Komatsu Hydraulic Excavator PC130-8 Shop Manual SEN03763-13TH PDF

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Komatsu Hydraulic Excavator PC130-8 Shop Manual SEN03763-13TH – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC130-8 Shop Manual SEN03763-13TH – PDF DOWNLOAD

Language : English
Pages :1043
Downloadable : Yes
File Type : PDF

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Komatsu Hydraulic Excavator PC130-8 Shop Manual SEN03763-13TH – PDF DOWNLOAD

SERIAL NUMBERS C30001 and up

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC130-8 Shop Manual SEN03763-13TH – PDF DOWNLOAD

SERIAL NUMBERS C30001 and up

00 Index and foreword 3
Index 3
Composition of shop manual1 4
Table of contents1 6
Foreword and general information 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
How to read electric wire code 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table 46
Conversion table 50
01 Specification 57
Specification and technical data 57
Specification dimension drawings 58
Working range diagram 59
Specifications 60
List of weights 64
List of lubricant and coolant to be filled 66
10 Structure, function and maintenance standard 69
Engine and cooling system 69
Engine mount 70
PTO 71
Cooling system 72
Power train 75
Power train 76
Swing circle 77
Swing machinery 78
Undercarriage and frame 81
Track frame 82
Idler cushion 83
Idler 84
Track roller 85
Carrier roller 86
Sprocket 87
Track shoe 88
Hydraulic system, Part 1 93
Hydraulic equipment layout drawing 94
Valve control 96
Hydraulic tank and filter 98
Hydraulic pump 100
Hydraulic system, Part 2 129
Control valve 130
CLSS 140
Functions and operation by valve 144
Hydraulic system, Part 3 175
PPC valve 176
Swing motor 191
Travel motor 199
Center swivel joint 208
Solenoid valve 210
Accumulator 214
Anti-drop valve for boom 216
Anti-drop valve for arm 221
Hydraulic cylinder 226
Work equipment 229
Work equipment 230
Dimensions of components 232
Cab and its attachments 237
Air conditioner 238
Electrical system 241
Electronic control system 242
Machine monitor system 274
KOMTRAX system 288
Sensor 290
20 Standard value table 299
Standard service value table 299
Standard value table for engine related parts 300
Standard value table for chassis related parts 301
30 Testing and adjusting 311
Testing and adjusting, Part 1 311
Tools for testing, adjusting, and troubleshooting 313
Sketches of special tools 318
Testing engine speed 319
Testing exhaust temperature 320
Checking exhaust gas color 321
Adjusting valve clearance 322
Testing compression pressure 324
Testing blow-by pressure 326
Testing engine oil pressure 327
Reduced cylinder mode operation 328
No-injection cranking 328
Handling fuel system parts 329
Releasing residual pressure from fuel system 329
Testing fuel pressure 330
Testing fuel return rate and fuel leakage 331
Bleeding air from fuel circuit 333
Checking fuel circuit for leakage 334
Testing and adjusting alternator belt tension 335
Checking and adjusting air conditioner compressor belt tension 336
Testing swing circle bearing clearance 337
Checking and adjusting track shoe tension 338
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 340
Testing control circuit basic pressure 343
Testing and adjusting oil pressure in pump PC control circuit 344
Testing and adjusting oil pressure in pump LS control circuit 347
Testing solenoid valve output pressure 350
Testing PPC valve output pressure 354
Adjusting play of work equipment and swing PPC valves 355
Checking parts which cause hydraulic drift of work equipment 356
Testing and adjusting travel deviation 358
Releasing residual pressure from hydraulic circuit 360
Testing oil leakage 363
Bleeding air from each part 366
Checking cab tipping stopper 368
Installation and adjustment of mirrors and camera 369
Inspection of air conditioner Recirc/Fresh air filter 380
Testing and adjusting, Part 2 383
Special functions of machine monitor 384
Testing and adjusting, Part 3 435
Handling voltage circuit of engine controller 436
Preparation work for troubleshooting of electrical system 437
Procedure for testing diodes 442
Pm Clinic service 443
40 Troubleshooting 449
Failure code table and fuse locations 449
Failure code table 450
Fuse locations 454
General information on troubleshooting 457
Points to remember when troubleshooting 458
Sequence of events in troubleshooting 459
Checks before troubleshooting 460
Classification and procedures for troubleshooting 461
Information in troubleshooting table 462
Phenomena looking like troubles and troubleshooting Nos 464
Connection table for connector pin numbers 467
T- branch box and T- branch adapter table 503
Troubleshooting by failure code, Part 1 507
Failure code [989L00] Engine controller lock caution 1 509
Failure code [989M00] Engine controller lock caution 2 509
Failure code [989N00] Engine controller lock caution 3 510
Failure code [AA10NX] Air cleaner clogging 511
Failure code [AB00KE] Charge voltage low 512
Failure code [B@BAZG] Eng oil press low 514
Failure code [B@BAZK] Eng oil level low 515
Failure code [B@BCNS] Eng coolant overheat 516
Failure code [B@BCZK] Eng water level low 518
Failure code [B@HANS] Hydr oil overheat 520
Failure code [CA111] ECM critical internal failure 522
Failure code [CA115] Eng Ne and Bkup speed sensor error 525
Failure code [CA122] Charge air press sensor high error 526
Failure code [CA123] Charge air press sensor low error 528
Failure code [CA131] Throttle sensor high error 530
Failure code [CA132] Throttle sensor low error 532
Failure code [CA144] Coolant temp sensor high error 534
Failure code [CA145] Coolant temp sensor low error 536
Failure code [CA153] Charge air temp sensor high error 538
Failure code [CA154] Charge air temp sensor low error 540
Failure code [CA155] Chg air temp high speed derate 540
Failure code [CA187] Sensor sup 2 volt low error 541
Failure code [CA221] Ambient air press sensor high error 542
Failure code [CA222] Ambient air press sensor low error 544
Failure code [CA227] Sensor sup 2 volt high error 545
Failure code [CA234] Eng overspeed 546
Failure code [CA238] Ne speed sensor sup volt error 548
Failure code [CA271] IMV/PCV1 short error 550
Failure code [CA272] IMV/PCV1 open error 551
Failure code [CA322] Injector #1 (L #1) system open/short error 552
Failure code [CA324] Injector #3 (L #3) system open/short error 554
Failure code [CA331] Injector #2 (L #2) system open/short error 556
Failure code [CA332] Injector #4 (L #4) system open/short error 558
Troubleshooting by failure code, Part 2 561
Failure code [CA342] Calibration code incompatibility 563
Failure code [CA351] Inj drive circuit error 564
Failure code [CA352] Sensor sup 1 volt low error 567
Failure code [CA386] Sensor sup 1 volt high error 568
Failure code [CA435] Abnormality in engine oil pressure switch 570
Failure code [CA441] Battery voltage low error 571
Failure code [CA442] Battery voltage high error 572
Failure code [CA449] Rail press very high error 573
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 577
Failure code [CA553] Rail press high error 578
Failure code [CA559] Rail press low error 579
Failure code [CA689] Eng Ne speed sensor error 582
Failure code [CA731] Eng Bkup speed sensor phase error 584
Failure code [CA757] All persistent data lost error 585
Failure code [CA778] Eng Bkup speed sensor error 586
Failure code [CA1633] KOMNET datalink timeout error 588
Failure code [CA2185] Throttle sens sup volt high error 590
Failure code [CA2186] Throttle sens sup volt low error 592
Failure code [CA2249] Rail press very low error 592
Failure code [CA2311] Abnormality in IMV solenoid 593
Failure code [D110KB] Battery relay drive short 594
Failure code [D19JKZ] Personal code relay abnormality 596
Failure code [D862KA] GPS antenna discon 598
Failure code [DA22KK] Pump solenoid power low error 600
Failure code [DA25KP] 5V sensor 1 power abnormality 602
Failure code [DA26KP] 5V sensor 2 power abnormality 605
Failure code [DA29KQ] Model selection abnormality 606
Troubleshooting by failure code, Part 3 609
Failure code [DA2RMC] CAN discon (Pump controller detected) 612
Failure code [DAF8KB] Short circuit in camera power supply 614
Failure code [DAFGMC] GPS module error 616
Failure code [DAFRMC] CAN discon (Monitor detected) 618
Failure code [DGH2KB] Hydr oil sensor short 620
Failure code [DHPAMA] Pump press sensor abnormality 622
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality 624
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality 626
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality 628
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality 630
Failure code [DHX1MA] Overload sensor abnormality (Analog) 632
Failure code [DV20KB] Travel alarm short circuit 633
Failure code [DW43KA] Travel speed sol discon 634
Failure code [DW43KB] Travel speed sol short 635
Failure code [DW45KA] Swing brake sol discon 636
Failure code [DW45KB] Swing brake sol short 638
Failure code [DW91KA] Travel junction sol discon 640
Failure code [DW91KB] Travel junction sol short 642
Failure code [DWJ0KA] Merge-divider sol discon 644
Failure code [DWJ0KB] Merge-divider sol short 646
Failure code [DWK0KA] 2-stage relief sol discon 648
Failure code [DWK0KB] 2-stage relief sol short 650
Troubleshooting by failure code, Part 4 653
Failure code [DXA8KA] PC-EPC sol discon 654
Failure code [DXA8KB] PC-EPC sol short 656
Failure code [DXE4KA] Service current EPC discon 658
Failure code [DXE4KB] Service current EPC short 660
Failure code [DY20KA] Wiper working abnormality 662
Failure code [DY20MA] Wiper parking abnormality 664
Failure code [DY2CKA] Washer drive discon 666
Failure code [DY2CKB] Washer drive short 668
Failure code [DY2DKB] Wiper drive (for) short 670
Failure code [DY2EKB] Wiper drive (rev) short 672
Troubleshooting of electrical system (E-mode) 675
Before carrying out troubleshooting of electrical system 677
Information in troubleshooting table 679
E-1 When starting switch turned ON, machine monitor displays nothing 680
E-2 When starting switch turned ON (before starting engine), basic check item lights up 682
E-3 Engine does not start (Engine does not turn) 685
E-4 Preheater does not operate 688
E-5 Automatic warm-up system does not operate (in cold season) 690
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 692
E-7 Precaution lights up while engine is running 694
E-8 Emergency stop item lights up while engine is running 699
E-9 Engine coolant temperature gauge does not indicate normally 700
E-10 Hydraulic oil temperature gauge does not indicate normally 701
E-11 Fuel level gauge does not indicate normally 703
E-12 Contents of display by machine monitor are different from applicable machine 705
E-13 Machine monitor does not display some items 705
E-14 Function switch does not work 705
E-15 Auto-decelerator does not operate normally 706
E-16 Working mode does not change 707
E-17 Travel speed does not change 708
E-18 Alarm buzzer cannot be stopped 709
E-19 Windshield wiper and window washer do not operate 710
E-20 Power maximizing function does not operate normally 714
E-21 Swing holding brake does not operate normally 716
E-22 Travel alarm does not sound or does not stop sounding 718
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 719
E-24 While starting switch is in OFF position, service meter is not displayed 731
E-25 Machine monitor cannot be set in service mode 731
E-26 Monitoring function does not display lever control signal normally 732
E-27 KOMTRAX system does not operate normally 748
Troubleshooting of hydraulic and mechanical system (H-mode) 751
Information contained in troubleshooting table 753
System chart for hydraulic and mechanical systems 754
H-1 Speed or power of all work equipment, swing, and travel are low 756
H-2 Engine speed sharply drops or engine stalls 757
H-3 No work equipment, travel and swing move 758
H-4 Abnormal noise is heard from around hydraulic pump 758
H-5 Fine control mode does not function 759
H-6 Speed or power of boom is low 760
H-7 Speed or power of arm is low 761
H-8 Speed or power of bucket is low 762
H-9 Work equipment does not move in its single operation 763
H-10 Hydraulic drift of work equipment is large 764
H-11 Time lag of work equipment is large 765
H-12 Power maximizing function does not operate normally 765
H-13 Work equipment loaded more is slower during compound operation 766
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE 766
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel 767
H-16 Machine deviates during travel 768
H-17 Travel speed is low 769
H-18 Machine cannot be steered easily or steering power is low 770
H-19 Travel speed does not change or it is kept low or high 771
H-20 Track does not move (Only either side) 771
H-21 Machine does not swing 772
H-22 Swing acceleration or swing speed is low 773
H-23 Excessive overrun when stopping swing 774
H-24 When upper structure stops swinging, it makes large shock 775
H-25 When upper structure stops swinging, it makes large sound 775
H-26 Hydraulic drift of swing is large 776
H-27 Flow rate in attachment circuit cannot be adjusted 777
Troubleshooting of engine (S-mode) 779
Method of using troubleshooting chart 782
S-1 Starting performance is poor 786
S-2 Engine does not start 787
S-3 Engine does not pick up smoothly 790
S-4 Engine stops during operations 791
S-5 Engine does not rotate smoothly 792
S-6 Engine lacks output (or lacks power) 793
S-7 Exhaust smoke is black (incomplete combustion) 794
S-8 Oil consumption is excessive (or exhaust smoke is blue) 795
S-9 Oil becomes contaminated quickly 796
S-10 Fuel consumption is excessive 797
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 798
S-12 Oil pressure drops 799
S-13 Oil level rises (Entry of coolant or fuel) 800
S-14 Coolant temperature becomes too high (overheating) 801
S-15 Abnormal noise is made 802
S-16 Vibration is excessive 803
50 Disassembly and assembly 805
General information on disassembly and assembly 805
How to read this manual 806
Coating materials list 808
Special tool list 811
Sketch of special tool 815
Engine and cooling system 821
Removal and installation of fuel supply pump assembly 822
Removal and installation of fuel injector assembly 825
Removal and installation of front oil seal 828
Removal and installation of rear oil seal 830
Removal and installation of cylinder head assembly 833
Removal and installation of radiator assembly 843
Removal and installation of aftercooler assembly 845
Removal and installation of work equipment oil cooler assembly 847
Removal and installation of engine and work equipment pump assembly 849
Removal and installation of fuel tank assembly 857
Power train 861
Removal and installation of travel motor and final drive assembly 862
Disassembly and assembly of travel motor and final drive assembly 864
Removal and installation of swing motor and swing machinery assembly 901
Disassembly and assembly of swing machinery assembly 903
Removal and installation of swing circle assembly 909
Undercarriage and frame 911
Disassembly and assembly of track roller 912
Disassembly and assembly of idler assembly 915
Disassembly and assembly of recoil spring 918
Spreading and installation of track shoe assembly 921
Removal and installation of sprocket 923
Removal and installation of revolving frame assembly 924
Removal and installation of counterweight assembly 926
Hydraulic system 929
Removal and installation of center swivel joint assembly 930
Disassembly and assembly of center swivel joint assembly 932
Removal and installation of hydraulic tank assembly 933
Removal and installation of work equipment pump assembly 936
Removal and installation of control valve assembly 940
Disassembly and assembly of control valve assembly 944
Disassembly and assembly of work equipment PPC valve assembly 956
Disassembly and assembly of travel PPC valve assembly 958
Removal and installation of anti- drop valve for boom assembly 961
Removal and installation of anti- drop valve for arm assembly 963
Disassembly and assembly of anti-drop valve assembly 965
Disassembly and assembly of hydraulic cylinder assembly 966
Work equipment 973
Removal and installation of work equipment assembly 974
Cab and its attachments 979
Removal and installation of operator’s cab assembly 980
Removal and installation of operator cab glass (stuck glass) 983
Removal and installation of front window assembly 993
Removal and installation of floor frame assembly1000
Removal and installation of front wiper assembly1004
Electrical system1013
Removal and installation of air compressor assembly1014
Removal and installation of air conditioner condenser1015
Removal and installation of air compressor unit assembly1016
Removal and installation of KOMTRAX communication modem assembly1019
Removal and installation of monitor assembly1020
Removal and installation of pump controller assembly1022
Removal and installation of engine controller assembly1024
90 Diagrams and drawings1027
Hydraulic diagrams and drawings1027
Hydraulic circuit diagram (1/2)1029
Hydraulic circuit diagram (2/2)1030
Electrical diagrams and drawings1033
Electrical circuit diagram (1/6)1035
Electrical circuit diagram (2/6)1036
Electrical circuit diagram (3/6)1037
Electrical circuit diagram (4/6)1038
Electrical circuit diagram (5/6)1039
Electrical circuit diagram (6/6)1040
Connectors table and arrangement drawing PC130-81041

S.M 29/12/24