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KOMATSU PW140-7 SHOP MANUAL VEBM410101 – PDF DOWNLOAD
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KOMATSU PW140-7 SHOP MANUAL VEBM410101 – PDF DOWNLOAD
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KOMATSU PW140-7 SHOP MANUAL VEBM410101 – PDF DOWNLOAD
Language : English
Pages : 1144
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File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PW140-7 SHOP MANUAL VEBM410101 – PDF DOWNLOAD
PW140-7 VEBM410101................................................................................................ 1 CONTENTS............................................................................................................. 3 FOREWORD............................................................................................................. 5 Safety........................................................................................................... 5 Important safety notice...................................................................................... 5 General precautions.......................................................................................... 5 Preparations for work........................................................................................ 5 Precautions during work...................................................................................... 6 List of revised pages............................................................................................ 7 General.......................................................................................................... 13 General...................................................................................................... 13 Structure and function....................................................................................... 13 Testing, adjusting and troubleshooting....................................................................... 13 Disassembly and assembly..................................................................................... 13 Maintenance standard......................................................................................... 13 How to read the shop manual...................................................................................... 14 Volumes...................................................................................................... 14 Distribution and updating................................................................................ 14 Filing method................................................................................................ 14 Revised edition mark......................................................................................... 14 Revisions.................................................................................................... 14 Symbols...................................................................................................... 14 Hoisting instructions............................................................................................ 15 Hoisting..................................................................................................... 15 Wire Ropes............................................................................................... 15 Coating materials................................................................................................ 16 Standard tightening torque....................................................................................... 18 Standard tightening torque of bolts and nuts................................................................. 18 Tightening torque of hose nuts............................................................................... 19 Tightening torque of split flange bolts...................................................................... 19 Tightening torques for hoses (taper seal type and face seal type)............................................ 19 Tightening torque for 107 engine series (bolts and nuts)..................................................... 20 Tightening torque for 107 engine series (eye joints)......................................................... 20 Tightening torque for 107 engine series (tapered screws)..................................................... 20 Electric wire code............................................................................................... 21 Classification by thickness.................................................................................. 21 Classification by color and code............................................................................. 21 Conversion tables................................................................................................ 22 Method of using the conversion table......................................................................... 22 Units............................................................................................................ 28 GENERAL.............................................................................................................. 29 Specification dimension drawings................................................................................. 30 Dimensions................................................................................................... 30 1 Piece boom............................................................................................. 30 Dimensions................................................................................................... 32 2 Piece boom............................................................................................. 32 Working ranges................................................................................................... 34 Working range: 1 piece boom.................................................................................. 34 Working range: 2 piece boom.................................................................................. 35 Specifications................................................................................................... 37 Weight table..................................................................................................... 39 1 piece boom................................................................................................. 40 2 piece boom................................................................................................. 41 Fuel, coolant and lubricants..................................................................................... 42 Engine related parts............................................................................................. 44 Outline...................................................................................................... 44 Radiator - Oil cooler - Charge air cooler........................................................................ 45 Specifications............................................................................................... 45 Power train...................................................................................................... 46 Swing circle..................................................................................................... 48 Specifications............................................................................................... 48 Swing machinery & motor.......................................................................................... 49 Specification................................................................................................ 50 Operation of swing lock...................................................................................... 51 Relief valve portion......................................................................................... 52 Operation................................................................................................ 52 Undercarriage.................................................................................................... 54 Transmission..................................................................................................... 56 Specifications............................................................................................... 56 Function..................................................................................................... 57 Quick coupler control valve...................................................................................... 59 Specification................................................................................................ 59 Operation.................................................................................................... 59 Travel motor..................................................................................................... 62 Function..................................................................................................... 63 Operation of travel motor.................................................................................... 64 Clutch control circuit........................................................................................... 66 Function..................................................................................................... 67 Axle............................................................................................................. 68 Outline...................................................................................................... 68 Suspension lock cylinder......................................................................................... 72 Specifications............................................................................................... 72 Structure and function....................................................................................... 72 Circuit...................................................................................................... 73 Axle oscillation............................................................................................. 73 Braking system................................................................................................... 74 Structure and function....................................................................................... 75 Brake/steer pump................................................................................................. 76 Specifications............................................................................................... 76 Function..................................................................................................... 76 Priority valve................................................................................................... 77 Specification................................................................................................ 77 Function..................................................................................................... 77 Power brake valve................................................................................................ 78 Specifications............................................................................................... 79 Function..................................................................................................... 79 Accumulator for brake valve...................................................................................... 80 Specifications............................................................................................... 80 Structure ans function....................................................................................... 80 Steering system.................................................................................................. 81 Structure and function....................................................................................... 81 Steering column.................................................................................................. 82 Orbitrol valve................................................................................................... 83 Specifications............................................................................................... 83 Structure and function....................................................................................... 83 Hydraulic equipment layout drawings.............................................................................. 84 Hydraulic circuit diagram........................................................................................ 86 Hydraulic tank................................................................................................... 87 Specifications............................................................................................... 88 Hydraulic pump................................................................................................... 89 Function..................................................................................................... 91 Structure.................................................................................................... 91 Operation.................................................................................................... 92 LS valve..................................................................................................... 94 PC valve..................................................................................................... 95 Function................................................................................................. 96 Operation................................................................................................ 98 1. LS valve.............................................................................................. 98 2. PC valve.............................................................................................. 102 LS(PC)-EPC valve............................................................................................. 109 Function................................................................................................. 110 Operation................................................................................................ 110 Pilot pressure control (PPC) system.............................................................................. 113 Function..................................................................................................... 114 Operation.................................................................................................... 114 Control valve.................................................................................................... 115 PW140-7...................................................................................................... 115 Outline.................................................................................................. 115 CLSS............................................................................................................. 126 Outline of CLSS.............................................................................................. 126 Features................................................................................................. 126 Structure................................................................................................ 126 Basic Principle.............................................................................................. 127 Operation for each function and valve........................................................................ 129 Hydraulic circuit diagram and name of valves............................................................. 129 1. Unload valve.............................................................................................. 131 Function................................................................................................. 131 Operation................................................................................................ 131 Operation................................................................................................ 132 Operation................................................................................................ 133 2. Introduction of LS pressure............................................................................... 134 Work equipment valve..................................................................................... 134 Function................................................................................................. 134 Operation................................................................................................ 134 3. LS bypass plug............................................................................................ 135 Outline.................................................................................................. 135 Operation................................................................................................ 135 4. Pressure compensation valve............................................................................... 137 Function................................................................................................. 137 Operation................................................................................................ 138 5. Area ratio of pressure compensation valve................................................................. 139 Function................................................................................................. 139 6. Boom regeneration circuit................................................................................. 141 Function................................................................................................. 141 Operation................................................................................................ 141 Function................................................................................................. 142 Operation................................................................................................ 142 7. Arm regeneration circuit.................................................................................. 143 Function................................................................................................. 143 Operation................................................................................................ 143 Function................................................................................................. 144 Operation................................................................................................ 144 8. Swing bleeding valve...................................................................................... 145 Function................................................................................................. 145 Operation (In fine control operation).................................................................... 145 9. Variable type pressure compensation valve (for service)................................................... 146 Function................................................................................................. 146 Simultaneous operation with work equipment under heavy load (boom RAISE, etc.)........................... 146 10. LS select valve.......................................................................................... 147 Function................................................................................................. 147 Operation................................................................................................ 147 Centre swivel joint.............................................................................................. 148 Travel PPC pedal................................................................................................. 149 Work equipment - Swing PPC valve................................................................................. 151 Operation.................................................................................................... 154 Solenoid valve block............................................................................................. 157 Solenoid valve block......................................................................................... 159 2 position 3 way valve....................................................................................... 159 Operation................................................................................................ 159 2 position 4 way valve................................................................................... 161 Operation................................................................................................ 161 Attachment PPC valve......................................................................................... 163 Function................................................................................................. 164 Operation................................................................................................ 164 Boom safety valve................................................................................................ 166 Operation.................................................................................................... 167 Hydraulic cylinder............................................................................................... 168 Boom cylinder................................................................................................ 168 Arm cylinder................................................................................................. 168 Bucket cylinder.............................................................................................. 168 Adjust cylinder.............................................................................................. 169 Outrigger cylinder............................................................................................... 170 Function..................................................................................................... 171 Dozer cylinder................................................................................................... 172 Function..................................................................................................... 173 Work equipment................................................................................................... 174 Work equipment............................................................................................... 175 1. Dimension of arm.......................................................................................... 176 2. Dimension of bucket....................................................................................... 178 Air conditioner.................................................................................................. 180 Air conditioner piping....................................................................................... 180 Electrical wiring diagramm....................................................................................... 181 Electrical system................................................................................................ 182 Engine control............................................................................................... 182 1. Operation of System................................................................................... 182 2. Component............................................................................................. 183 Engine controller........................................................................................ 184 Engine throttle and pump controller...................................................................... 186 Electrical control system........................................................................................ 188 Machine control system diagram............................................................................... 189 1. Engine and pump control function...................................................................... 191 Function................................................................................................. 192 Function................................................................................................. 196 Function................................................................................................. 198 Function................................................................................................. 200 Operation................................................................................................ 201 Function................................................................................................. 202 Function................................................................................................. 204 Function................................................................................................. 206 Function................................................................................................. 209 Specifications........................................................................................... 210 Function................................................................................................. 210 Function................................................................................................. 211 Operation................................................................................................ 211 Machine monitor system........................................................................................... 213 Monitor panel................................................................................................ 214 Outline.................................................................................................. 214 Monitor control, display portion............................................................................. 216 Monitor gauge displays....................................................................................... 219 Keypad layout................................................................................................ 223 Liquid crystal monitor adjustment switch..................................................................... 234 Adjustment screens....................................................................................... 234 Password function........................................................................................ 237 Method of setting, changing password..................................................................... 237 Service meter check function............................................................................. 239 Display lcd check function............................................................................... 239 User code display function............................................................................... 240 Overload warning device.......................................................................................... 241 Outline...................................................................................................... 241 Function................................................................................................. 241 Structure................................................................................................ 241 Sensor........................................................................................................... 242 Coolant temperature sensor................................................................................... 243 Oil pressure switch.......................................................................................... 243 Rotation sensor.............................................................................................. 244 Boost pressure and temperature sensor........................................................................ 244 WIF (Water-In-Fuel detection) sensor......................................................................... 245 Engine oil level sensor...................................................................................... 245 Coolant level sensor......................................................................................... 246 Coolant temperature sensor................................................................................... 247 Hydraulic oil temperature sensor......................................................................... 247 Fuel level sensor............................................................................................ 247 Air cleaner clogging sensor.................................................................................. 248 Overload Caution sensor...................................................................................... 248 Swing proximity sensor....................................................................................... 249 Travel PPC sensor............................................................................................ 249 PPC pressure sensor.......................................................................................... 249 Park brake pressure sensor................................................................................... 250 Brake accumulator low pressure sensor.................................................................... 250 Brake stop light sensor.................................................................................. 250 1st attachment circuit hydraulic performance (main valve bypassed)............................................... 251 Travel system.................................................................................................... 252 Travel circuit............................................................................................... 252 1. Travel motor.......................................................................................... 254 2. Travel pedal.......................................................................................... 263 3. Forward / Neutral / Reverse switch (F-N-R)............................................................ 264 4. Forward / Reverse travel solenoid..................................................................... 265 5. Travel / neutral solenoid............................................................................. 266 6. Travel creep solenoid................................................................................. 267 7. 2-Stage relief solenoid............................................................................... 268 8. Transmission clutch control valve..................................................................... 270 Steering system.................................................................................................. 271 Operating principles......................................................................................... 271 Dynamic Steering......................................................................................... 271 2 - stage principle...................................................................................... 271 1. Condition 1........................................................................................... 272 2. Condition 2........................................................................................... 273 3. Condition 3........................................................................................... 274 4. Condition 4........................................................................................... 275 5. Condition 5........................................................................................... 276 6. Condition 6........................................................................................... 277 7. OLS priority valve.................................................................................... 278 8. Load sensing steering unit............................................................................ 279 Service brake and suspension system.............................................................................. 284 Braking system............................................................................................... 284 Operation................................................................................................ 287 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD......................................................................... 43 Operational and control features................................................................................. 253 Operational and Control features (1)......................................................................... 253 Operational and Control features (2)......................................................................... 253 Operational and Control features (3)......................................................................... 253 Shematic..................................................................................................... 60 Komtrax terminal system.......................................................................................... 289 ATT EPC valve assembly........................................................................................... 61 KOMTRAX terminal............................................................................................. 290 Standard value table for engine related parts.................................................................... 294 Standard value table for chassis related parts................................................................... 295 TESTING AND ADJUSTING (20-1)......................................................................................... 293 Checking fuel circuit for leakage................................................................................ 330 Checking and adjusting air conditioner compressor belt tension................................................... 331 Checking..................................................................................................... 331 Adjusting.................................................................................................... 331 Replacing the fan belt........................................................................................... 332 Measurement of clearance in swing circle bearing................................................................. 333 Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel.... 334 Measurement.................................................................................................. 334 Adjustment................................................................................................... 335 Inspection and adjustment of control circuit oil pressure........................................................ 337 Measurement.................................................................................................. 337 Procedure for pressure reducing adjustment................................................................... 338 Inspection and adjustment of pump PC (valve inlet) control oil pressure.......................................... 339 Measurement.................................................................................................. 339 Adjustment................................................................................................... 341 Inspection and adjustment of pump LS valve control oil pressure.................................................. 342 Measurement.................................................................................................. 342 Adjustment................................................................................................... 345 Measurement of solenoid valve output pressure.................................................................... 346 Measurement of PPC valve output pressure......................................................................... 351 Checking Proportional Control PPC Circuit.................................................................... 352 Adjustment of work equipment and swing PPC valve................................................................. 353 TESTING AND ADJUSTING (20-101)....................................................................................... 309 Measuring and adjusting quick coupler control valve output pressure.............................................. 354 Measuring engine speed........................................................................................... 310 Measuring intake air pressure (boost pressure)................................................................... 311 Checking exhaust gas colour...................................................................................... 312 Adjusting valve clearance........................................................................................ 314 Measurement of compression pressure.............................................................................. 316 Measuring blow-by pressure....................................................................................... 318 Measuring engine oil pressure.................................................................................... 319 Handling fuel system parts....................................................................................... 320 Releasing residual pressure from fuel system..................................................................... 321 Measuring fuel pressure.......................................................................................... 322 Measuring fuel return rate and leakage........................................................................... 324 Bleeding air from fuel circuit................................................................................... 328 Operation of operators menu and diplay (outline)............................................................. 374 Table for failure code no.................................................................................... 381 Operation and display of service menu........................................................................ 384 Way of switching to service menu......................................................................... 384 Table for monitoring items............................................................................... 387 Solenoid valve block......................................................................................... 348 Testing travel motor relief pressure............................................................................. 356 Measuring travel motor relief pressure....................................................................... 356 Adjusting travel motor relief pressure........................................................................... 357 Testing propshaft speed.......................................................................................... 358 Measuring rotating speed of propshaft........................................................................ 358 Testing transmission clutch control circuit...................................................................... 359 Description.................................................................................................. 359 Inspection of locations of hydraulic drift of work equipment..................................................... 361 Release of remaining pressure in hydraulic circuit............................................................... 363 Measurement of oil leakage....................................................................................... 364 Air bleeding of various parts.................................................................................... 367 Inspection procedures for diode.................................................................................. 370 Special function of monitor panel................................................................................ 372 Preparations for troubleshooting of electrical system............................................................ 404 Procedure for turning on KOMTRAX terminal........................................................................ 406 TESTING AND ADJUSTING (20-201)....................................................................................... 413 Troubleshooting.................................................................................................. 413 Points to remember when troubleshooting.......................................................................... 414 Sequence of events in troubleshooting............................................................................ 415 Points to remember when carrying out maintenance................................................................. 416 1. Points to remember when handling electric equipment....................................................... 416 2. Points to remember when troubleshooting electric circuits................................................. 422 3. Points to remember when handling hydraulic equipment...................................................... 423 Checks before troubleshooting.................................................................................... 425 Classification and steps for troubleshooting..................................................................... 426 Classification of troubleshooting............................................................................ 426 Steps for troubleshooting................................................................................ 426 Failure-looking phenomenon and troubleshooting no................................................................ 427 Connector location chart and electrical circuit diagram by system................................................ 434 Connector table.............................................................................................. 434 Connector locations.............................................................................................. 442 Connection table for connector pin numbers....................................................................... 464 T-boxes and T-adapters table................................................................................. 492 Before carrying out troubleshooting when failure code is displayed............................................... 500 Information contained in troubleshooting table................................................................... 501 Failure code [6B2JMA] - Abnormality in travel PPC switch hydraulics.............................................. 503 Failure code [989L00] - Engine controller lock caution 1......................................................... 504 Failure code [989M00] - Engine controller lock caution 2......................................................... 505 Failure code [989N00] - Engine controller lock caution 3......................................................... 506 Failure code [AA10NX] - Air cleaner clogging..................................................................... 507 Failure code [AB00KE] - Charge voltage low....................................................................... 508 Failure code [B@BAZG] - Eng oil press. low....................................................................... 509 Failure code [B@BAZK] - Eng oil level low........................................................................ 510 Failure code [B@BCNS] - Eng water overheat....................................................................... 511 Failure code [B@BCZK] - Eng water level low...................................................................... 512 Failure code [B@HANS] - Hydr oil overheat........................................................................ 513 Failure code [CA111] - EMC critical internal failure............................................................. 514 Failure code [CA115] - Engine neutral and backup speed sensor error.............................................. 515 Failure code [CA122] - Chg air press sensor high error........................................................... 516 Failure code [CA123] - Chg air press sensor low error............................................................ 518 Failure code [CA131] - Throttle sensor high error................................................................ 520 Failure code [CA132] - Throttle sensor low error................................................................. 522 Failure code [CA144] - Coolant temp sens high error.............................................................. 524 Failure code [CA145] - Coolant temp sens low error............................................................... 526 Failure code [CA153] - Chg air temp sensor high error............................................................ 528 Failure code [CA154] - Chg air temp sensor low error............................................................. 530 Failure code [CA155] - Chg air temp high speed derate............................................................ 532 Failure code [CA187] - Sens supply 2 volt low error.............................................................. 534 Failure code [CA221] - Ambient press sens high error............................................................. 536 Failure code [CA222] - Ambient press sens low error.............................................................. 538 Failure code [CA227] - Sens supply 2 volt high error............................................................. 540 Failure code [CA234] - Eng overspeed............................................................................. 541 Failure code [CA238] - Ne speed sens supply volt error........................................................... 542 Failure code [CA271] - IMV/PCV1 short error...................................................................... 543 Failure code [CA272] - IMV/PCV1 open error....................................................................... 544 Failure code [CA322] - Inj #1 (L#1) open/short error............................................................. 546 Failure code [CA324] - Inj #3 (L#3) open/short error............................................................. 548 Failure code [CA331] - Inj #2 (L#2) open/short error............................................................. 550 Failure code [CA332] - Inj #4 (L#4) open/short error............................................................. 552 Failure code [CA342] - Calibration code incompatibility.......................................................... 554 Failure code [CA351] - Injectors drive circuit error............................................................. 556 Failure code [CA352] - Sens supply 1 volt low error.............................................................. 558 Failure code [CA386] - Sens supply 1 volt high error............................................................. 560 Failure code [CA428] - Water in fuel sensor high error........................................................... 562 Failure code [CA429] - Water in fuel sensor low error............................................................ 564 Failure code [CA435] - Eng oil press sw error.................................................................... 566 Failure code [CA441] - Battery voltage low error................................................................. 567 Failure code [CA442] - Battery voltage high error................................................................ 570 Failure code [CA449] - Rail press very high error................................................................ 572 Failure code [CA451] - Rail press sensor high error.............................................................. 574 Failure code [CA452] - Rail press sensor low error............................................................... 576 Failure code [CA488] - Chg air temp high torque derate........................................................... 578 Failure code [CA553] - Rail press high error..................................................................... 579 Failure code [CA559] - Rail press low error...................................................................... 580 Failure code [CA689] - Eng Ne speed sensor error................................................................. 582 Failure code [CA731] - Eng bkup speed sens phase error........................................................... 584 Failure code [CA757] - All continuous data lost error............................................................ 586 Failure code [CA778] - Eng G speed sensor error.................................................................. 588 Failure code [CA1633] - KOMNET datalink timeout error............................................................ 590 Failure code [CA2185] - Throttle sensor supply voltage high error................................................ 592 Failure code [CA2186] - Throttle sensor supply voltage low error................................................. 593 Failure code [CA2249] - Rail press very low error................................................................ 594 Failure code [CA2311] - IMV solenoid error....................................................................... 596 Failure code [CA2555] - Grid htr relay volt high error........................................................... 598 Failure code [CA2556] - Grid heater relay volt low error......................................................... 600 Failure code [D110KB] - Short-circuiting in battery relay........................................................ 602 Failure code [D19JKZ] - Personal code relay abnormality.......................................................... 604 Failure code [DA25KP] - Press. sensor power abnormality.......................................................... 608 Failure code [DA2RMC] - Pump comm. abnormality................................................................... 610 Failure code [DA2SKQ] - Abnormality in inputting model code...................................................... 612 Failure code [DA2SKQ] - Abnormality in inputting model code...................................................... 614 Failure code [DAFRMC] - Monitor comm. abnormality................................................................ 616 Failure code [DDHPAKP] - Abnormality in pump pressure sensor..................................................... 620 Failure code [DDP4KX] - Abnormality in travel PPC pressure switch................................................ 622 Failure code [DDWCKZ] - Abnormality in travel direction control switch........................................... 623 Failure code [DH1OKS] - Abnormality in Pressure sensor power source.............................................. 632 Failure code [DHPAMA] - F pump press sensor abnormality.......................................................... 634 Failure code [DHS5KX] - Abnormality in travel PPC sensor......................................................... 636 Failure code [DHX1MA] - Abnormality in overload caution sensor................................................... 638 Failure code [DLT4KA] - Disconnection in transmission speed sensor in pump controller system..................... 640 Failure code [DW27KA] - Disconnection in transmission clutch solenoid............................................ 642 Failure code [DW27KB] - Short-circuiting in transmission clutch solenoid......................................... 644 Failure code [DW4AKA] - Disconnection in suspension lock solenoid................................................ 646 Failure code [DW4AKB] - Short circuiting in suspension lock solenoid............................................. 648 Failure code [DW4CKA] - Disconnection in PPC lock solenoid....................................................... 650 Failure code [DW4CKB] - PPC lock sol. S/C........................................................................ 652 Failure code [DW4MKA] - Disconnection in creep solenoid.......................................................... 654 Failure code [DW4MKB] - Short-circuiting in creep solenoid....................................................... 656 Failure code [DW44KA] - Disconnection of travel F/R solenoid..................................................... 658 Failure code [DW44KB] - Short-circuiting of travel F/R solenoid.................................................. 660 Failure code [DW45KA] - Disconnection in swing parking brake solenoid............................................ 662 Failure code [DW45KB] - Swing brake sol. S/C..................................................................... 664 Failure code [DW91KA] - Disconnection in travel neutral solenoid................................................. 666 Failure code [DW91KB] - Short-circuiting in travel neutral solenoid.............................................. 668 Failure code [DWK0KA] - Disconnection in 2-stage relief solenoid................................................. 670 Failure code [DWK0KB] - Short-circuiting in 2-stage relief solenoid.............................................. 672 Failure code [DWK2KA] - Disconnection in 2-stage back pressure solenoid.......................................... 674 Failure code [DWK2KB] - Short circuiting in 2-stage back pressure solenoid....................................... 676 Failure code [DXA0KA] - Disconnection in PC-EPC solenoid system.................................................. 678 Failure code [DXA0KB] - Short-circuiting in PC-EPC solenoid...................................................... 680 Failure code [DXE0KA] - Disconnection in LS-EPC solenoid system.................................................. 682 Failure code [DXE0KB] - Short-circuiting in LS-EPC solenoid...................................................... 683 Failure code [DXE4KA] - Service current EPC1 discon.............................................................. 684 Failure code [DXE4KB] - Service current EPC1 short............................................................... 686 Failure code [DXE7KA] - Service current EPC2 discon.............................................................. 688 Failure code [DXE7KB] - Service current EPC2 short............................................................... 690 Failure code [DXE8KA] - Service current EPC3 discon.............................................................. 692 Failure code [DY20KA] - Wiper working abnormality................................................................ 700 Failure code [DY20MA] - Wiper parking abnormality................................................................ 702 Failure code [DY2CKB] - Washer drive S/C......................................................................... 704 Failure code [DY2DKB] - Wiper drive (for) S/C.................................................................... 706 Failure code [DY2EKB] - Wiper drive (rev) S/C.................................................................... 708 TESTING AND ADJUSTING (20-301)....................................................................................... 497 Troubleshooting when failure code is indicated................................................................... 497 Failure code [D862KA] - GPS antenna disconnection................................................................ 606 Failure code [DDC3KZ] - Outrigger switch select abnormality...................................................... 618 Failure code [DFB1KZ] - Service lever potentio 1 abnormality..................................................... 624 Failure code [DFB2KZ] - Service lever potentio 2 abnormality..................................................... 626 Failure code [DFB3L8] - Service lever 1 potentio error........................................................... 628 Failure code [DFB4L8] - Service lever 2 potentio error........................................................... 629 Failure code [DGH2KB] - Hydraulic oil sensor short............................................................... 631 Failure code [DXE8KB] - Service current EPC3 short............................................................... 694 Failure code [DXE9KA] - Service current EPC4 discon.............................................................. 696 Failure code [DXE9KB] - Service current EPC4 short............................................................... 698 Information contained in troubleshooting table................................................................... 712 E-1 - Engine does not start (engine does not rotate)............................................................. 714 E-5 - Auto-decelerator does not work............................................................................. 718 E-6 - Auto engine warm-up device does not work................................................................... 720 E-7 - Preheater does not operate................................................................................. 722 E-8 - All work equipment, swing and travel do not move........................................................... 724 E-9 - One-touch power max switch does not work................................................................... 726 E-10 - No display in monitor panel at all........................................................................ 727 E-11 - Part of display on monitor panel is missing............................................................... 728 E-12 - Monitor panel displays contents irrelevant to the model................................................... 728 E-13 - Fuel level monitor red lamp lights up while engine is running............................................. 729 E-14 - Engine coolant temperature gauge does not indicate normally............................................... 730 E-15 - Hydraulic oil temperature gauge does not display correctly................................................ 732 E-16 - Fuel gauge does not display correctly..................................................................... 733 E-17 - Swing lock monitor does not display correctly............................................................. 734 E-18 - When the monitor switch is operated, no display appears................................................... 736 E-19 - Windshield wiper and window washer do not operate......................................................... 738 E-20 - Alarm buzzer cannot be stopped............................................................................ 740 E-21 - "Boom/Stabiliser RAISE" is not correctly displayed in monitor function.................................... 742 E-22 - "Boom/Stabiliser LOWER" is not correctly displayed in monitor function.................................... 743 E-23 - "Arm DIGGING" is not correctly displayed in monitor function.............................................. 744 E-24 - "Arm DUMPING" is not correctly displayed in monitor function.............................................. 745 E-25 - "Bucket DIGGING" is not correctly displayed in monitor function........................................... 746 E-26 - "Bucket DUMPING" is not correctly displayed in monitor function........................................... 747 E-27 - "SWING" is not correctly displayed in monitor function.................................................... 748 E-28 - "TRAVEL" is not correctly displayed in monitor function................................................... 750 E-29 - "2 Piece Boom" is not correctly displayed in monitor function............................................. 752 E-30 - Air Conditioner does not work............................................................................. 754 E-31 - Travel reverse alarm does not sound....................................................................... 756 E-32 - KOMTRAX system does not operate normally.................................................................. 758 TESTING AND ADJUSTING (20-501)....................................................................................... 711 Troubleshooting of electrical system (E-Mode).................................................................... 711 Information contained in troubleshooting table................................................................... 762 Radio cassette & telephone socket................................................................................ 764 PPC lock circuit................................................................................................. 766 Brake light circuit.............................................................................................. 768 Undercarriage attachments - Mode selection....................................................................... 770 Undercarriage attachments - Front left outrigger................................................................. 772 Undercarriage attachments - Front right outrigger................................................................ 774 Undercarriage attachments - Rear left outrigger.................................................................. 776 Undercarriage attachments - Rear right outrigger................................................................. 778 Heated seat does not warm up..................................................................................... 780 Suspension lock.................................................................................................. 782 Lower wiper does not work (optional fitment)..................................................................... 784 Work lights (operator cab front left)............................................................................ 786 Work lights (operator cab front right)........................................................................... 787 Work lights (operator cab rear).................................................................................. 788 Worklights (boom, arm & counterweight)........................................................................... 790 Cab and counterweight beacon light............................................................................... 792 Air seat compressor (option - air suspension seat)............................................................... 794 Operator cab interior light...................................................................................... 796 Cigar lighter.................................................................................................... 798 Park brake (not activating)...................................................................................... 800 Park brake (displayed symbol).................................................................................... 802 RH PPC Lever clamshell roller switch pushed to the LH position................................................... 804 RH PPC Lever clamshell roller switch pushed to the RH position................................................... 806 RH PPC Lever clamshell roller switch pushed to the RH or LH...................................................... 808 Horns............................................................................................................ 810 Swing lock - Normal operation.................................................................................... 812 Swing lock - Emergency operation................................................................................. 814 Neutral start (engine)........................................................................................... 816 Neutral start (engine) cont’d (A)................................................................................ 817 Neutral start (engine) cont’d (B)................................................................................ 818 Neutral start (engine) cont’d (C)................................................................................ 819 Emergency travel control - Forward............................................................................... 822 Emergency travel control - Neutral............................................................................... 824 Emergency travel control - Reverse............................................................................... 826 Emergency travel control - Reverse cont’d........................................................................ 827 Driving lights - Main beam....................................................................................... 830 Driving lights - Main beam flash................................................................................. 832 Driving lights - Main beam dipped................................................................................ 834 Driving lights - Position lights................................................................................. 836 Driving lights - Position lights cont’d (1) and (2).............................................................. 838 Indicators - Right hand.......................................................................................... 840 Indicators - Left hand........................................................................................... 842 Hazard warning lights............................................................................................ 844 Hazard warning lights cont’d (A)................................................................................. 846 Swing lock proximity switch...................................................................................... 848 TESTING AND ADJUSTING (20-601)....................................................................................... 761 Troubleshooting of electrical system (Error checking of items without monitor codes)............................. 761 System chart for hydraulic and mechanical systems................................................................ 853 Information contained in troubleshooting table................................................................... 857 H-1 - All work equipment lacks power, or travel and swing speeds are slow........................................ 858 H-2 - Engine speed sharply drops or engine stalls................................................................ 859 H-3 - No work equipment, travel or swing move.................................................................... 860 H-4 - Abnormal noise is heard from around hydraulic pump......................................................... 860 H-5 - Auto-decelerator does not work............................................................................. 861 H-6 - Fine control mode does not function........................................................................ 861 H-7 - Boom moves slowly or lacks power........................................................................... 862 H-8 - Arm moves slowly or lacks power............................................................................ 863 H-9 - Bucket moves slowly or lacks power......................................................................... 864 H-10 - Work equipment does not move in its single operation...................................................... 864 H-11 - Work equipment hydraulic drift is too fast................................................................ 865 H-12 - Work equipment has big time lag........................................................................... 866 H-13 - Other work equipment moves when relieving single circuit.................................................. 866 H-14 - One-touch power max. switch does not operate.............................................................. 867 H-15 - In compound operation, work equipment with larger load moves slowly....................................... 867 H-16 - In swing + boom RAISE operation, boom moves slowly........................................................ 867 H-17 - In swing + travel, travel speed drops sharply............................................................. 868 H-18 - Travel speed does not switch.............................................................................. 869 H-19 - Travel speed does not shift, or it is too slow or fast.................................................... 870 H-20 - Machine does not swing.................................................................................... 871 H-21 - Swing acceleration is poor, or swing speed is slow........................................................ 872 H-22 - Excessive overrun when stopping swing..................................................................... 873 H-23 - There is big shock when stopping swing.................................................................... 874 H-24 - There is loud abnormal noise caused when stopping swing................................................... 874 H-25 - Swing natural drift is too big............................................................................ 875 H-26 - Swing speed is faster than specified swing speed.......................................................... 875 Troubleshooting of engine (S-MODE)............................................................................... 878 Method of using troubleshooting chart........................................................................ 878 S-1 - Starting performance is poor............................................................................... 881 S-2 - Engine does not start...................................................................................... 882 S-3 - Engine does not pick up smoothly........................................................................... 885 S-4 - Engine stops during operations............................................................................. 886 S-5 - Engine does not rotate smoothly............................................................................ 887 S-6 - Engine lacks output (or lacks power)....................................................................... 888 S-7 - Exhaust smoke is black (incomplete combustion)............................................................. 889 S-8 - Oil consumption is excessive (or exhaust smoke is blue).................................................... 890 S-9 - Oil becomes contaminated quickly........................................................................... 891 S-10 - Fuel consumption is excessive............................................................................. 892 S-11 - Oil is in coolant (or coolant spurts back or coolant level goes down)..................................... 893 S-12 - Oil pressure drops........................................................................................ 894 S-13 - Oil level rises (Entry of coolant/fuel)................................................................... 895 S-14 - Coolant temperature becomes too high (overheating)........................................................ 896 S-15 - Abnormal noise is made.................................................................................... 897 S-16 - Vibration is excessive.................................................................................... 898 TESTING AND ADJUSTING (20-701)....................................................................................... 851 Troubleshooting of hydraulic and mechanical system (H-MODE)...................................................... 851 Quick coupler.................................................................................................... 876 How to read this manual.......................................................................................... 904 Removal and installation of assemblies....................................................................... 904 Special tools............................................................................................ 904 Removal of parts......................................................................................... 904 Installation of parts.................................................................................... 904 Sketches of special tools................................................................................ 904 DISASSEMBLY AND ASSEMBLY............................................................................................. 899 Coating material lists........................................................................................... 905 Special tools list............................................................................................... 908 Sketches of special tools........................................................................................ 910 List of tools.................................................................................................... 912 Precautions when performing operation............................................................................ 913 Removal and installation of fuel supply pump assembly............................................................ 915 Removal...................................................................................................... 915 Installation................................................................................................. 916 Removal and installation of fuel injector assembly............................................................... 918 Special tools................................................................................................ 918 Removal...................................................................................................... 918 Installation................................................................................................. 920 Removal and installation of front oil seal....................................................................... 923 Special tools................................................................................................ 923 Removal...................................................................................................... 923 Installation................................................................................................. 923 Removal and installation of rear oil seal........................................................................ 925 Special tools................................................................................................ 925 Removal...................................................................................................... 925 Installation................................................................................................. 926 Removal and installation of cylinder head assembly............................................................... 928 Special tools................................................................................................ 928 Removal...................................................................................................... 928 Installation................................................................................................. 933 Removal and installation of combination cooler assembly.......................................................... 938 Removal...................................................................................................... 938 Installation................................................................................................. 940 Removal and installation of engine and hydraulic pump assembly................................................... 941 Special tools................................................................................................ 941 Removal...................................................................................................... 941 Installation................................................................................................. 946 Removal and installation of engine hood assembly................................................................. 948 Removal...................................................................................................... 948 Installation................................................................................................. 948 Removal and installation of travel motor......................................................................... 950 Removal...................................................................................................... 950 Installation................................................................................................. 950 Disassembly and assembly of travel motor assembly................................................................ 952 Disassembly.................................................................................................. 952 Assembly..................................................................................................... 954 Removal and installation of swing motor and swing machinery...................................................... 956 Removal...................................................................................................... 956 Installation............................................................................................. 957 Removal of swing motor assembly.................................................................................. 958 Removal...................................................................................................... 958 Installation................................................................................................. 959 Disassembly and assembly of swing motor and swing machinery...................................................... 960 Disassembly.................................................................................................. 960 Assembly..................................................................................................... 962 Removal and installation of front axle assembly.................................................................. 966 Removal...................................................................................................... 966 Installation................................................................................................. 967 Disassembly and assembly of front axle........................................................................... 968 Disassembly of steering cylinder............................................................................. 968 Assembly of steering cylinder................................................................................ 970 Disassembly of epicyclic reduction gear and brake............................................................ 974 Assembly of epicylic reduction gear and brake................................................................ 978 Disassembly of joint box..................................................................................... 985 Assembly of joint box........................................................................................ 990 Disassembly of beam trumpet and differential unit............................................................ 995 Assembly of beam trumpet and differential unit............................................................... 999 Disassembly of pinion group..................................................................................1006 Assembly of pinion group.....................................................................................1008 Toe-in adjustment............................................................................................1014 Steering angle adjustment....................................................................................1015 Removal and installation of rear axle and transmission...........................................................1017 Removal......................................................................................................1017 Installation.................................................................................................1019 Disassembly and assembly of rear axle assembly...................................................................1020 Special tools................................................................................................1020 Removal of epicyclic reduction gear and brake................................................................1020 Installation of epicylic reduction gear and brake............................................................1024 Disassembly of beam trumpet and differential unit............................................................1032 Installation of beam trumpet and differential unit...........................................................1036 Disassembly of pinion group..................................................................................1042 Installation of pinion group.................................................................................1045 Disassembly and assembly of transmission.........................................................................1051 Special tools................................................................................................1051 Removal of travel motor and flange...........................................................................1051 Installation of travel motor.................................................................................1053 Removal of transmission box..................................................................................1056 Installation of transmission box.............................................................................1066 Removal and installation of propshaft assembly...................................................................1079 Removal......................................................................................................1079 Installation.................................................................................................1079 Removal and installation of wheel................................................................................1080 Removal......................................................................................................1080 Installation.................................................................................................1080 Removal and installation of suspension lock cylinder assembly....................................................1081 Removal......................................................................................................1081 Installation.................................................................................................1081 Disassembly and assembly of suspension lock cylinders............................................................1082 Change Rod Seal..............................................................................................1082 Removal and installation of outrigger assembly...................................................................1083 Removal......................................................................................................1083 Installation.................................................................................................1083 Disassembly and assembly of outriggers...........................................................................1084 Disassembly..................................................................................................1084 Assembly.....................................................................................................1084 Removal and installation of dozer blade assembly.................................................................1085 Removal......................................................................................................1085 Installation.................................................................................................1085 Disassembly and assembly of dozer blade..........................................................................1086 Disassembly..................................................................................................1086 Assembly.....................................................................................................1086 Removal and installation of swing circle assembly................................................................1087 Removal......................................................................................................1087 Installation.................................................................................................1087 Removal and installation of revolving frame assembly.............................................................1088 Removal......................................................................................................1088 Installation.................................................................................................1090 Removal and installation of centre swivel joint..................................................................1091 Removal......................................................................................................1091 Installation.................................................................................................1093 Disassembly and assembly of centre swivel joint assembly.........................................................1094 Special tools................................................................................................1094 Disassembly..................................................................................................1094 Assembly.....................................................................................................1095 Removal and installation of fuel tank assembly...................................................................1096 Removal......................................................................................................1096 Installation.................................................................................................1097 Removal and installation of hydraulic tank assembly..............................................................1098 Removal......................................................................................................1098 Installation.................................................................................................1100 Removal and installation of control valve assembly...............................................................1101 Removal......................................................................................................1101 Installation.................................................................................................1103 Removal and installation of LS separation valve assembly.........................................................1104 Removal......................................................................................................1104 Installation.................................................................................................1104 Removal and installation of pressure compensation valve assembly.................................................1105 Removal......................................................................................................1105 Installation.................................................................................................1105 Removal and installation of main relief valve assembly...........................................................1106 Removal......................................................................................................1106 Installation.................................................................................................1106 Removal and installation of LS control EPC valve.................................................................1107 Removal......................................................................................................1107 Installation.................................................................................................1107 Removal and installation of PC EPC valve assembly................................................................1108 Removal......................................................................................................1108 Installation.................................................................................................1108 Removal and installation of PPC valve block assembly.............................................................1109 Removal......................................................................................................1109 Installation.................................................................................................1109 Removal and installation of oil seal in hydraulic pump input shaft...............................................1110 Special tools................................................................................................1110 Removal......................................................................................................1110 Installation.................................................................................................1110 Disassembly and assembly of work equipment PPC valve.............................................................1111 Assembly.....................................................................................................1111 Disassembly and assembly of hydraulic cylinder...................................................................1112 Special tools................................................................................................1112 Disassembly..............................................................................................1112 Assembly.................................................................................................1114 Removal and installation of monoboom work equipment..............................................................1118 Special tools................................................................................................1118 Removal......................................................................................................1118 Installation.................................................................................................1119 Removal and installation of 2 piece boom work equipment..........................................................1120 Special tools................................................................................................1120 Removal......................................................................................................1120 Installation.................................................................................................1121 Removal and installation of air conditioner unit.................................................................1122 Special tools................................................................................................1122 Removal......................................................................................................1122 Installation.................................................................................................1125 Removal and installation of counterweight........................................................................1126 Removal......................................................................................................1126 Installation.................................................................................................1127 Removal and installation of operator cab assembly................................................................1128 Removal......................................................................................................1128 Installation.................................................................................................1129 Removal and installation of monitor assembly.....................................................................1130 Removal......................................................................................................1130 Installation.................................................................................................1130 Removal and installation of pump controller assembly.............................................................1131 Removal......................................................................................................1131 Installation.................................................................................................1131 Removal and Installation of KOMTRAX terminal.....................................................................1132 Removal......................................................................................................1132 Installation.................................................................................................1132 OTHER................................................................................................................1133 Hydraulic circuit diagram (1/3)..................................................................................1135 Hydraulic circuit diagram (2/3)..................................................................................1136 Hydraulic circuit diagram (3/3)..................................................................................1137 Electrical circuit diagram (1/7).................................................................................1138 Electrical circuit diagram (2/7).................................................................................1139 Electrical circuit diagram (3/7).................................................................................1140 Electrical circuit diagram (4/7).................................................................................1141 Electrical circuit diagram (5/7) - For multi monitor (1/3).......................................................1142 Electrical circuit diagram (6/7) - For multi monitor (2/3).......................................................1143 Electrical circuit diagram (7/7) - For multi monitor (3/3).......................................................1144
DESCRIPTION:
KOMATSU PW140-7 SHOP MANUAL VEBM410101 – PDF DOWNLOAD
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
S.S 21/12/24
