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Komatsu PC130-8 Hydraulic Excavator Shop Manual C30001 and up – PDF DOWNLOAD
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Komatsu PC130-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS 80001 and up
Book Code: SEN03763-00TH
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Description
Komatsu PC130-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC130-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC130-8
Serial Number: C30001 and up
Book Code: SEN03763-00TH
Language: English
Pages: 975
File Format: Portable Document Format (PDF)
KOMATSU PC130-8 HYDRAULIC EXCAVATOR SHOP MANUAL C30001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC130-8 Hydraulic Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC130-8 Hydraulic Excavator Shop Manual
COVER.................................................................................................... 1 00 Index and foreword.................................................................................... 0 Index................................................................................................ 2 Composition of shop manual....................................................................... 3 Table of contents................................................................................ 5 Foreword and general information..................................................................... 14 Safety notice.................................................................................... 15 How to read the shop manual...................................................................... 20 Explanation of terms for maintenance standard.................................................... 22 Handling of electric equipment and hydraulic component........................................... 24 Handling of connectors newly used for engines.................................................... 33 How to read electric wire code................................................................... 36 Precautions when carrying out operation.......................................................... 39 Method of disassembling and connecting push-pull type coupler.................................... 42 Standard tightening torque table................................................................. 45 Conversion table................................................................................. 49 01 Specification......................................................................................... 0 Specification and technical data..................................................................... 56 Specification dimension drawings................................................................. 57 Working range diagram............................................................................ 58 Specifications................................................................................... 59 List of weights.................................................................................. 63 List of lubricant and coolant to be filled....................................................... 65 10 Structure, function and maintenance standard.......................................................... 0 Engine and cooling system............................................................................ 68 Engine mount..................................................................................... 69 PTO.............................................................................................. 70 Cooling system................................................................................... 71 Power train.......................................................................................... 74 Power train...................................................................................... 75 Swing circle..................................................................................... 76 Swing machinery.................................................................................. 77 Undercarriage and frame.............................................................................. 80 Track frame...................................................................................... 81 Idler cushion.................................................................................... 82 Idler............................................................................................ 83 Track roller..................................................................................... 84 Carrier roller................................................................................... 85 Sprocket......................................................................................... 86 Track shoe....................................................................................... 87 Hydraulic system, Part 1............................................................................. 92 Hydraulic equipment layout drawing............................................................... 93 Valve control.................................................................................... 95 Hydraulic tank and filter........................................................................ 97 Hydraulic pump................................................................................... 99 Hydraulic system, Part 2.............................................................................128 Control valve....................................................................................129 CLSS.............................................................................................139 Functions and operation by valve.................................................................143 Hydraulic system, Part 3.............................................................................174 PPC valve........................................................................................175 Swing motor......................................................................................190 Travel motor.....................................................................................198 Center swivel joint..............................................................................207 Solenoid valve...................................................................................209 Accumulator......................................................................................213 Holding valve....................................................................................215 Hydraulic cylinder...............................................................................221 Work equipment.......................................................................................224 Work equipment...................................................................................225 Dimensions of components.........................................................................227 Cab and its attachments..............................................................................232 Air conditioner..................................................................................233 Electrical system....................................................................................236 Electronic control system........................................................................237 Machine monitor system...........................................................................268 KOMTRAX system...................................................................................282 Sensor...........................................................................................284 20 Standard value table.................................................................................. 0 Standard service value table.........................................................................292 Standard value table for engine related parts....................................................293 Standard value table for chassis related parts...................................................294 30 Testing and adjusting................................................................................. 0 Testing and adjusting, Part 1........................................................................304 Tools for testing, adjusting, and troubleshooting................................................306 Testing engine speed.............................................................................310 Testing exhaust temperature......................................................................311 Checking exhaust gas color.......................................................................312 Adjusting valve clearance........................................................................313 Testing compression pressure.....................................................................315 Testing blow-by pressure.........................................................................317 Testing engine oil pressure......................................................................318 Handling fuel system parts.......................................................................319 Releasing residual pressure from fuel system.....................................................319 Testing fuel pressure............................................................................320 Testing fuel return rate and fuel leakage........................................................321 Bleeding air from fuel circuit...................................................................323 Checking fuel circuit for leakage................................................................325 Testing and adjusting alternator belt tension....................................................326 Checking and adjusting air conditioner compressor belt tension...................................327 Testing swing circle bearing clearance...........................................................328 Checking and adjusting track shoe tension........................................................329 Testing and adjusting oil pressure in work equipment, swing, and travel circuits.................331 Testing control circuit basic pressure...........................................................334 Testing and adjusting oil pressure in pump PC control circuit....................................335 Testing and adjusting oil pressure in pump LS control circuit....................................338 Testing solenoid valve output pressure...........................................................341 Testing PPC valve output pressure................................................................345 Adjusting play of work equipment and swing PPC valves............................................346 Checking parts which cause hydraulic drift of work equipment.....................................347 Testing and adjusting travel deviation...........................................................349 Releasing residual pressure from hydraulic circuit...............................................351 Testing oil leakage..............................................................................352 Bleeding air from each part......................................................................355 Checking cab tipping stopper.....................................................................357 Installation and adjustment of mirrors and camera................................................358 Inspection of air conditioner Recirc/Fresh air filter............................................362 Testing and adjusting, Part 2........................................................................364 Special functions of machine monitor.............................................................365 Testing and adjusting, Part 3........................................................................416 Handling voltage circuit of engine controller....................................................417 Preparation work for troubleshooting of electrical system........................................418 Procedure for testing diodes.....................................................................423 Pm Clinic service................................................................................424 40 Troubleshooting....................................................................................... 0 Failure code table and fuse locations................................................................430 Failure code table...............................................................................431 Fuse locations...................................................................................435 General information on troubleshooting...............................................................438 Points to remember when troubleshooting..........................................................439 Sequence of events in troubleshooting............................................................440 Checks before troubleshooting....................................................................441 Classification and procedures for troubleshooting................................................442 Information in troubleshooting table.............................................................443 Phenomena looking like troubles and troubleshooting Nos..........................................445 Connection table for connector pin numbers.......................................................448 T- branch box and T- branch adapter table........................................................484 Troubleshooting by failure code, Part 1..............................................................488 Failure code [989L00] Engine controller lock caution 1...........................................490 Failure code [989M00] Engine controller lock caution 2...........................................490 Failure code [989N00] Engine controller lock caution 3...........................................491 Failure code [AA10NX] Air cleaner clogging.......................................................492 Failure code [AB00KE] Charge voltage low.........................................................493 Failure code [B@BAZG] Eng oil press. low.........................................................495 Failure code [B@BAZK] Eng oil level low..........................................................496 Failure code [B@BCNS] Eng coolant overheat.......................................................497 Failure code [B@BCZK] Eng water level low........................................................499 Failure code [B@HANS] Hydr oil overheat..........................................................501 Failure code [CA111] ECM critical internal failure...............................................503 Failure code [CA115] Eng Ne and Bkup speed sensor error..........................................506 Failure code [CA122] Charge air press sensor high error..........................................507 Failure code [CA123] Charge air press sensor low error...........................................509 Failure code [CA131] Throttle sensor high error..................................................511 Failure code [CA132] Throttle sensor low error...................................................513 Failure code [CA144] Coolant temp. sensor high error.............................................515 Failure code [CA145] Coolant temp. sensor low error..............................................517 Failure code [CA153] Charge air temp. sensor high error..........................................519 Failure code [CA154] Charge air temp. sensor low error...........................................521 Failure code [CA155] Chg air temp high speed derate..............................................521 Failure code [CA187] Sensor sup. 2 volt. low error...............................................522 Failure code [CA221] Ambient air press. sensor high error........................................523 Failure code [CA222] Ambient air press. sensor low error.........................................525 Failure code [CA227] Sensor sup. 2 volt. high error..............................................526 Failure code [CA234] Eng. overspeed..............................................................527 Failure code [CA238] Ne speed sensor sup. volt. error............................................529 Failure code [CA271] IMV/PCV1 short error........................................................531 Failure code [CA272] IMV/PCV1 open error.........................................................532 Failure code [CA322] Injector #1 (L #1) system open/short error..................................533 Failure code [CA324] Injector #3 (L #3) system open/short error..................................535 Failure code [CA331] Injector #2 (L #2) system open/short error..................................537 Failure code [CA332] Injector #4 (L #4) system open/short error..................................539 Troubleshooting by failure code, Part 2..............................................................542 Failure code [CA342] Calibration code incompatibility............................................544 Failure code [CA351] Inj. drive circuit error....................................................545 Failure code [CA352] Sensor sup. 1 volt. low error...............................................548 Failure code [CA386] Sensor sup. 1 volt. high error..............................................549 Failure code [CA435] Abnormality in engine oil pressure switch...................................551 Failure code [CA441] Battery voltage low error...................................................552 Failure code [CA442] Battery voltage high error..................................................553 Failure code [CA449] Rail press. very high error.................................................554 Failure code [CA451] Rail press. sensor high error...............................................555 Failure code [CA452] Rail press. sensor low error................................................557 Failure code [CA488] Chg air temp high torque derate.............................................558 Failure code [CA553] Rail press. high error......................................................559 Failure code [CA559] Rail press. low error.......................................................560 Failure code [CA689] Eng. Ne speed sensor error..................................................563 Failure code [CA731] Eng. Bkup speed sensor phase error..........................................565 Failure code [CA757] All persistent data lost error..............................................566 Failure code [CA778] Eng. Bkup speed sensor error................................................567 Failure code [CA1633] KOMNET datalink timeout error..............................................569 Failure code [CA2185] Throttle sens. sup. volt. high error.......................................571 Failure code [CA2186] Throttle sens. sup. volt. low error........................................573 Failure code [CA2249] Rail press. very low error.................................................573 Failure code [CA2311] Abnormality in IMV solenoid................................................574 Failure code [D110KB] Battery relay drive short..................................................575 Failure code [D19JKZ] Personal code relay abnormality............................................577 Failure code [D862KA] GPS antenna discon.........................................................579 Failure code [DA22KK] Pump solenoid power low error..............................................581 Failure code [DA25KP] 5V sensor 1 power abnormality..............................................583 Failure code [DA26KP] 5V sensor 2 power abnormality..............................................586 Failure code [DA29KQ] Model selection abnormality................................................587 Troubleshooting by failure code, Part 3..............................................................590 Failure code [DA2RMC] CAN discon (Pump controller detected)......................................593 Failure code [DAF8KB] Short circuit in camera power supply.......................................595 Failure code [DAFGMC] GPS module error...........................................................597 Failure code [DAFRMC] CAN discon (Monitor detected)..............................................599 Failure code [DGH2KB] Hydr oil sensor short......................................................601 Failure code [DHPAMA] Pump press sensor abnormality..............................................603 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality...........................605 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality..........................607 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality...........................609 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality..........................611 Failure code [DHX1MA] Overload sensor abnormality (Analog).......................................613 Failure code [DV20KB] Travel alarm short circuit.................................................614 Failure code [DW43KA] Travel speed sol discon....................................................615 Failure code [DW43KB] Travel speed sol short.....................................................616 Failure code [DW45KA] Swing brake sol discon.....................................................617 Failure code [DW45KB] Swing brake sol short......................................................619 Failure code [DW91KA] Travel junction sol discon.................................................621 Failure code [DW91KB] Travel junction sol short..................................................623 Failure code [DWJ0KA] Merge-divider sol discon...................................................625 Failure code [DWJ0KB] Merge-divider sol short....................................................627 Failure code [DWK0KA] 2-stage relief sol discon..................................................629 Failure code [DWK0KB] 2-stage relief sol short...................................................631 Troubleshooting by failure code, Part 4..............................................................634 Failure code [DXA8KA] PC-EPC sol discon..........................................................635 Failure code [DXA8KB] PC-EPC sol short...........................................................637 Failure code [DXE4KA] Service current EPC discon.................................................639 Failure code [DXE4KB] Service current EPC short..................................................641 Failure code [DY20KA] Wiper working abnormality..................................................643 Failure code [DY20MA] Wiper parking abnormality..................................................645 Failure code [DY2CKA] Washer drive discon........................................................647 Failure code [DY2CKB] Washer drive short.........................................................649 Failure code [DY2DKB] Wiper drive (for) short....................................................651 Failure code [DY2EKB] Wiper drive (rev) short....................................................653 Troubleshooting of electrical system (E-mode)........................................................656 Before carrying out troubleshooting of electrical system.........................................658 Information in troubleshooting table.............................................................660 E-1 When starting switch turned ON, machine monitor displays nothing.............................661 E-2 When starting switch turned ON (before starting engine), basic check item lights up..........663 E-3 Engine does not start (Engine does not turn).................................................666 E-4 Preheater does not operate...................................................................669 E-5 Automatic warm-up system does not operate (in cold season)...................................671 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked..............673 E-7 Precaution lights up while engine is running.................................................675 E-8 Emergency stop item lights up while engine is running........................................680 E-9 Engine coolant temperature gauge does not indicate normally..................................681 E-10 Hydraulic oil temperature gauge does not indicate normally..................................682 E-11 Fuel level gauge does not indicate normally.................................................684 E-12 Contents of display by machine monitor are different from applicable machine................686 E-13 Machine monitor does not display some items.................................................686 E-14 Function switch does not work...............................................................686 E-15 Auto-decelerator does not operate normally..................................................687 E-16 Working mode does not change................................................................688 E-17 Travel speed does not change................................................................689 E-18 Alarm buzzer cannot be stopped..............................................................690 E-19 Windshield wiper and window washer do not operate...........................................691 E-20 Power maximizing function does not operate normally.........................................695 E-21 Swing holding brake does not operate normally...............................................697 E-22 Travel alarm does not sound or does not stop sounding.......................................699 E-23 Air conditioner does not operate normally (including air conditioner abnormality record)....700 E-24 While starting switch is in OFF position, service meter is not displayed....................712 E-25 Machine monitor cannot be set in service mode...............................................712 E-26 Monitoring function does not display lever control signal normally..........................713 E-27 KOMTRAX system does not operate normally....................................................729 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................732 Information contained in troubleshooting table...................................................734 System chart for hydraulic and mechanical systems................................................735 H-1 Speed or power of all work equipment, swing, and travel are low..............................737 H-2 Engine speed sharply drops or engine stalls..................................................738 H-3 No work equipment, travel and swing move.....................................................739 H-4 Abnormal noise is heard from around hydraulic pump...........................................739 H-5 Fine control mode does not function..........................................................740 H-6 Speed or power of boom is low................................................................741 H-7 Speed or power of arm is low.................................................................742 H-8 Speed or power of bucket is low..............................................................743 H-9 Work equipment does not move in its single operation.........................................744 H-10 Hydraulic drift of work equipment is large..................................................745 H-11 Time lag of work equipment is large.........................................................746 H-12 Power maximizing function does not operate normally.........................................746 H-13 Work equipment loaded more is slower during compound operation..............................747 H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE.........................747 H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel......748 H-16 Machine deviates during travel..............................................................749 H-17 Travel speed is low.........................................................................750 H-18 Machine cannot be steered easily or steering power is low...................................751 H-19 Travel speed does not change or it is kept low or high......................................752 H-20 Track does not move (Only either side)......................................................752 H-21 Machine does not swing......................................................................753 H-22 Swing acceleration or swing speed is low....................................................754 H-23 Excessive overrun when stopping swing.......................................................755 H-24 When upper structure stops swinging, it makes large shock...................................756 H-25 When upper structure stops swinging, it makes large sound...................................756 H-26 Hydraulic drift of swing is large...........................................................757 H-27 Flow rate in attachment circuit cannot be adjusted..........................................758 Troubleshooting of engine (S-mode)...................................................................760 Method of using troubleshooting chart............................................................763 S-1 Starting performance is poor.................................................................767 S-2 Engine does not start........................................................................768 S-3 Engine does not pick up smoothly.............................................................771 S-4 Engine stops during operations...............................................................772 S-5 Engine does not rotate smoothly..............................................................773 S-6 Engine lacks output (or lacks power).........................................................774 S-7 Exhaust smoke is black (incomplete combustion)...............................................775 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................776 S-9 Oil becomes contaminated quickly.............................................................777 S-10 Fuel consumption is excessive...............................................................778 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).......................779 S-12 Oil pressure drops..........................................................................780 S-13 Oil level rises (Entry of coolant or fuel)..................................................781 S-14 Coolant temperature becomes too high (overheating)..........................................782 S-15 Abnormal noise is made......................................................................783 S-16 Vibration is excessive......................................................................784 50 Disassembly and assembly.............................................................................. 0 General information on disassembly and assembly......................................................786 How to read this manual..........................................................................787 Coating materials list...........................................................................789 Special tool list................................................................................792 Sketch of special tool...........................................................................796 Engine and cooling system............................................................................802 Removal and installation of fuel supply pump assembly............................................803 Removal and installation of fuel injector assembly...............................................806 Removal and installation of front oil seal.......................................................809 Removal and installation of rear oil seal........................................................811 Removal and installation of cylinder head assembly...............................................814 Removal and installation of radiator assembly....................................................824 Removal and installation of aftercooler assembly.................................................826 Removal and installation of work equipment oil cooler assembly...................................828 Removal and installation of engine and work equipment pump assembly..............................830 Removal and installation of fuel tank assembly...................................................838 Power train..........................................................................................842 Removal and installation of travel motor and final drive assembly................................843 Removal and installation of swing motor and swing machinery assembly.............................845 Disassembly and assembly of swing machinery assembly.............................................847 Removal and installation of swing circle assembly................................................853 Undercarriage and frame..............................................................................856 Disassembly and assembly of track roller.........................................................857 Disassembly and assembly of idler assembly.......................................................860 Disassembly and assembly of recoil spring........................................................863 Spreading and installation of track shoe assembly................................................866 Removal and installation of sprocket.............................................................868 Removal and installation of revolving frame assembly.............................................869 Removal and installation of counterweight assembly...............................................871 Hydraulic system.....................................................................................874 Removal and installation of center swivel joint assembly.........................................875 Disassembly and assembly of center swivel joint assembly.........................................877 Removal and installation of hydraulic tank assembly..............................................878 Removal and installation of work equipment pump assembly.........................................881 Removal and installation of control valve assembly...............................................885 Disassembly and assembly of control valve assembly...............................................889 Disassembly and assembly of work equipment PPC valve assembly....................................901 Disassembly and assembly of travel PPC valve assembly............................................903 Disassembly and assembly of hydraulic cylinder assembly..........................................906 Work equipment.......................................................................................914 Removal and installation of work equipment assembly..............................................915 Cab and its attachments..............................................................................920 Removal and installation of operator's cab assembly..............................................921 Removal and installation of operator cab glass (stuck glass).....................................924 Removal and installation of front window assembly................................................934 Removal and installation of floor frame assembly.................................................941 Electrical system....................................................................................946 Removal and installation of air compressor assembly..............................................947 Removal and installation of air conditioner condenser............................................948 Removal and installation of air compressor unit assembly.........................................949 Removal and installation of KOMTRAX communication modem assembly.................................952 Removal and installation of monitor assembly.....................................................953 Removal and installation of pump controller assembly.............................................955 Removal and installation of engine controller assembly...........................................957 90 Diagrams and drawings................................................................................. 0 Hydraulic diagrams and drawings......................................................................960 Hydraulic circuit diagram (1/2)..................................................................962 Hydraulic circuit diagram (2/2)..................................................................963 Electrical diagrams and drawings.....................................................................966 Electrical circuit diagram (1/5).................................................................968 Electrical circuit diagram (2/5).................................................................969 Electrical circuit diagram (3/5).................................................................970 Electrical circuit diagram (4/5).................................................................971 Electrical circuit diagram (5/5).................................................................972 Connectors table and arrangement drawing.........................................................973
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