EEBM001701

PW130ES-6K
MACHINE MODEL SERIAL NUMBER

PW130ES-6k K30545 and up

• This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local Komatsu distributor for those items you may require. Materials and specifications
are subject to change without notice.

© 1998
All Rights Reserved
Printed in Belgium 08-98
00-1


 CONTENTS

No. of page

10 STRUCTURE AND FUNCTION......................................................... 10-1

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY .................................................... 30-1

40 MAINTENANCE STANDARD............................................................ 40-1

00-2


The affected pages are indicated by the use of the
following marks. It is requested that necessary ac- Mark Indication Action required
tions be taken to these pages according to the table
below.
Page to be newly
왌 Add
added

쐌 Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

or made additions.

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

쐌 00-1
10-12 10-43 10-79 10-114

쐌 00-2 10-13 10-44 10-80 10-115
쐌 00-2-1
10-14 10-45 10-81 10-116
쐌 00-2-2
10-15 10-47 10-82 10-117
쐌 00-2-3
10-16 10-49 10-83 10-118
쐌 00-2-4 10-17 10-50 10-84 10-120
쐌 00-3 10-18 10-51 10-85 10-121
쐌 00-4 10-19 10-52 10-86 10-122
쐌 00-5 10-20 10-53 10-87 10-124
쐌 00-6 10-21 10-54 10-88 10-125
쐌 00-7 쐌 10-21-1
10-55 10-89 10-126
쐌 00-8 쐌 10-21-2
10-56 10-90 10-127
쐌 00-9 쐌 10-21-3
10-57 10-91 10-128
쐌 00-10 쐌 10-21-4
10-58 10-92 10-129
쐌 00-11 10-23 10-59 10-93 10-130
쐌 00-12 10-24 10-60 10-94 10-131
쐌 00-13 10-25 10-61 10-95 10-132
쐌 00-14 10-26 10-62 10-96 10-133
쐌 00-15 10-27 10-63 10-98 10-134
쐌 00-16 10-28 10-64 10-99 10-137
쐌 00-17 10-29 10-65 10-100 10-138
쐌 10-1
10-30 10-66 10-101 10-139
10-2 10-31 10-67 10-102 10-140
10-3 10-32 10-68 10-103 10-140
10-4 10-33 10-69 10-104 10-141
10-5 10-34 10-70 10-105 10-142
10-6 10-35 10-72 10-106 10-143
10-7 10-36 10-73 10-107 10-144
10-8 10-38 10-74 10-108 10-145
10-9 10-39 10-75 10-109 10-146
10-9 A 10-40 10-76 10-111 10-147
10-9 B 10-41 10-77 10-112 10-148
10-10 10-42 10-78 10-113 10-149

00-2-1


 Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

10-150 20-33 20-87 20-141 20-195

10-151 20-34 20-88 20-142 20-196
10-152 20-35 20-89 20-143 20-197
10-153 20-36 20-90 20-144 20-198
10-154 20-37 20-91 20-145 20-199
10-155 20-38 20-92 20-146 20-200
10-156 쐌 20-39
20-93 20-147 20-201
10-157 20-40 20-94 20-148 20-202
10-158 20-41 20-95 20-149 20-203
10-159 20-42 20-96 20-150 20-204
10-160 20-43 20-97 20-151 20-205
10-161 20-44 20-98 20-152 20-206
10-162 20-45 20-99 20-153 20-207
10-163 20-46 20-100 20-154 20-208
10-164 20-47 20-101 20-155 20-209
10-165 20-48 20-102 20-156 20-210
10-166 20-49 20-103 20-157 20-211
10-167 20-50 20-104 20-158 20-212
10-168 20-51 20-105 20-159 20-213
10-169 20-52 20-106 20-160 20-214
10-170 20-53 20-107 20-161 20-215
10-171 20-54 20-108 20-162 20-216
10-172 20-55 20-109 20-163 20-217
20-1 20-56 20-110 20-164 20-218
20-2 20-57 20-111 20-165 20-219
20-3 20-58 20-112 20-166 20-220
20-4 20-59 20-113 20-167 20-221
20-5 20-60 20-114 20-168 20-222
20-6 20-61 20-115 20-169 20-223
20-7 20-62 20-116 20-170 20-224
20-8 20-63 20-117 20-171 20-225
20-9 20-64 20-118 20-172 20-226
20-10 20-65 20-119 20-173 20-227
20-11 20-66 20-120 20-174 20-228
20-12 20-67 20-121 20-175 20-229
20-13 20-68 20-122 20-176 20-230
20-14 20-69 20-123 20-177 20-231
20-15 20-70 20-124 20-178 20-232
20-16 20-71 20-125 20-179 20-233
20-17 20-72 20-126 20-180 20-234
20-18 20-73 20-127 20-181 20-235
20-20 20-74 20-128 20-182 20-236
20-21 20-75 20-129 20-183 20-237
20-22 20-76 20-130 20-184 20-238
20-23 20-77 20-131 20-185 20-239
20-24 20-78 20-132 20-186 20-240
20-25 20-79 20-133 20-187 20-241
20-26 20-80 20-134 20-188 20-242
20-27 20-81 20-135 20-189 20-243
20-28 20-82 20-136 20-190 20-244
20-29 20-83 20-137 20-191 20-245
20-30 20-84 20-138 20-192 20-246
20-31 20-85 20-139 20-193 20-247
쐌 20-32
20-86 20-140 20-194 20-248

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 Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision

20-249 30-31 30-85 40-4

20-250 30-32 30-86 40-6
20-251 30-33 30-87 40-7
20-252 30-34 30-88 40-8
20-253 30-35 30-89 40-10
20-254 30-36 30-90 40-11
20-255 30-37 30-91 40-12
20-256 30-38 30-92 40-13
20-257 30-39 30-93 40-14
20-258 30-40 30-94 40-15
20-259 30-41 30-95 40-16
20-260 30-42 30-96 40-17
20-261 30-43 30-97 40-18
20-262 30-44 30-98 40-19
20-263 30-45 30-99 40-20
20-264 30-46 30-100 40-21
20-265 30-47 30-101 40-22
20-266 30-48 30-102 40-23
20-267 30-49 30-103 40-24
20-268 30-50 30-104 40-25
20-269 30-51 30-105 40-26
20-270 30-52 30-106 40-27
20-271 30-53 30-107 40-28
20-272 30-54 30-108 40-29
20-273 30-55 30-109 40-30
20-274 30-56 30-110 40-31
30-1 30-57 30-111 40-32
30-2 30-58 30-112 40-33
30-3 30-59 30-113 40-34
30-4 30-60 30-114
30-5 30-61 30-115
30-6 30-62 30-116
30-9 30-63 30-117
30-10 30-64 30-118
30-11 30-65 30-119
30-12 30-66 30-120
30-13 30-67 30-121
30-14 30-68 30-122
30-15 30-69 30-123
30-16 30-70 30-124
30-17 30-71 30-125
30-18 30-72 30-126
30-19 30-73 30-127
30-20 30-74 30-128
30-21 30-75 30-129
30-22 30-76 30-130
30-23 30-77 30-131
30-24 30-78 30-132
30-25 30-79 30-133
30-26 30-80 30-134
30-27 30-81 30-135
30-28 30-82 40-1
30-29 30-83 40-2
30-30 30-84 40-3

00-2-3


SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repairs extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both sepcially
designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol is used to mark safety precautions in this
manual. The cautions accompaning these symbols should always be followed carefully. If any
dangerous situation arises or may possibly arise, first consider safety, and take the necessary
actions to deal with the situation.

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance carefully BE- the work area clean and make sure that there is
FORE operating the machine. no dirt or oil on the floor. Smoke only in the ar-
eas provided for smoking. Never smoke while
1. Before carrying out any greasing or re- working.
pairs, read all the precautions given on the
decals which are fixed to the machine. PREPARATIONS FOR WORK.

2. When carrying out any operation, always 7. Before adding the oil or making any repairs
wear safety shoes and helmet. Do not wear park the machine on hard, level ground, and
loose work clothes, or clothes with buttons block the wheels or tracks to prevent the ma-
missing. chine from moving.
• Always wear safety glasses when hit-
ting parts with a hammer. 8. Before starting work, lower blade, ripper, bucket
• Always wear safety glasses when or any other work equipment to the ground. If
grinding parts with a grinder, etc. this is not possible, insert the safety pin or use
blocks to prevent the wrok equipment from fall-
3. If welding repairs are needed, always have ing. In addition, be sure to lock all the control
a trained, experienced welder carry out the levers and hang warning signs on them.
work. When carrying out welding work, al-
ways wear welding gloves, apron, glasses, 9. When disassembling or assembling, support
cap and other clothes suited for welding the machine with blocks, jacks or stands before
work. starting work.

4. When carrying out any operation with two 10. Remove all mud and oil from the steps or other
or more workers, always agree on the op- paces used to get on and off the machine. Al-
erating procedure before starting. Always ways use the handrails, ladders or steps when
inform your fellow workers before starting getting on or off the machine. Never jump on or
any step of the operation. Before starting off the machine. If it is impossible to use the
work, hang UNDER REPAIR signs on the handrails, ladders or steps, use a stand to pro-
controls in the operator's compartment. vide safe footing.

5. Keep all tools in good condition and learn

the correct way to use them.

00-3


SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 20. When installing high pressure hoses, make
sure that they are not twisted. Damaged tubes
11. When removing the oil filter cap, drain plug or are dangerous, so be extremely careful when
hydraulic pressure measuring plugs, loosen installing tubes for high pressure circuits. Also,
them slowly to prevent the oil from spurting out. check that connecting parts are correctly in-
Before disconnecting or removing components stalled.
of the oil, water or air circuits, first remove the
pressure completely from the circuit. 21. When assembling or installing parts, always
use the specified tightening torques. When in-
12. The water and oil in the circuits are hot when stalling protective parts such as guards. or
the engine is stopped, so be careful not to get parts which vibrate violently or rotate at high
burned. speed, be particulary careful to check that they
Wait for the oil and water to cool before carrying are installed correctly.
out any work on the oil or water circuits.
22. When aligning two holes, never insert your fin-
13. Before starting work, remove the leads from the gers or hand. Be careful not to get your fingers
battery. Always remove the lead from the nega- caught in a hole.
tive (-) terminal first.
23. When messuring hydraulic pressure, check that
14. When raising heavy components, use a hoist or the messuring tool is correctly assembled for
crane. taking any measurements.
Check that the wire rope, chains and hooks are
free from damage. 24. Take care when removing or installing the
Always use lifting equipment which has ample tracks of track-type machines. When removing
capacity. the track, the track separates suddenly, so
Install the lifting equipment at he correct places. never let anyone stand at either end of the
Use a hoist of crane and operate slowly to pre- track.
vent the component from hitting any other part.
Do not work with any part still raised by the
hoist or crane.

15. When removing covers which are under inter-

nal pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.

16. When removing components, be careful not to

break or damage the wiring. Damaged wiring
may cause electrical fires.

17. When removing piping, stop the fuel or oil from

spilling out. If any oil or fuel drops onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.

18. As a general rule, do not use gasoline to wash

parts. In particular, only use the minimum of
gasoline when washing electrical parts.

19. Be sure to assemble all parts again in their

original places.
Replace any damaged parts with new parts.
• When installing hoses and wires, be sure
that the will not be damaged by contact
with oter parts when the machine is being
operated.

00-4


FOREWORD FOREWORD GENERAL

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters: these chapters are
further divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs , as well as adjustments to be
made at completion of the checks and repairs. Troubleshooting charts correlating "problems" to "Causes"
are also included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling
eachr component, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

NOTICE

The specifiactions contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.

00-5


FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Shop manuals are issued as a guide to carrying out When a manual is revised, an edition mark (1,2,3,...)
repairs. They are devided as follows: is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model REVISIONS

Engine model: Issued for each engine series
Revised pages are shown in the LIST OF REVISED
Each issued as one
Electrical volume:
Attachments volume: } volume to cover all
models
PAGES next to the CONTENTS page.

SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model, it is necessary that chas- use, important safety and quality portions are
sis, engine , electrical and attachement volumes be marked with the following symbols.
available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be Symbol Item Remarks

sent to KOMATSU distributors. Get the most up-to-
Special safety precautions
date information before you start any work.
Safety are necessary when
performing the work.
FILING METHOD
Special technical
1. See the page number on the bottom of the precautions or other
page. File the pages in correct order. ★ Caution precautions for preserving
standards are necessary
2. Following examples show how to read the page
number when performing the work.
Example 1 (Chassis volume:) Weight of parts of systems.
Caution necessary when
10 - 3 Weight selecting hoisting wire, or
Item number (10. Structure when working posture is
and Function) important, ect.
Consecutive page number
for each item Places that require special
Tightening
attention for the tightening
torque
Example 2 (Engine Volume:) torque during assembly.
Places to be coated with
12 - 5 Coat adhesives and lubricants,
Unit number (1. Engine) etc.
Item number (2. Testing and Places where oil, water or
Adjusting) Oil, water fuel must be added, and the
Consecutive page number capacity.
for each item
Places where oil or water
3. Additional pages: Additional pages are indi- Drain must be drained, and
cated by a hyphen (-) and number after the quantity to be drained.
page number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204

00-6


FOREWORD HOISTING INSTRUCTIONS

Slinging near the edge of the hook may cause the

HOISTING INSTRUCTIONS rope to slip off the hook during hoisting, and a seri-
ous accident can result. Hooks have a maximum
HOISTING strength at the middle portion.
Heavy parts (25 kg or more) must be
lifted with a hoist, etc. In the DISASSEM-
BLY AND ASSEMBLY section, every
part weighing 25 kg op mroe is indicated
with the symbol

• If a part cannot be smootlhy removed from the

machine by hoisting, the following checks
should be made: 3) Do not sling a heavy load with one rope alone,
1) Check for removal of all bolts fastening the but sling with two or more ropes symmetrically
part to the relative parts. wound onto the load.
2) Check for existence of another part caus- Slinging with one rope may cause turning
ing interference with the part to be re- of the load during hoisting, untwisting of
moved. the rope, or slipping of the rope from its
original winding position on the load, which
WIRE ROPES can result in a dangerous accident.
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to 4) Do not sling a heavy load with ropes forming a
the table below: wide hanging angle from the hook. When hoist-
ing a load with two or more ropes, the force sub-
Wire ropes jected to each rope will increase with the
(Standard "Z" or "S" twist ropes nahging angles. The table below shows the
without galvanizing variation of allowable load (kg) when hoisting is
made with two ropes, each of which is allowed
Rope diameter (mm) Allowable load (tons)
to sling up to 1000 kg vertically, at various hang-
10 1.0 ing angles.
When two ropes sling a load vertically, up to
11.2 1.4 2000 kg of total weight can be suspended. This
12.5 1.6 weight becomes 1000 kg when two ropes make
a 120° hanging angle. On the other hand, two
14 2.2
ropes are subjected to an excessive force as
16 2..8 large as 4000 kg if they sling a 2000 kg load at a
18 3.6 lifting angle of 150°.

20 4.4
22.4 5.6
30 10.0
40 18.0
50 28.0
60 40.0

★ The allowable load value is estimated to be

one-sixth or one-seventh of the breaking
strength of the rope used.

2) Sling wire ropes from the middle portion of the

hook.

00-7


FOREWROD COATING MATERIALS

COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Category Komatsu code Part No. Q'ty Container Main applications, features

LT-1A 790-129-9030 150 g Tube • Used to prevent rubber gaskets, rubber cushions, and
cork plugs from coming out

• Used in places requiring an immediately effective, strong

LT-1B 790-129-9050 20 g Plastic adhesive. Used for plastics (except polyethylene,
(x2) container polyprpylene, tetrafluoroethylene and vinyl chloride),
rubber, metal, and non-metal.

50 g Plastic • Features: resistance to heat, chemicals

LT-2 09940-00030 container • Used for anti-lossening and sealant purposes for bolts
Adhesive and plugs

LT-3 790-129-9060 Adhesive Can • Used as adhesive or sealant for metal, glass, plastic
(Set of adhesive : 1 kg
and hardening Hardening
agent) agent
: 500 g

LT-4 250 g Plastic • Used as sealant for machined holes

container

(Loctite 648-50) 790-129-9040 50 cc - • Features: Resistance to heat, chemicals

• Used at joint portions subject to high temperature

LG-1 79A-129-9110 200 g Tube • Used as adhesive or sealant for gaskets and packings of
power train case, etc.

• Features: Resistance to heat

• Used as sealant for flange surfaces and bolts at high
LG-3 790-129-9070 1kg Can temperature locations, used te prevent seizure
• Used as sealant for heat resistant gasket for high
temperature locations such as engine precombustion
chamber, exhaust pipe

• Features: Resistance to water, oil

• Used as sealant for flange surface, thread
LG-4 790-120-9020 200 g Tube • Aiso possible to use as sealant for flanges with large
Gasket sealant clearance
• Used as sealant for mating surfaces of final drive case,
transmission case.

Plastic • Used as sealant for various threads, pipe joints, flanges

LG-5 790-129-9080 1 kg container • Used as sealant for tapered plugs, elbows, nipples of
hydraulic piping

• Features: Silicon based, resistance to heat, cold

LG-6 09940-00011 250 g Tube • Used as sealant for flange surface, thread
• Used as sealant for oil pan, final drive case, etc.

• Features: Silicon based, quick hardening type

LG-7 09920-00150 150 g Tube • Used as sealant fo rflywheel housing, intake manifold, oil
pan, thermostat housing, etc.

Rust prevention - 09940-00051 60 g Can • Used as lubricant for sliding parts (to prevent squeaking)
lubricant
Molybdenum • Used to prevent seizure or scuffing of the thread when
disulphide - 09940-00040 200 g Tube presss fitting or shrink fitting
lubricant • Used as lubricant for linkage, bearings, etc.

SYG350LI
SYG-400LI
Lithium grease G2-LI SYG-400LI-A Various Various • General purpose type
SYG-160LI
SYGA-160CNLI

SSG2-400CA Various • Used for normal temperature, light load bearing at places
SYG2-350CA Various in contact with water or steam
Calcium grease G2-CA SYG2-400CA-A
SYG2-160CA
SYGA-16NCA
Molybdenum
disulphide - SYG2-400M 400 g (10 Bellows type • Used for places with heavy load
grease per case)

00-8


FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in section of
DISASSEMBLY AND ASSEMBLY.

1 Kgm = 9.806 Nm

Thread diameter Width

of bolt across flats

mm mm kgm Nm
6 10 1.35 ± 0.15 13.2 ± 1.4
8 13 3.2 ± 0.3 31.4 ± 2.9
10 17 6.7 ± 0.7 65.7 ± 6.8
12 19 11.5 ± 1.0 112 ± 9.8
14 22 18.0 ± 2 .0 177 ± 19
16 24 28.5 ± 3 279 ± 29
18 27 39 ± 4 383 ± 39
20 30 56 ± 6 549 ± 58
22 32 76 ± 8 745 ± 78
24 36 94.5 ± 10 927 ± 98
27 41 135 ± 15 1320 ± 140
30 46 175 ± 20 1720 ± 190
33 50 225 ± 25 2210 ± 240
36 55 280 ± 30 2750 ± 290
39 60 335 ± 25 3280 ± 340

★ This torque table does not apply to the bolts with nylon packaging or other nonferrous metal wash-
ers are to be used, or which require tightening to otherwise specified torque.

00-9


FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Thread daimeter Width

Tightening torque
of bolt across flats
mm mm kgm Nm
10 14 6.7 ± 0.7 65.7 ± 6.8
12 17 11.5 ± 1 112 ± 9.8
16 22 28.5 ± 3 279 ± 29

TIGHTENING TORQUE FOR FLRED NUTS

Use these torques for flared part of nut.

Thread daimeter Width

Tightening torque
of bolt across flats
mm mm kgm Nm
14 19 2.5 ± 0.5 24.5 ± 4.9
18 24 5±2 49 ± 19.6
22 27 8±2 78.5 ± 19.6
24 32 14 ± 3 137.3 ± 29.4
30 36 18 ± 3 176.5 ± 29.4
33 41 20 ± 5 196.1 ± 49
36 46 25 ± 5 245.2 ± 49
42 55 30 ± 5 294.2 ± 49

00-10


FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This
wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominale number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire
Nominal Cable Current
Number of Dia. of Cross section O.D. (mm) Applicable circuit
number rating (A)
strands strands (mm) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 harging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Circuits
Prior-
Charging Ground Starting Lighting Instrument Signal Other
ity Clas-
sification
Code W B B R Y G L
Pri-
1
mary Color White Black Black Red Yellow Green Blue
Code WR - BW RW YR GW LW
2
Color White & Red - Black & White Red & White Yellow & Red Green & White Blue & White
Code WB - BY RB YB GR LR
3
Color White & Black - Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red
Code WL - BR RY YG GY LY
Auxi-
4
liary Color White & Blue - Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
Code WG - - RG YL GB LBB
5
Color White & Green - - Red & Green Yellow & Blue Green & Black Blue & Black
Code - - - RL YW GL -
6
Color - - - Red & Blue Yellow & White Green & Blue -

00-11


FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method
of using the Conversion Table, see the example given below.

EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm to inches
(1) Locate the number 50 in the vertical column at the left side, take this as 훽, then draw a horizontal line
from 훽.
(2) Locate the number 5 in the row across the top, take this as 훾, then draw a perpendicular line down
from 훾.
(3) Take the point where the two lines cross as 훿. This pint 훿 gives the value when converting from
millimeters to inches. Therefore, 55mm = 2.165 inches.

2. Convert 550 mm into inches.

(1) The nuber 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the orginal value. This gives 550 mm = 21.65 inches.

훾
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
훿
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
훽
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.385 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-12


FORWORD CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.712
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 33.07 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound
1kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 135.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.03 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-13


FORWORD CONVERSION TABLE

Litre to U.S. Gallon

1l = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.3340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Litre to U.K. Gallon

1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 35.20 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-14


FORWORD CONVERSION TABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1245.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-15


FORWORD CONVERSION TABLE

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 1617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 4471 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-16


FORWORD CONVERSION TABLE

Temperature
Fahrenheit-Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vice is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F

°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 03 199.4
-23.9 -11 12.2 -4.4 24 73.4 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 75.2 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 77.0 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 78.8 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 80.6 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 82.4 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-17


10 STRUCTURE AND FUNCTION

ENGINE RELATED PARTS ...................... 10-2 CLSS ......................................................... 10-66

RADIATOR & OIL COOLER...................... 10-3 SWING MOTOR........................................ 10-96
PTO ........................................................... 10-4 CENTRE SWIVEL JOINT ......................... 10-101
POWER TRAIN ......................................... 10-5 TRAVEL MOTORS .................................... 10-102
SWING CIRCLE ........................................ 10-7 WORK EQUIPMENT -
SWING MACHINERY ............................... 10-8 SWING PPC VALVE ................................. 10-108
UNDERCARRIAGE ................................... 10-9 TRAVEL PPC PEDAL ............................... 10-112
TRANSMISSION ....................................... 10-11 SERVICE PPC PEDAL ............................. 10-113
CLUTCH CONTROL ................................. 10-13 SAFETY LOCK VALVE ............................. 10-116
AXLE ......................................................... 10-15 PPC ACCUMULATOR .............................. 10-116
SUSPENSION LOCK CYLINDER ............. 10-19 PPC PRESSURE SWITCH BLOCK .......... 10-117
BRAKING TRAIN ...................................... 10-21 SOLENOID VALVE ................................... 10-118
BRAKE & STEERING CIRCUIT TRAVEL - BOOM -
(ITALIAN SPECIFICATION) ...................... 10-21-1 STABILIZER SOLENOID VALVE .............. 10-120
BRAKE/STEER PUMP .............................. 10-23 BOOM SAFETY VALVE ............................ 10-121
BRAKE PEDAL ......................................... 10-24 HYDRAULIC CYLINDER
BRAKE VALVE .......................................... 10-25 (BOOM - ARM - BUCKET) ........................ 10-124
PRIORITY VALVE ..................................... 10-26 OUTRIGGER CYLINDER ......................... 10-126
ACCUMULATOR FOR BRAKE SYSTEM . 10-27 DOZER BLADE CYLINDER ...................... 10-127
STEERING TRAIN .................................... 10-28 WORK EQUIPMENT ................................. 10-128
STEERING COLUMN ............................... 10-29 ELECTRICAL WIRING DIAGRAM ............ 10-129
ORBITROL VALVE .................................... 10-30 ENGINE CONTROL SYSTEM .................. 10-132
HYDRAULIC CIRCUIT DIAGRAM ............ 10-31 ELECTRONIC CONTROL SYSTEM ......... 10-139
HYDRAULIC TANK ................................... 10-33 MACHINE MONITOR SYSTEM ................ 10-162
HYDRAULIC PUMP .................................. 10-34 OVERLOAD WARNING DEVICE ............. 10-169
PILOT PRESSURE BREAKER MODE HYDRAULIC
CONTROL SYSTEM ................................. 10-54 PERFORMANCE ...................................... 10-171
CONTROL VALVE ..................................... 10-56

10-1


STRUCTURE AND FUNCTION ENGINE RELATED PARTS

ENIGNE RELATED PARTS

1. Air cleaner
2. Intake hose
3. Muffler
4. Rear engine mount
5. Front engine mount

10-2
STRUCTURE AND FUNCTION BRAKE AND STEERING CIRCUIT

ITEM
POSITIONS
1. HYDRAULIC OIL FILTER

2. HYDRAULIC OIL PUMP (STEERING) .................................................................................... 14.6 cc/REV

3. PRIORITY VALVE
CONTROL SPRING PRESSURE ........................................................................................................ 7 bar

4. STEERING VALVE .................................................................................................. OSPD 70/195 LS DYN.

5. STEERING CILINDER ................................................................................ D=Ø90, d=Ø50, STROKE=170-10

STEERING CILINDER VOLUME = (9-5) x x 17 = 748 cm2
4
6. HYDRAULIC OIL PUMP (BRAKE) ............................................................................................. 6.4 cc/REV

7. BRAKE VALUE

8. BRAKE CYLINDER (20FF) ....................................................................... D=211, d=Ø180, STROKE=1.12

9. BRAKE CYLINDER (20FF) ........................................................................ D=311, d=Ø273, STROKE= 0.9

10. PARK BRAKE CYLINDER .................................................................... D=Ø145, d=Ø135, STROKE= 3.13

11. PRESSURE REDUCING VALUE

10-21-2


STRUCTURE AND FUNCTION BRAKE AND STEERING CIRCUIT

The function of the steer/brake circuit (Italian specification) is identical to the standard circuit except for the
tandem gear pump.
The tandem pump consists of two gear pumps, one for each circuit. The priority value is maintained in the
steering circuit to provide emergency steering if required.

10-21-3


 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO
TESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE

2. Measuring LS differential pressure

1) Measuring with a differential pressure gauge
i) Remove oil pressure measurement plugs (1)
and (2) (Thread dia.=10mm, Pitch=1.25mm),
and install differential pressure gauge C4.
Lift the wheels from the ground using the
work equipment and dozer blade/outriggers
and measure at full speed, no load in Me
travel speed mode.
ii) Set to the conditions in table 2 and measure
the LS differential pressure.

Table 2
Fuel Differential
Working
control Operation pressure
mode
lever MPa {kg/cm2}
H/O 0.83 ± 0.1
Full Pedal at neutral
mode {8.5 ± 1}
Travel
Travel speed:
speed: HiMiTravel
Travel
H/O circuit 2.2 ± 0.1
Full circuit under
under nono load
load
mode (pedal {22 ± 1}
(pedal fully
fully operated)
operated)

2) Measuring with oil pressure gauge

+1.0
★ The maximum differential pressure is 2.7 - 0.7 MPa
+10 2
{28 - 7 kg/cm }, so measure with the same gauge.
i) Install oil pressure gauge C1 (58.8 MPa {600 kg/
cm2}) to plug (1) for measuring the pump dis-
charge pressure.
★ Use a gauge with a scale in units of 1.0 MPa
{10 kg/cm2}.
(If no 58.8 MPa {600 kg/cm2} pressure gauge
is available, a 39.2 MPa {400 kg/cm2) pres-
sure gauge can be used.)
ii) Set to the conditions in Table 2 and measure the
pump discharge pressure.
★ Stand directly in front of the indicator and be
sure to read it correctly.
iii) Remove oil pressure gauge C1, then install to LS
pressure measurement plug (2).
iv) Set to the conditions in Table 2 and measure the
LS pressure.
★ Stand directly in front of the indicator and be
sure to read it correctly.
(Pump discharge pressure) - (LS pressure) =
Differential pressure.

Note: A differential pressure meter can also be used

and will give more accurate measurement.

20-32


TESTING AND ADJUSTING TESTING PROPSHAFT SPEED

TESTING PROPSHAFT SPEED

MEASURING ROTATING SPEED OF
PROPSHAFT
• Lift the wheels form the ground using the blade and
outriggers on work equipment.
• Set the machine HO mode High idle.
• Measure first in Lo, then Mi, then Hi travel mode.
• Select forward travel on the steering column switch
then gently depress the travel pedal to full stroke.

WARNING
Hazard from rotating wheels exits.

• Allow the speed of the propshafts/wheels to stabilize

for a few minutes then measure the rotating speed of
the propshaft using an optical tachometer.
• Gently release the travel pedal to stop the wheel rota-
tion.
★ Always change rotating speed slowly. Sudden release
of the travel pedal could damage the transmission or
motors.

★ JUDGEMENT TABLE

Propshaft speed in rpm Oil temperature 45 - 550C

Version
20 kph 30 kph Remarks
Travel mode
Lo 371 ± 50 455 ± 50 If too high check travel EPC valve and bypass valve

Mi 742 ± 50 110 ± 50
If high or low refer to trouble shooting section H17. Do
not attempt to adjust travel motor displacement.
Hi 85.5 ±± 100
11855 100 2800 ± 100

20-39


STRUCTURE AND FUNCTION BRAKE AND STEERING CIRCUIT
BRAKE & STEERING CIRCUIT (ITALIAN SPECIFICATION)

10-21-1
햲
STRUCTURE AND FUNCTION BRAKE AND STEERING CIRCUIT
GEAR PUMP (ITALIAN SPECIFICATION)

10-21-4
햲