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KOMATSU PW130ES-6K SHOP MANUAL UEBM001201 – PDF DOWNLOAD
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KOMATSU PW130ES-6K SHOP MANUAL UEBM001201 – PDF DOWNLOAD
Language : English
Pages : 643
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PW130ES-6K SHOP MANUAL UEBM001201 – PDF DOWNLOAD
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
DESCRIPTION:
KOMATSU PW130ES-6K SHOP MANUAL UEBM001201 – PDF DOWNLOAD
GENERAL
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.
S.S 22/12/24
