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Komatsu PC130-8 Hydraulic Excavator Shop Manual SEN03763-10 – PDF DOWNLOAD
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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: 80001 and up
Book Code: SEN03763-10
Language: English
Pages: 1023
File Format: Portable Document Format (PDF)
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. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, 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. TESTING AND ADJUSTING:
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.
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.
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.
30. 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. OTHERS (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................................................................................................ 3 Composition of shop m............................................................................ 4 Table of cont.................................................................................... 6 Foreword and general information..................................................................... 16 Safety notice.................................................................................... 17 How to read the shop manual...................................................................... 22 Explanation of terms for maintenance standard.................................................... 24 Handling of electric equipment and hydraulic component........................................... 26 Handling of connectors newly used for engines.................................................... 35 How to read electric wire code................................................................... 38 Precautions when carrying out operation.......................................................... 41 Method of disassembling and connecting push-pull type coupler.................................... 44 Standard tightening torque table................................................................. 47 Conversion table................................................................................. 51 01 Specification......................................................................................... 0 Specification and technical data..................................................................... 58 Specification dimension drawings................................................................. 59 Working range diagram............................................................................ 60 Specifications................................................................................... 61 List of weights.................................................................................. 65 List of lubricant and coolant to be filled....................................................... 67 10 Structure, function and maintenance standard.......................................................... 0 Engine and cooling system............................................................................ 70 Engine mount..................................................................................... 71 PTO.............................................................................................. 72 Cooling system................................................................................... 73 Power train.......................................................................................... 76 Power train...................................................................................... 77 Swing circle..................................................................................... 78 Swing machinery.................................................................................. 79 Undercarriage and frame.............................................................................. 82 Track frame...................................................................................... 83 Idler cushion.................................................................................... 84 Idler............................................................................................ 85 Track roller..................................................................................... 86 Carrier roller................................................................................... 87 Sprocket......................................................................................... 88 Track shoe....................................................................................... 89 Hydraulic system, Part 1............................................................................. 94 Hydraulic equipment layout drawing............................................................... 95 Valve control.................................................................................... 97 Hydraulic tank and filter........................................................................ 99 Hydraulic pump................................................................................... 101 Hydraulic system, Part 2............................................................................. 130 Control valve.................................................................................... 131 CLSS............................................................................................. 141 Functions and operation by valve................................................................. 145 Hydraulic system, Part 3............................................................................. 176 PPC valve........................................................................................ 177 Swing motor...................................................................................... 192 Travel motor..................................................................................... 200 Center swivel joint.............................................................................. 209 Solenoid valve................................................................................... 211 Accumulator...................................................................................... 215 Holding valve.................................................................................... 217 Hydraulic cylinder............................................................................... 223 Work equipment....................................................................................... 226 Work equipment................................................................................... 227 Dimensions of components......................................................................... 229 Cab and its attachments.............................................................................. 234 Air conditioner.................................................................................. 235 Electrical system.................................................................................... 239 Electronic control system........................................................................ 240 Machine monitor sy............................................................................... 272 KOMTRAX system................................................................................... 286 Sensor........................................................................................... 288 20 Standard value table.................................................................................. 0 Standard service value table......................................................................... 238 Standard value table for engine related parts.................................................... 297 Standard value table for chassis related parts................................................... 298 30 Testing and adjusting................................................................................. 0 Testing and adjusting, Part 1........................................................................ 308 Tools for testing, adjusting, and troubleshooting................................................ 310 Sketches of special tools........................................................................ 315 Testing engine speed............................................................................. 316 Testing exhaust temperature...................................................................... 317 Checking exhaust gas color....................................................................... 318 Adjusting valve clearance........................................................................ 319 Testing compression pressure..................................................................... 321 Testing blow-by pressure......................................................................... 323 Testing engine oil pressure...................................................................... 324 Reduced cylinder mode operation.................................................................. 325 No-injection cranking............................................................................ 325 Handling fuel system parts....................................................................... 326 Releasing residual pressure from fuel system..................................................... 326 Testing fuel pressure............................................................................ 327 Testing fuel return rate and fuel leakage........................................................ 328 Bleeding air from fuel circuit................................................................... 330 Checking fuel circuit for leakage................................................................ 331 Testing and adjusting alternator belt tension.................................................... 332 Checking and adjusting air conditioner compressor belt tension................................... 333 Testing swing circle bearing clearance........................................................... 334 Checking and adjusting track shoe tension........................................................ 335 Testing and adjusting oil pressure in work equipment, swing, and travel circuits................. 337 Testing control circuit basic pressure........................................................... 340 Testing and adjusting oil pressure in pump PC control circuit.................................... 341 Testing and adjusting oil pressure in pump LS control circuit.................................... 344 Testing solenoid valve output pressure........................................................... 347 Testing PPC valve output pressure................................................................ 351 Adjusting play of work equipment and swing PPC valves............................................ 352 Checking parts which cause hydraulic drift of work equipment..................................... 353 Testing and adjusting travel deviation........................................................... 355 Releasing residual pressure from hydraulic circuit............................................... 357 Testing oil leakage.............................................................................. 358 Bleeding air from each part...................................................................... 361 Checking cab tipping stopper..................................................................... 363 Installation and adjustment of mirrors and camera................................................ 364 Inspection of air conditioner Recirc/Fresh air filter............................................ 373 Testing and adjusting, Part 2........................................................................ 376 Special functions of machine monitor............................................................. 377 Testing and adjusting, Part 3........................................................................ 428 Handling voltage circuit of engine controller.................................................... 429 Preparation work for troubleshooting of electrical system........................................ 430 Procedure for testing diodes..................................................................... 435 Pm Clinic service................................................................................ 436 40 Troubleshooting....................................................................................... 0 Failure code table and fuse locations................................................................ 442 Failure code table............................................................................... 443 Fuse locations................................................................................... 447 General information on troubleshooting............................................................... 450 Points to remember when troubleshooting.......................................................... 451 Sequence of events in troubleshooting............................................................ 452 Checks before troubleshooting.................................................................... 453 Classification and procedures for troubleshooting................................................ 454 Information in troubleshooting table............................................................. 455 Phenomena looking like troubles and troubleshooting Nos.......................................... 457 Connection table for connector pin numbers....................................................... 460 T- branch box and T- branch adapter table........................................................ 496 Troubleshooting by failure code, Part 1.............................................................. 500 Failure code [989L00] Engine controller lock caution 1........................................... 502 Failure code [989M00] Engine controller lock caution 2........................................... 502 Failure code [989N00] Engine controller lock caution 3........................................... 503 Failure code [AA10NX] Air cleaner clogging....................................................... 504 Failure code [AB00KE] Charge voltage low......................................................... 505 Failure code [B@BAZG] Eng oil press. low......................................................... 507 Failure code [B@BAZK] Eng oil level low.......................................................... 508 Failure code [B@BCNS] Eng coolant overheat....................................................... 509 Failure code [B@BCZK] Eng water level low........................................................ 511 Failure code [B@HANS] Hydr oil overheat.......................................................... 513 Failure code [CA111] ECM critical internal failure............................................... 515 Failure code [CA115] Eng Ne and Bkup speed sensor error.......................................... 518 Failure code [CA122] Charge air press sensor high error.......................................... 519 Failure code [CA123] Charge air press sensor low error........................................... 521 Failure code [CA131] Throttle sensor high error.................................................. 523 Failure code [CA132] Throttle sensor low error................................................... 525 Failure code [CA144] Coolant temp. sensor high error............................................. 527 Failure code [CA145] Coolant temp. sensor low error.............................................. 529 Failure code [CA153] Charge air temp. sensor high error.......................................... 531 Failure code [CA154] Charge air temp. sensor low error........................................... 533 Failure code [CA155] Chg air temp high speed derate.............................................. 533 Failure code [CA187] Sensor sup. 2 volt. low error............................................... 534 Failure code [CA221] Ambient air press. sensor high error........................................ 535 Failure code [CA222] Ambient air press. sensor low error......................................... 537 Failure code [CA227] Sensor sup. 2 volt. high error.............................................. 538 Failure code [CA234] Eng. overspeed.............................................................. 539 Failure code [CA238] Ne speed sensor sup. volt. error............................................ 541 Failure code [CA271] IMV/PCV1 short error........................................................ 543 Failure code [CA272] IMV/PCV1 open error......................................................... 544 Failure code [CA322] Injector #1 (L #1) system open/short error.................................. 545 Failure code [CA324] Injector #3 (L #3) system open/short error.................................. 547 Failure code [CA331] Injector #2 (L #2) system open/short error.................................. 549 Failure code [CA332] Injector #4 (L #4) system open/short error.................................. 551 Troubleshooting by failure code, Part 2.............................................................. 554 Failure code [CA342] Calibration code incompatibility............................................ 556 Failure code [CA351] Inj. drive circuit error.................................................... 557 Failure code [CA352] Sensor sup. 1 volt. low error............................................... 560 Failure code [CA386] Sensor sup. 1 volt. high error.............................................. 561 Failure code [CA435] Abnormality in engine oil pressure switch................................... 563 Failure code [CA441] Battery voltage low error................................................... 564 Failure code [CA442] Battery voltage high error.................................................. 565 Failure code [CA449] Rail press. very high error................................................. 566 Failure code [CA451] Rail press. sensor high error............................................... 567 Failure code [CA452] Rail press. sensor low error................................................ 569 Failure code [CA488] Chg air temp high torque derate............................................. 570 Failure code [CA553] Rail press. high error...................................................... 571 Failure code [CA559] Rail press. low error....................................................... 572 Failure code [CA689] Eng. Ne speed sensor error.................................................. 575 Failure code [CA731] Eng. Bkup speed sensor phase error.......................................... 577 Failure code [CA757] All persistent data lost error.............................................. 578 Failure code [CA778] Eng. Bkup speed sensor error................................................ 579 Failure code [CA1633] KOMNET datalink timeout error.............................................. 581 Failure code [CA2185] Throttle sens. sup. volt. high error....................................... 583 Failure code [CA2186] Throttle sens. sup. volt. low error........................................ 585 Failure code [CA2249] Rail press. very low error................................................. 585 Failure code [CA2311] Abnormality in IMV solenoid................................................ 586 Failure code [D110KB] Battery relay drive short.................................................. 587 Failure code [D19JKZ] Personal code relay abnormality............................................ 589 Failure code [D862KA] GPS antenna discon......................................................... 591 Failure code [DA22KK] Pump solenoid power low error.............................................. 593 Failure code [DA25KP] 5V sensor 1 power abnormality.............................................. 595 Failure code [DA26KP] 5V sensor 2 power abnormality.............................................. 598 Failure code [DA29KQ] Model selection abnormality................................................ 599 Troubleshooting by failure code, Part 3.............................................................. 602 Failure code [DA2RMC] CAN discon (Pump controller detected)...................................... 605 Failure code [DAF8KB] Short circuit in camera power supply....................................... 607 Failure code [DAFGMC] GPS module error........................................................... 609 Failure code [DAFRMC] CAN discon (Monitor detected).............................................. 611 Failure code [DGH2KB] Hydr oil sensor short...................................................... 613 Failure code [DHPAMA] Pump press sensor abnormality.............................................. 615 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality........................... 617 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality.......................... 619 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality........................... 621 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality.......................... 623 Failure code [DHX1MA] Overload sensor abnormality (Analog)....................................... 625 Failure code [DV20KB] Travel alarm short circuit................................................. 626 Failure code [DW43KA] Travel speed sol discon.................................................... 627 Failure code [DW43KB] Travel speed sol short..................................................... 628 Failure code [DW45KA] Swing brake sol discon..................................................... 629 Failure code [DW45KB] Swing brake sol short...................................................... 631 Failure code [DW91KA] Travel junction sol discon................................................. 633 Failure code [DW91KB] Travel junction sol short.................................................. 635 Failure code [DWJ0KA] Merge-divider sol discon................................................... 637 Failure code [DWJ0KB] Merge-divider sol short.................................................... 639 Failure code [DWK0KA] 2-stage relief sol discon.................................................. 641 Failure code [DWK0KB] 2-stage relief sol short................................................... 643 Troubleshooting by failure code, Part 4.............................................................. 646 Failure code [DXA8KA] PC-EPC sol discon.......................................................... 647 Failure code [DXA8KB] PC-EPC sol short........................................................... 649 Failure code [DXE4KA] Service current EPC discon................................................. 651 Failure code [DXE4KB] Service current EPC short.................................................. 653 Failure code [DY20KA] Wiper working abnormality.................................................. 655 Failure code [DY20MA] Wiper parking abnormality.................................................. 657 Failure code [DY2CKA] Washer drive discon........................................................ 659 Failure code [DY2CKB] Washer drive short......................................................... 661 Failure code [DY2DKB] Wiper drive (for) short.................................................... 663 Failure code [DY2EKB] Wiper drive (rev) short.................................................... 665 Troubleshooting of electrical system (E-mode)........................................................ 668 Before carrying out troubleshooting of electrical system......................................... 670 Information in troubleshooting table............................................................. 672 E-1 When starting switch turned ON, machine monitor displays nothing............................. 673 E-2 When starting switch turned ON (before starting engine), basic check item lights up.......... 675 E-3 Engine does not start (Engine does not turn)................................................. 678 E-4 Preheater does not operate................................................................... 681 E-5 Automatic warm-up system does not operate (in cold season)................................... 683 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked.............. 685 E-7 Precaution lights up while engine is running................................................. 687 E-8 Emergency stop item lights up while engine is running........................................ 692 E-9 Engine coolant temperature gauge does not indicate normally.................................. 693 E-10 Hydraulic oil temperature gauge does not indicate normally.................................. 694 E-11 Fuel level gauge does not indicate normally................................................. 696 E-12 Contents of display by machine monitor are different from applicable machine................ 698 E-13 Machine monitor does not display some items................................................. 698 E-14 Function switch does not work............................................................... 698 E-15 Auto-decelerator does not operate normally.................................................. 699 E-16 Working mode does not change................................................................ 700 E-17 Travel speed does not change................................................................ 701 E-18 Alarm buzzer cannot be stopped.............................................................. 702 E-19 Windshield wiper and window washer do not operate........................................... 703 E-20 Power maximizing function does not operate normally......................................... 707 E-21 Swing holding brake does not operate normally............................................... 709 E-22 Travel alarm does not sound or does not stop sounding....................................... 711 E-23 Air conditioner does not operate normally (including air conditioner abnormality record).... 712 E-24 While starting switch is in OFF position, service meter is not displayed.................... 724 E-25 Machine monitor cannot be set in service mode............................................... 724 E-26 Monitoring function does not display lever control signal normally.......................... 725 E-27 KOMTRAX system does not operate normally.................................................... 741 Troubleshooting of hydraulic and mechanical system (H-mode).......................................... 744 Information contained in troubleshooting table................................................... 746 System chart for hydraulic and mechanical systems................................................ 747 H-1 Speed or power of all work equipment, swing, and travel are low.............................. 749 H-2 Engine speed sharply drops or engine stalls.................................................. 750 H-3 No work equipment, travel and swing move..................................................... 751 H-4 Abnormal noise is heard from around hydraulic pump........................................... 751 H-5 Fine control mode does not function.......................................................... 752 H-6 Speed or power of boom is low................................................................ 753 H-7 Speed or power of arm is low................................................................. 754 H-8 Speed or power of bucket is low.............................................................. 755 H-9 Work equipment does not move in its single operation......................................... 756 H-10 Hydraulic drift of work equipment is large.................................................. 757 H-11 Time lag of work equipment is large......................................................... 758 H-12 Power maximizing function does not operate normally......................................... 758 H-13 Work equipment loaded more is slower during compound operation.............................. 759 H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE......................... 759 H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel...... 760 H-16 Machine deviates during travel.............................................................. 761 H-17 Travel speed is low......................................................................... 762 H-18 Machine cannot be steered easily or steering power is low................................... 763 H-19 Travel speed does not change or it is kept low or high...................................... 764 H-20 Track does not move (Only either side)...................................................... 764 H-21 Machine does not swing...................................................................... 765 H-22 Swing acceleration or swing speed is low.................................................... 766 H-23 Excessive overrun when stopping swing....................................................... 767 H-24 When upper structure stops swinging, it makes large shock................................... 768 H-25 When upper structure stops swinging, it makes large sound................................... 768 H-26 Hydraulic drift of swing is large........................................................... 769 H-27 Flow rate in attachment circuit cannot be adjusted.......................................... 770 Troubleshooting of engine (S-mode)................................................................... 772 Method of using troubleshooting chart............................................................ 775 S-1 Starting performance is poor................................................................. 779 S-2 Engine does not start........................................................................ 780 S-3 Engine does not pick up smoothly............................................................. 783 S-4 Engine stops during operations............................................................... 784 S-5 Engine does not rotate smoothly.............................................................. 785 S-6 Engine lacks output (or lacks power)......................................................... 786 S-7 Exhaust smoke is black (incomplete combustion)............................................... 787 S-8 Oil consumption is excessive (or exhaust smoke is blue)...................................... 788 S-9 Oil becomes contaminated quickly............................................................. 789 S-10 Fuel consumption is excessive............................................................... 790 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....................... 791 S-12 Oil pressure drops.......................................................................... 792 S-13 Oil level rises (Entry of coolant or fuel).................................................. 793 S-14 Coolant temperature becomes too high (overheating).......................................... 794 S-15 Abnormal noise is made...................................................................... 795 S-16 Vibration is excessive...................................................................... 796 50 Disassembly and assembly.............................................................................. 0 General information on disassembly and assembly...................................................... 798 How to read this manual.......................................................................... 799 Coating materials list........................................................................... 801 Special tool list................................................................................ 804 Sketch of special tool........................................................................... 808 Engine and cooling system............................................................................ 814 Removal and installation of fuel supply pump assembly............................................ 815 Removal and installation of fuel injector assembly............................................... 818 Removal and installation of front oil seal....................................................... 821 Removal and installation of rear oil seal........................................................ 823 Removal and installation of cylinder head assembly............................................... 826 Removal and installation of radiator assembly.................................................... 836 Removal and installation of aftercooler assembly................................................. 838 Removal and installation of work equipment oil cooler assembly................................... 840 Removal and installation of engine and work equipment pump assembly.............................. 842 Removal and installation of fuel tank assembly................................................... 850 Power train.......................................................................................... 854 Removal and installation of travel motor and final drive assembly................................ 855 Disassembly and assembly of travel motor and final drive assembly................................ 857 Removal and installation of swing motor and swing machinery assembly............................. 894 Disassembly and assembly of swing machinery assembly............................................. 896 Removal and installation of swing circle assembly................................................ 902 Undercarriage and frame.............................................................................. 904 Disassembly and assembly of track roller......................................................... 905 Disassembly and assembly of idler assembly....................................................... 908 Disassembly and assembly of recoil spring........................................................ 911 Spreading and installation of track shoe assembly................................................ 914 Removal and installation of sprocket............................................................. 916 Removal and installation of revolving frame assembly............................................. 917 Removal and installation of counterweight assembly............................................... 919 Hydraulic system..................................................................................... 922 Removal and installation of center swivel joint assembly......................................... 923 Disassembly and assembly of center swivel joint assembly......................................... 925 Removal and installation of hydraulic tank assembly.............................................. 926 Removal and installation of work equipment pump assembly......................................... 929 Removal and installation of control valve assembly............................................... 933 Disassembly and assembly of control valve assembly............................................... 937 Disassembly and assembly of work equipment PPC valve assembly.................................... 949 Disassembly and assembly of travel PPC valve assembly............................................ 951 Disassembly and assembly of hydraulic cylinder assembly.......................................... 954 Work equipment....................................................................................... 962 Removal and installation of work equipment assembly.............................................. 963 Cab and its attachments.............................................................................. 968 Removal and installation of operator's cab assembly.............................................. 969 Removal and installation of operator cab glass (stuck glass)..................................... 972 Removal and installation of front window assembly................................................ 982 Removal and installation of floor frame assembly................................................. 989 Electrical system.................................................................................... 994 Removal and installation of air compressor assembly.............................................. 995 Removal and installation of air conditioner condenser............................................ 996 Removal and installation of air compressor unit assembly......................................... 997 Removal and installation of KOMTRAX communication modem assembly.................................1000 Removal and installation of monitor assembly.....................................................1001 Removal and installation of pump controller assembly.............................................1003 Removal and installation of engine controller assembly...........................................1005 90 Diagrams and drawings................................................................................. 0 Hydraulic diagrams and drawings......................................................................1008 Hydraulic circuit diagram (1/2)..................................................................1010 Hydraulic circuit diagram (2/2)..................................................................1011 Electrical diagrams and drawings.....................................................................1014 Electrical circuit diagram (1/5).................................................................1016 Electrical circuit diagram (2/5).................................................................1017 Electrical circuit diagram (3/5).................................................................1018 Electrical circuit diagram (4/5).................................................................1019 Electrical circuit diagram (5/5).................................................................1020 Connectors table and arrangement drawing.........................................................1021
KOMATSU PC130-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN03763-10 – PDF DOWNLOAD:
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