Description
Komatsu PW140-7 Hydraulic Excavator Shop Manual (VEBM410101)
Komatsu PW140-7 Hydraulic Excavator Index:
PW140-7 VEBM410101
CONTENTS
FOREWORD
Safety
List of revised pages
General
How to read the shop manual
Hoisting instructions
Coating materials
Standard tightening torque
Electric wire code
Conversion tables
Units
GENERAL
Specification dimension drawings
Working ranges
Specifications
Weight table
Fuel, coolant and lubricants
Engine related parts
Radiator – Oil cooler – Charge air cooler
Power train
Swing circle
Swing machinery & motor
Undercarriage
Transmission
Quick coupler control valve
Travel motor
Clutch control circuit
Axle
Suspension lock cylinder
Braking system
Brake/steer pump
Priority valve
Power brake valve
Accumulator for brake valve
Steering system
Steering column
Orbitrol valve
Hydraulic equipment layout drawings
Hydraulic circuit diagram
Hydraulic tank
Hydraulic pump
Pilot pressure control (PPC) system
Control valve
CLSS
Centre swivel joint
Travel PPC pedal
Work equipment – Swing PPC valve
Solenoid valve block
Boom safety valve
Hydraulic cylinder
Outrigger cylinder
Dozer cylinder
Work equipment
Air conditioner
Electrical wiring diagramm
Electrical system
Electrical control system
Machine monitor system
Overload warning device
Sensor
1st attachment circuit hydraulic performance (main valve bypassed)
Travel system
Steering system
Service brake and suspension system
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
Operational and control features
Komtrax terminal system
ATT EPC valve assembly
Standard value table for engine related parts
Standard value table for chassis related parts
TESTING AND ADJUSTING (20-1)
Checking fuel circuit for leakage
Checking and adjusting air conditioner compressor belt tension
Replacing the fan belt
Measurement of clearance in swing circle bearing
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel
Inspection and adjustment of control circuit oil pressure
Inspection and adjustment of pump PC (valve inlet) control oil pressure
Inspection and adjustment of pump LS valve control oil pressure
Measurement of solenoid valve output pressure
Measurement of PPC valve output pressure
Adjustment of work equipment and swing PPC valve
TESTING AND ADJUSTING (20-101)
Measuring and adjusting quick coupler control valve output pressure
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas colour
Adjusting valve clearance
Measurement of compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Testing travel motor relief pressure
Adjusting travel motor relief pressure
Testing propshaft speed
Testing transmission clutch control circuit
Inspection of locations of hydraulic drift of work equipment
Release of remaining pressure in hydraulic circuit
Measurement of oil leakage
Air bleeding of various parts
Inspection procedures for diode
Special function of monitor panel
Preparations for troubleshooting of electrical system
Procedure for turning on KOMTRAX terminal
TESTING AND ADJUSTING (20-201)
Troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Points to remember when carrying out maintenance
Checks before troubleshooting
Classification and steps for troubleshooting
Failure-looking phenomenon and troubleshooting no.
Connector location chart and electrical circuit diagram by system
Connector locations
Connection table for connector pin numbers
Before carrying out troubleshooting when failure code is displayed
Information contained in troubleshooting table
Failure code [6B2JMA] – Abnormality in travel PPC switch hydraulics
Failure code [989L00] – Engine controller lock caution 1
Failure code [989M00] – Engine controller lock caution 2
Failure code [989N00] – Engine controller lock caution 3
Failure code [AA10NX] – Air cleaner clogging
Failure code [AB00KE] – Charge voltage low
Failure code [B@BAZG] – Eng oil press. low
Failure code [B@BAZK] – Eng oil level low
Failure code [B@BCNS] – Eng water overheat
Failure code [B@BCZK] – Eng water level low
Failure code [B@HANS] – Hydr oil overheat
Failure code [CA111] – EMC critical internal failure
Failure code [CA115] – Engine neutral and backup speed sensor error
Failure code [CA122] – Chg air press sensor high error
Failure code [CA123] – Chg air press sensor low error
Failure code [CA131] – Throttle sensor high error
Failure code [CA132] – Throttle sensor low error
Failure code [CA144] – Coolant temp sens high error
Failure code [CA145] – Coolant temp sens low error
Failure code [CA153] – Chg air temp sensor high error
Failure code [CA154] – Chg air temp sensor low error
Failure code [CA155] – Chg air temp high speed derate
Failure code [CA187] – Sens supply 2 volt low error
Failure code [CA221] – Ambient press sens high error
Failure code [CA222] – Ambient press sens low error
Failure code [CA227] – Sens supply 2 volt high error
Failure code [CA234] – Eng overspeed
Failure code [CA238] – Ne speed sens supply volt error
Failure code [CA271] – IMV/PCV1 short error
Failure code [CA272] – IMV/PCV1 open error
Failure code [CA322] – Inj #1 (L#1) open/short error
Failure code [CA324] – Inj #3 (L#3) open/short error
Failure code [CA331] – Inj #2 (L#2) open/short error
Failure code [CA332] – Inj #4 (L#4) open/short error
Failure code [CA342] – Calibration code incompatibility
Failure code [CA351] – Injectors drive circuit error
Failure code [CA352] – Sens supply 1 volt low error
Failure code [CA386] – Sens supply 1 volt high error
Failure code [CA428] – Water in fuel sensor high error
Failure code [CA429] – Water in fuel sensor low error
Failure code [CA435] – Eng oil press sw error
Failure code [CA441] – Battery voltage low error
Failure code [CA442] – Battery voltage high error
Failure code [CA449] – Rail press very high error
Failure code [CA451] – Rail press sensor high error
Failure code [CA452] – Rail press sensor low error
Failure code [CA488] – Chg air temp high torque derate
Failure code [CA553] – Rail press high error
Failure code [CA559] – Rail press low error
Failure code [CA689] – Eng Ne speed sensor error
Failure code [CA731] – Eng bkup speed sens phase error
Failure code [CA757] – All continuous data lost error
Failure code [CA778] – Eng G speed sensor error
Failure code [CA1633] – KOMNET datalink timeout error
Failure code [CA2185] – Throttle sensor supply voltage high error
Failure code [CA2186] – Throttle sensor supply voltage low error
Failure code [CA2249] – Rail press very low error
Failure code [CA2311] – IMV solenoid error
Failure code [CA2555] – Grid htr relay volt high error
Failure code [CA2556] – Grid heater relay volt low error
Failure code [D110KB] – Short-circuiting in battery relay
Failure code [D19JKZ] – Personal code relay abnormality
Failure code [DA25KP] – Press. sensor power abnormality
Failure code [DA2RMC] – Pump comm. abnormality
Failure code [DA2SKQ] – Abnormality in inputting model code
Failure code [DA2SKQ] – Abnormality in inputting model code
Failure code [DAFRMC] – Monitor comm. abnormality
Failure code [DDHPAKP] – Abnormality in pump pressure sensor
Failure code [DDP4KX] – Abnormality in travel PPC pressure switch
Failure code [DDWCKZ] – Abnormality in travel direction control switch
Failure code [DH1OKS] – Abnormality in Pressure sensor power source
Failure code [DHPAMA] – F pump press sensor abnormality
Failure code [DHS5KX] – Abnormality in travel PPC sensor
Failure code [DHX1MA] – Abnormality in overload caution sensor
Failure code [DLT4KA] – Disconnection in transmission speed sensor in pump controller system
Failure code [DW27KA] – Disconnection in transmission clutch solenoid
Failure code [DW27KB] – Short-circuiting in transmission clutch solenoid
Failure code [DW4AKA] – Disconnection in suspension lock solenoid
Failure code [DW4AKB] – Short circuiting in suspension lock solenoid
Failure code [DW4CKA] – Disconnection in PPC lock solenoid
Failure code [DW4CKB] – PPC lock sol. S/C
Failure code [DW4MKA] – Disconnection in creep solenoid
Failure code [DW4MKB] – Short-circuiting in creep solenoid
Failure code [DW44KA] – Disconnection of travel F/R solenoid
Failure code [DW44KB] – Short-circuiting of travel F/R solenoid
Failure code [DW45KA] – Disconnection in swing parking brake solenoid
Failure code [DW45KB] – Swing brake sol. S/C
Failure code [DW91KA] – Disconnection in travel neutral solenoid
Failure code [DW91KB] – Short-circuiting in travel neutral solenoid
Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid
Failure code [DWK0KB] – Short-circuiting in 2-stage relief solenoid
Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid
Failure code [DWK2KB] – Short circuiting in 2-stage back pressure solenoid
Failure code [DXA0KA] – Disconnection in PC-EPC solenoid system
Failure code [DXA0KB] – Short-circuiting in PC-EPC solenoid
Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system
Failure code [DXE0KB] – Short-circuiting in LS-EPC solenoid
Failure code [DXE4KA] – Service current EPC1 discon
Failure code [DXE4KB] – Service current EPC1 short
Failure code [DXE7KA] – Service current EPC2 discon
Failure code [DXE7KB] – Service current EPC2 short
Failure code [DXE8KA] – Service current EPC3 discon
Failure code [DY20KA] – Wiper working abnormality
Failure code [DY20MA] – Wiper parking abnormality
Failure code [DY2CKB] – Washer drive S/C
Failure code [DY2DKB] – Wiper drive (for) S/C
Failure code [DY2EKB] – Wiper drive (rev) S/C
TESTING AND ADJUSTING (20-301)
Troubleshooting when failure code is indicated
Failure code [D862KA] – GPS antenna disconnection
Failure code [DDC3KZ] – Outrigger switch select abnormality
Failure code [DFB1KZ] – Service lever potentio 1 abnormality
Failure code [DFB2KZ] – Service lever potentio 2 abnormality
Failure code [DFB3L8] – Service lever 1 potentio error
Failure code [DFB4L8] – Service lever 2 potentio error
Failure code [DGH2KB] – Hydraulic oil sensor short
Failure code [DXE8KB] – Service current EPC3 short
Failure code [DXE9KA] – Service current EPC4 discon
Failure code [DXE9KB] – Service current EPC4 short
Information contained in troubleshooting table
E-1 – Engine does not start (engine does not rotate)
E-5 – Auto-decelerator does not work
E-6 – Auto engine warm-up device does not work
E-7 – Preheater does not operate
E-8 – All work equipment, swing and travel do not move
E-9 – One-touch power max switch does not work
E-10 – No display in monitor panel at all
E-11 – Part of display on monitor panel is missing
E-12 – Monitor panel displays contents irrelevant to the model
E-13 – Fuel level monitor red lamp lights up while engine is running
E-14 – Engine coolant temperature gauge does not indicate normally
E-15 – Hydraulic oil temperature gauge does not display correctly
E-16 – Fuel gauge does not display correctly
E-17 – Swing lock monitor does not display correctly
E-18 – When the monitor switch is operated, no display appears
E-19 – Windshield wiper and window washer do not operate
E-20 – Alarm buzzer cannot be stopped
E-21 – “Boom/Stabiliser RAISE” is not correctly displayed in monitor function
E-22 – “Boom/Stabiliser LOWER” is not correctly displayed in monitor function
E-23 – “Arm DIGGING” is not correctly displayed in monitor function
E-24 – “Arm DUMPING” is not correctly displayed in monitor function
E-25 – “Bucket DIGGING” is not correctly displayed in monitor function
E-26 – “Bucket DUMPING” is not correctly displayed in monitor function
E-27 – “SWING” is not correctly displayed in monitor function
E-28 – “TRAVEL” is not correctly displayed in monitor function
E-29 – “2 Piece Boom” is not correctly displayed in monitor function
E-30 – Air Conditioner does not work
E-31 – Travel reverse alarm does not sound
E-32 – KOMTRAX system does not operate normally
TESTING AND ADJUSTING (20-501)
Troubleshooting of electrical system (E-Mode)
Information contained in troubleshooting table
Radio cassette & telephone socket
PPC lock circuit
Brake light circuit
Undercarriage attachments – Mode selection
Undercarriage attachments – Front left outrigger
Undercarriage attachments – Front right outrigger
Undercarriage attachments – Rear left outrigger
Undercarriage attachments – Rear right outrigger
Heated seat does not warm up
Suspension lock
Lower wiper does not work (optional fitment)
Work lights (operator cab front left)
Work lights (operator cab front right)
Work lights (operator cab rear)
Worklights (boom, arm & counterweight)
Cab and counterweight beacon light
Air seat compressor (option – air suspension seat)
Operator cab interior light
Cigar lighter
Park brake (not activating)
Park brake (displayed symbol)
RH PPC Lever clamshell roller switch pushed to the LH position
RH PPC Lever clamshell roller switch pushed to the RH position
RH PPC Lever clamshell roller switch pushed to the RH or LH
Horns
Swing lock – Normal operation
Swing lock – Emergency operation
Neutral start (engine)
Neutral start (engine) cont’d (A)
Neutral start (engine) cont’d (B)
Neutral start (engine) cont’d (C)
Emergency travel control – Forward
Emergency travel control – Neutral
Emergency travel control – Reverse
Emergency travel control – Reverse cont’d
Driving lights – Main beam
Driving lights – Main beam flash
Driving lights – Main beam dipped
Driving lights – Position lights
Driving lights – Position lights cont’d (1) and (2)
Indicators – Right hand
Indicators – Left hand
Hazard warning lights
Hazard warning lights cont’d (A)
Swing lock proximity switch
TESTING AND ADJUSTING (20-601)
Troubleshooting of electrical system (Error checking of items without monitor codes)
System chart for hydraulic and mechanical systems
Information contained in troubleshooting table
H-1 – All work equipment lacks power, or travel and swing speeds are slow
H-2 – Engine speed sharply drops or engine stalls
H-3 – No work equipment, travel or swing move
H-4 – Abnormal noise is heard from around hydraulic pump
H-5 – Auto-decelerator does not work
H-6 – Fine control mode does not function
H-7 – Boom moves slowly or lacks power
H-8 – Arm moves slowly or lacks power
H-9 – Bucket moves slowly or lacks power
H-10 – Work equipment does not move in its single operation
H-11 – Work equipment hydraulic drift is too fast
H-12 – Work equipment has big time lag
H-13 – Other work equipment moves when relieving single circuit
H-14 – One-touch power max. switch does not operate
H-15 – In compound operation, work equipment with larger load moves slowly
H-16 – In swing + boom RAISE operation, boom moves slowly
H-17 – In swing + travel, travel speed drops sharply
H-18 – Travel speed does not switch
H-19 – Travel speed does not shift, or it is too slow or fast
H-20 – Machine does not swing
H-21 – Swing acceleration is poor, or swing speed is slow
H-22 – Excessive overrun when stopping swing
H-23 – There is big shock when stopping swing
H-24 – There is loud abnormal noise caused when stopping swing
H-25 – Swing natural drift is too big
H-26 – Swing speed is faster than specified swing speed
Troubleshooting of engine (S-MODE)
S-1 – Starting performance is poor
S-2 – Engine does not start
S-3 – Engine does not pick up smoothly
S-4 – Engine stops during operations
S-5 – Engine does not rotate smoothly
S-6 – Engine lacks output (or lacks power)
S-7 – Exhaust smoke is black (incomplete combustion)
S-8 – Oil consumption is excessive (or exhaust smoke is blue)
S-9 – Oil becomes contaminated quickly
S-10 – Fuel consumption is excessive
S-11 – Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 – Oil pressure drops
S-13 – Oil level rises (Entry of coolant/fuel)
S-14 – Coolant temperature becomes too high (overheating)
S-15 – Abnormal noise is made
S-16 – Vibration is excessive
TESTING AND ADJUSTING (20-701)
Troubleshooting of hydraulic and mechanical system (H-MODE)
Quick coupler
How to read this manual
DISASSEMBLY AND ASSEMBLY
Coating material lists
Special tools list
Sketches of special tools
List of tools
Precautions when performing operation
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of front oil seal
Removal and installation of rear oil seal
Removal and installation of cylinder head assembly
Removal and installation of combination cooler assembly
Removal and installation of engine and hydraulic pump assembly
Removal and installation of engine hood assembly
Removal and installation of travel motor
Disassembly and assembly of travel motor assembly
Removal and installation of swing motor and swing machinery
Removal of swing motor assembly
Disassembly and assembly of swing motor and swing machinery
Removal and installation of front axle assembly
Disassembly and assembly of front axle
Removal and installation of rear axle and transmission
Disassembly and assembly of rear axle assembly
Disassembly and assembly of transmission
Removal and installation of propshaft assembly
Removal and installation of wheel
Removal and installation of suspension lock cylinder assembly
Disassembly and assembly of suspension lock cylinders
Removal and installation of outrigger assembly
Disassembly and assembly of outriggers
Removal and installation of dozer blade assembly
Disassembly and assembly of dozer blade
Removal and installation of swing circle assembly
Removal and installation of revolving frame assembly
Removal and installation of centre swivel joint
Disassembly and assembly of centre swivel joint assembly
Removal and installation of fuel tank assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Removal and installation of LS separation valve assembly
Removal and installation of pressure compensation valve assembly
Removal and installation of main relief valve assembly
Removal and installation of LS control EPC valve
Removal and installation of PC EPC valve assembly
Removal and installation of PPC valve block assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve
Disassembly and assembly of hydraulic cylinder
Removal and installation of monoboom work equipment
Removal and installation of 2 piece boom work equipment
Removal and installation of air conditioner unit
Removal and installation of counterweight
Removal and installation of operator cab assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and Installation of KOMTRAX terminal
OTHER
Hydraulic circuit diagram (1/3)
Hydraulic circuit diagram (2/3)
Hydraulic circuit diagram (3/3)
Electrical circuit diagram (1/7)
Electrical circuit diagram (2/7)
Electrical circuit diagram (3/7)
Electrical circuit diagram (4/7)
Electrical circuit diagram (5/7) – For multi monitor (1/3)
Electrical circuit diagram (6/7) – For multi monitor (2/3)
Electrical circuit diagram (7/7) – For multi monitor (3/3)
