSEMBLY ...........................................................................................................................................................505
INSTALLATION OF SWING CIRCLE ASSEMBLY ......................................................................................................................................................505
TRANSMISSION ...............................................................................................................................................................................506
	DISASSEMBLING, SETTING OPERATIONS AND REASSEMBLING .....................................................................................................................................506
	EMERGENCY BRAKE ( Refer to page 30- 49) ................................................................................................................................................508
	SPECIAL TOOLS ..........................................................................................................................................................................508
	GEAR AND CONTROL BOX ...................................................................................................................................................................510
	FLANGE POSITIONING .....................................................................................................................................................................512
	TIGHTENING TORQUES .....................................................................................................................................................................512
	PUMP & CLUTCH ASSEMBLY .................................................................................................................................................................514
FRONT AXLE .................................................................................................................................................................................515
	DISASSEMBLING, SETTING OPERATIONS AND REASSEMBLING .....................................................................................................................................515
	FINAL DRIVES ...........................................................................................................................................................................516
	WHEEL HUBS AND BRAKES ..................................................................................................................................................................517
	WHEEL HUBS AND BRAKES ..................................................................................................................................................................518
	SWIVEL HOUSING .........................................................................................................................................................................519
	SWIVEL PIN BEARING CLEARANCE ...........................................................................................................................................................520
	DRIVE SHAFTS ...........................................................................................................................................................................521
	STEERING CYLINDER - TOE- IN ............................................................................................................................................................522
	BEVEL GEAR AND PINION SET ..............................................................................................................................................................523
	PINION POSITIONING .....................................................................................................................................................................524
	PINION BEARINGS PRE- LOAD ..............................................................................................................................................................525
	ADJUSTMENT OF THE FLANGE ON THE PINION .................................................................................................................................................527
	DIFFERENTIAL ...........................................................................................................................................................................528
	AXLE BEAM ..............................................................................................................................................................................529
REAR AXLE ..................................................................................................................................................................................533
	DISASSEMBLING, SETTING OPERATIONS AND REASSEMBLING .....................................................................................................................................533
	FINAL DRIVES ...........................................................................................................................................................................534
	WHEEL HUBS .............................................................................................................................................................................535
	BRAKES .................................................................................................................................................................................537
	BEVEL GEAR AND PINION SET ..............................................................................................................................................................538
	PINION POSITIONING .....................................................................................................................................................................539
	PINION BEARING PRE- LOAD ...............................................................................................................................................................540
	ADJUSTMENT OF THE FLANGE ON THE PINION .................................................................................................................................................542
	DIFFERENTIAL ...........................................................................................................................................................................543
	AXLE BEAM ..............................................................................................................................................................................544
REMOVAL OF HYDRAULIC TANK ASSEMBLY .........................................................................................................................................................547
INSTALLATION OF HYDRAULIC TANK ASSEMBLY ....................................................................................................................................................548
REMOVAL OF MAIN PUMP ASSEMBLY ..............................................................................................................................................................549
INSTALLATION OF MAIN PUMP ASSEMBLY .........................................................................................................................................................550
REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL ..................................................................................................................................................551
INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL .............................................................................................................................................551
REMOVAL OF CONTROL VALVE ASSEMBLY ..........................................................................................................................................................552
INSTALLATION OF CONTROL VALVE ASSEMBLY .....................................................................................................................................................553
DISASSEMBLY OF CONTROL VALVE ASSEMBLY ......................................................................................................................................................554
ASSEMBLY OF CONTROL VALVE ASSEMBLY .........................................................................................................................................................556
	DISASSEMBLY OF LS SELECT VALVE .........................................................................................................................................................558
	ASSEMBLY OF LS SELECT VALVE ............................................................................................................................................................558
	DISASSEMBLY OF LS SHUTTLE VALVE ........................................................................................................................................................559
	ASSEMBLY OF LS SHUTTLE VALVE ...........................................................................................................................................................559
	IDENTIFICATION OF LS SHUTTLE VALVE .....................................................................................................................................................559
	DISASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY ....................................................................................................................................560
	IDENTIFICATION OF PRESSURE COMPENSATION VALVE ASSEMBLY .................................................................................................................................560
	ASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY .......................................................................................................................................561
	DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY ..............................................................................................................................................562
	ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY .................................................................................................................................................563
REMOVAL OF PC, LS- EPC VALVE ASSEMBLY ......................................................................................................................................................564
INSTALLATION PF PC, LS- EPC VALVE ASSEMBLY .................................................................................................................................................564
REMOVAL OF PC VALVE ASSEMBLY ...............................................................................................................................................................565
INSTALLATION OF PC VALVE ASSEMBLY ..........................................................................................................................................................565
REMOVAL OF LS VALVE ASSEMBLY ...............................................................................................................................................................566
INSTALLATION OF LS VALVE ASSEMBLY ..........................................................................................................................................................566
REMOVAL OF SOLENOID VALVE ASSEMBLY .........................................................................................................................................................567
INSTALLATION OF SOLENOID VALVE ASSEMBLY ....................................................................................................................................................567
REMOVAL OF WORK EQUIPMENT - SWING PPC VALVE ASSEMBLY .......................................................................................................................................568
INSTALLATION OF WORK EQUIPMENT - SWING PPC VALVE ASSEMBLY ..................................................................................................................................568
REMOVAL OF TRAVEL PPC PEDAL ASSEMBLY .......................................................................................................................................................569
INSTALLATION OF TRAVEL PPC PEDAL ASSEMBLY ..................................................................................................................................................569
REMOVAL OF 1ST BOOM CYLINDER ASSEMBLY ......................................................................................................................................................570
INSTALLATION OF 1ST BOOM CYLINDER ASSEMBLY .................................................................................................................................................571
REMOVAL OF ARM CYLINDER ASSEMBLY ...........................................................................................................................................................572
INSTALLATION OF ARM CYLINDER ASSEMBLY ......................................................................................................................................................573
REMOVAL OF BUCKET CYLINDER ASSEMBLY ........................................................................................................................................................574
INSTALLATION OF BUCKET CYLINDER ASSEMBLY ...................................................................................................................................................575
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ( PISTON FIXED WITH NUT TYPE) ...................................................................................................................576
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ( THREADED PISTON TYPE) .........................................................................................................................578
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ( PISTON FIXED WITH NUT TYPE) ......................................................................................................................581
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ( THREADED PISTON TYPE) ............................................................................................................................584
REMOVAL OF WORK EQUIPMENT ASSEMBLY .........................................................................................................................................................588
INSTALLATION OF WORK EQUIPMENT ASSEMBLY ....................................................................................................................................................589
REMOVAL OF BUCKET ASSEMBLY .................................................................................................................................................................590
INSTALLATION OF BUCKET ASSEMBLY ............................................................................................................................................................591
REMOVAL OF ARM ASSEMBLY ....................................................................................................................................................................592
INSTALLATION OF ARM ASSEMBLY ...............................................................................................................................................................593
REMOVAL OF BUCKET - ARM ASSEMBLY ...........................................................................................................................................................594
INSTALLATION OF BUCKET - ARM ASSEMBLY ......................................................................................................................................................595
REMOVAL OF BOOM ASSEMBLY ...................................................................................................................................................................596
INSTALLATION OF BOOM ASSEMBLY ..............................................................................................................................................................597
OUTRIGGER CYLINDER .........................................................................................................................................................................598
	REMOVAL OF OUTRIGGER CYLINDER ..........................................................................................................................................................598
	INSTALLATION OF OUTRIGGER CYLINDER .....................................................................................................................................................598
BLADE CYLINDER .............................................................................................................................................................................599
	REMOVAL OF BLADE CYLINDER ..............................................................................................................................................................599
	INSTALLATION OF BLADE CYLINDER .........................................................................................................................................................599
REMOVAL OF OPERATOR'S CAB ASSEMBLY .........................................................................................................................................................600
INSTALLATION OF OPERATOR'S CAB ASSEMBLY ....................................................................................................................................................602
REMOVAL OF COUNTERWEIGHT ASSEMBLY ..........................................................................................................................................................603
INSTALLATION OF COUNTERWEIGHT ASSEMBLY .....................................................................................................................................................603
REMOVAL OF GOVERNOR, PUMP CONTROLLER ASSEMBLY ..............................................................................................................................................604
INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY .........................................................................................................................................604
REMOVAL OF MONITOR PANEL ASSEMBLY ..........................................................................................................................................................605
INSTALLATION OF MONITOR PANEL ASSEMBLY .....................................................................................................................................................605
ADAPTER WELDING INSTRUCTION - ELECTRODE WELDING ............................................................................................................................................606
SWING MACHINERY ............................................................................................................................................................................610
SWING CIRCLE ...............................................................................................................................................................................612
TRANSMISSION ...............................................................................................................................................................................613
TRANSMISSION - PARK BRAKE ..................................................................................................................................................................614
CLUTCH .....................................................................................................................................................................................615
FRONT AXLE .................................................................................................................................................................................616
REAR AXLE ..................................................................................................................................................................................617
HYDRAULIC PUMP .............................................................................................................................................................................618
CONTROL VALVE ..............................................................................................................................................................................619
SWING MOTOR ................................................................................................................................................................................628
CENTER SWIVEL JOINT ........................................................................................................................................................................629
WORK EQUIPMENT, SWING PPC VALVE ............................................................................................................................................................630
SOLENOID VALVE .............................................................................................................................................................................631
EPC VALVE ..................................................................................................................................................................................632
ARM, BOOM SAFETY VALVE .....................................................................................................................................................................633
HYDRAULIC CYLINDER ( THREADED PISTON TYPE) .................................................................................................................................................634
HYDRAULIC CYLINDER ( PISTON FIXED WITH NUT TYPE) ...........................................................................................................................................635
	DOZER BLADE AND OUTRIGGERS HYDRAULIC CYLINDERS .........................................................................................................................................636
	OUTRIGGER BUSH PINS ....................................................................................................................................................................637
	WORK EQUIPMENT - ONE PIECE BOOM ........................................................................................................................................................638
	WORK EQUIPMENT - TWO PIECE BOOM ........................................................................................................................................................639
	DIMENSION OF WORK EQUIPMENT ............................................................................................................................................................641
	BUCKET CAPACITIES ......................................................................................................................................................................643

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KOMATSU MACHINE MODEL PW130ES-6K SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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