Komatsu PW170ES-6K Hydraulic Excavator Shop Manual UEBM000500 PDF

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Komatsu PW170ES-6K Hydraulic Excavator Shop Manual UEBM000500 – PDF DOWNLOAD

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Komatsu PW170ES-6K Hydraulic Excavator Shop Manual UEBM000500 – PDF DOWNLOAD 

Language : English
Pages : 625
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PW170ES-6K Hydraulic Excavator Shop Manual UEBM000500 – PDF DOWNLOAD 

SERIAL NUMBERS PW170ES-6 -K30001 and up

MAIN MENU 0
COVER 1
10 STRUCTURE AND FUNCTION 2
ENGINE RELATED PARTS 3
RADIATOR – OIL COOLER, AFTERCOOLER 4
POWER TRAIN 5
SWING CIRCLE 6
SWING MACHINERY 7
UNDERCARRIAGE 9
TRANSMISSION 10
AXLE 13
SUSPENSION LOCK CYLINDER 17
BRAKING TRAIN 19
BRAKE PEDAL 20
BRAKE VALVE 21
ACCUMULATOR FOR BRAKE SYSTEM 22
STEERING TRAIN 23
STEERING COLUMN 25
HYDRAULIC CIRCUIT DIAGRAM 26
HYDRAULIC TANK 28
HYDARULIC PUMP 29
CONTROL VALVE 48
CLSS 58
SWING MOTOR 93
CENTER SWIVEL JOINT 96
TRAVEL MOTOR (FRONT, REAR) 97
WORK EQUIPMENT, SWING PPC VALVE 99
TRAVEL PPC PEDAL 103
SERVICE PPC VALVE 104
SAFETY LOCK VALVE 107
PPC ACCUMULATOR 107
PPC SHUTTLE VALVE 108
EPC, SOLENOID VALVE 111
HYDRAULIC CYLINDER 123
WORK EQUIPMENT 127
ELECTRICAL WIRING DIAGRAM 128
ELECTRICAL WIRING DIAGRAM 129
ELECTRICAL WIRING DIAGRAM 130
ENGINE CONTROL SYSTEM 131
ELECTRONIC CONTROL SYSTEM 137
MACHINE MONITOR SYSTEM 160
20 TESTING AND ADJUSTING 171
TABLE OF JUDGEMENT STANDARD VALUE 172
STANDARD VALUE TABLE FOR ELETRICAL PARTS 182
CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 190
ADJUSTING ENGINE SPEED SENSOR 191
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE 192
TESTING CLEARANCE OF SWING CIRCLE BEARING 194
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 195
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 198
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 200
TESTING AND ADJUSTING PPC PRESSURE 203
TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE 204
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE 206
ADJUSTING WORK EQUIPMENT – SWING PPC VALVE 208
TESTING LOCATION CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 209
MEASURING OIL LEAKAGE 211
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 212
BLEEDING AIR 213
ACCUMULATORS 215
TROUBLESHOOTING 219
POINTS TO REMEMBER WHEN TROUBLESHOOTING 220
SEQUENCE OF EVENTS IN TROUBLESHOOTING 221
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 222
CHECKS BEFORE TROUBLESHOOTING 229
CONNECTOR TYPES 230
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 233
EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM 246
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 247
METHOD OF USING JUDGEMENT TABLE 255
METHOD OF USING TROUBLESHOOTING CHARTS 257
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE 259
SERVICE CODE TABLE 264
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE) 265
N-1 [E218] COMMUNICATION ABNORMALITY 266
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E-MODE 268
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSEM 269
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS 270
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS 274
ELECTRICAL CIRCUIT DIAGRAM OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) 276
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF) 278
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED 279
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED 280
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED 281
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED 282
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY OUTPUT SYSTEM IS DISPLAYED 283
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED 284
E-8 ENGINE DOES NOT START 285
E-9 ENGINE SPEED IS IRREGULAR 287
A) IDLING SPEED IS IRREGULAR 287
B) THERE IS HUNTING 289
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW) 291
E-11 ENGINE DOES NOT STOP 293
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP) 295
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 296
METHOD OF USING TROUBLESHOOTING CHARTS 297
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 301
S-2 ENGINE DOES NOT START 302
(1) ENGINE DOES NOT RUN 302
(2) ENGINE TURNS BUT NOT EXHAUST COMES OUT (FUEL IS NOT BEING INJECTED) 303
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 304
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 305
S-4 ENGINE STOPS DURING OPERATIONS 306
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 307
S-6 ENGINE LACKS OUTPUT (NO POWER) 308
S-7 EXHAUST SMOKE IS BLACK 309
S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST SMOKE IS BLUE 310
S-9 OIL BECOMES CONTAMINATED QUICKLY 311
S-10 FUEL CONSUMPTION IS EXCESSIVE 312
S-11 OIL IS IN COOLING WATER 313
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 314
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 315
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 316
S-15 ABNORMAL NOISE IS MADE 317
S-16 VIBRATION IS EXCESSIVE 318
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE) 319
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM 320
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS 321
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER AND HYDRAULIC RELATED PARTS 327
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEMS 329
C-1 ABNORMALITY IN CONTROLER POWER SOURCE (CONTROLLER LED IS OFF) 331
C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED 332
C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED 334
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED 336
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED 338
C-10 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED 340
C-11 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED 341
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED 342
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED 343
C-16[E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED 344
C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED 345
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED 346
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED 347
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE) 348
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE 349
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP 351
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWTICH DOES NOT LIGHT UP 352
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP 353
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP 354
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP 355
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP 356
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP 357
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP 358
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP 359
F-11 BIT PATTERN 22-(6) L H KNOB SWITCH DOES NOT LIGHT UP 360
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE) 361
TABLE OF FAILURE MODES AND CAUSES 362
ALL WORK EQUIPMENT, TRAVEL, SWING 366
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 366
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 368
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 369
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP) 369
H-5 AUTO-DECELERATION DOES NOT WORK 370
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 370
WORK EQUIPMENT 371
H-7 BOOM IS SLOW OR LACKS POWER 371
H-8 ARM IS SLOW OR LACKS POWER 373
H-9 BUCKET IS SLOW OR LACKS POWER 375
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE 376
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM BUCKET) 376
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 377
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED 377
H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED 378
H-15 LACK OF POWER WHEN PRESSURE RISES 378
COMPOUND OPERATIONS 378
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 378
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 379
TRAVEL SYSTEM 380
H-21 TRAVEL SPEED IS SLOW 380
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED 382
SWING SYSTEM 383
H-25 DOES NOT SWING (BOTH LEFT AND RIGHT, ON DIRECTION ONLY) 383
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY) 384
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY) 386
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 387
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 387
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN BRAKE IS ON, WHEN BRAKE IS OFF) 388
H-31 SWING SPEED IS FASTER THAN SPECIFIED SPEED 389
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 390
ACTION TAKEN BY PANEL AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS 391
ELECTRICAL CIRCUIT DIAGRAM OF MONITOR SYSTEM 393
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED [E102] ERROR IN CLOCK DATA IS DISPLAYED 395
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24 V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED 396
M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED 397
M-4 [E106] DROP IN ENGINE OIL PRESSURE HI DETECTED IS DISPLAYED 397
M-5 [E108] ENGINE WATER TEMPERATURE 105C DETECTED IS DISPLAYED 398
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL LIGHT UP FOR 3 SECONDS 399
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT 401
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL) 401
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH 402
M-10 PREHEATING IS NOT BEING USED BUT PREHEATING MONITOR LIGHTS UP 404
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH 405
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH 407
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH 409
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER 412
M-15 NO ABNROMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS 412
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL) 413
M-17 COOLANT TEMPERATURE GAUGE DOE NOT RISE 414
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY 414
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL 415
M-20 FUEL LEVEL GAUGE DOES NOT GIVE ANY DISPLAY 415
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT SWING LOCK MONITOR DOES NOT LIGHT UP 416
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH 416
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING 417
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED 417
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM 418
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM 419
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM 420
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM 421
M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED 422
30 DISASSEMBLY AND ASSEMBLY 426
METHOD OF USING MANUAL 428
PRECAUTIONS WHEN CARRYING OUT OPERATION 430
SPECIAL TOOL LIST 432
GOVERNOR MOTOR ASSEMBLY 435
REMOVAL AND INSTALLATION 435
HYDRAULIC COOLER ASSEMBLY 436
REMOVAL 436
RADIATOR, HYDRAULIC COOLER ASSEMBLY 437
REMOVAL 437
INSTALLATION 438
ENGINE, MAIN PUMP ASSEMBLY 439
REMOVAL 439
INSTALLATION 442
DAMPER ASSEMBLY 443
REMOVAL AND INSTALLATION 443
FUEL TANK ASSEMBLY 444
REMOVAL AND INSTALLATION 444
CENTER SWIVEL JOINT ASSEMBLY 445
REMOVAL AND INSTALLATION 445
SWING MOTOR ASSEMBLY 446
REMOVAL AND INSTALLATION 446
SWING MACHINERY ASSEMBLY 447
REMOVAL AND INSTALLATION 447
SWING MOTOR 449
DISASSEMBLY AND ASSEMBLY 449
REVOLVING FRAME ASSEMBLY 456
REMOVAL 456
INSTALLATION 458
SWING CIRCLE ASSEMBLY 459
REMOVAL AND INSTALLATION 459
HYDRAULIC TANK ASSEMBLY 461
REMOVAL 461
INSTALLATION 462
MAIN PUMP ASSEMBLY 463
REMOVAL 463
INSTALLATION 464
CONTROL VALVE ASSEMBLY 465
REMOVAL 465
INSTALLATION 466
DISASSEMBLY AND ASSEMBLY 467
LS SELECT VALVE ASSEMBLY 471
DISASSEMBLY AND ASSEMBLY 471
LS SHUTTLE VALVE 472
DISASSEMBLY AND ASSEMBLY 472
PRESSURE COMPENSATION VALVE 473
DISASSEMBLY AND ASSEMBLY 473
MAIN RELIEF VALVE ASSEMBLY 475
DISASSEMBLY 475
ASSEMBLY 476
LS CONTROL EPC VALVE ASSEMBLY 477
REMOVAL AND INSTALLATION 477
EPC SOLENOID VALVE ASSEMBLY 478
REMOVAL AND INSTALLATION 478
PPC SHUTTLE VALVE ASSEMBLY 479
REMOVAL 479
INSTALLATION 480
DISASSEMBLY 481
ASSEMBLY 482
WORK EQUIPMENT PPC VALVE ASSEMBLY 483
REMOVAL AND INSTALLATION 483
TRAVEL PPC PEDAL ASSEMBLY 484
REMOVAL AND INSTALLATION 484
BOOM CYLINDER ASSEMBLY 485
REMOVAL 485
INSTALLATION 486
ARM CYLINDER ASSEMBLY 487
REMOVAL 487
INSTALLATION 488
BUCKET CYLINDER ASSEMBLY 489
REMOVAL 489
INSTALLATION 490
HYDRAULIC CYLINDER ASSEMBLY 491
DISASSEMBLY 491
ASSEMBLY 493
WORK EQUIPMENT ASSEMBLY 496
REMOVAL 496
INSTALLATION 497
BUCKET ASSEMBLY 498
REMOVAL 498
INSTALLATION 498
ARM ASSEMBLY 498
REMOVAL 498
INSTALLATION 498
BUCKET, ARM ASSEMBLY 500
REMOVAL 500
INSTALLATION 500
BOOM ASSEMBLY 502
REMOVAL 502
INSTALLATION 503
OPERATOR’S CAB ASSEMBLY 504
REMOVAL 504
INSTALLATION 506
COUNTERWEIGHT ASSEMBLY 507
REMOVAL AND INSTALLATION 507
GOVERNOR, PUMP CONTROLLER ASSEMBLY 508
REMOVAL AND INSTALLATION 508
MONITOR PANEL ASSEMBLY 509
REMOVAL AND INSTALLATION 509
SWING MACHINERY ASSEMBLY 510
DISASSEMBLY 510
ASSEMBLY 525
(SPECIAL TOOLS) 545
TRANSMISSION 547
FRONT AXLE 554
REAR AXLE 571
BUCKET ADAPTER 585
WELDING INSTRUCTION 585
OUTRIGGER + BLADE CYLINDER 588
40 MAINTENANCE STANDARD 590
ENGINE MOUNT 591
SWING MACHINERY 592
SWING CIRCLE 594
CONTROL VALVE 595
SUCTION SAFETY VALVE 603
SWING MOTOR 604
WORK EQUIPMENT, SWING PPC VALVE 605
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE 606
EPC SOLENOID VALVE 607
CENTER SWIVEL JOINT 608
BOOM SAFETY VALVE (ARM SAFETY VALVE) 609
HYDRAULIC CYLINDER 610
WORK EQUIPMENT 611
DOZER BLADE, OUTRIGGER CLYINDERS 619
OUTRIGGER BUSH PINS 620
TRANSMISSION 621
FRONT AXLE 622
REAR AXLE 623
ARM ROTATION CIRCLE 624

S.V 26/12/24