Komatsu Pc130-8 Hydraulic Excavator Service Shop Repair Manual

HYDRAULIC EXCAVATOR SEN03763-05 PC130 -8 SERIAL NUMBERS 80001 and up

PC130-8 1 SEN03765-05 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC130-8 Machine model Serial number PC130-8 80001 and up 00 Index and foreword 1 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4

SEN03765-05 00 Index and foreword 2 PC130-8 Composition of shop manual 1 The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title Form Number Shop Manual, contents binder, binder label and tabs SEN03763-05 00 Index and foreword SEN03764-05 Index SEN03765-05 q Foreword and general information SEN03766-01 01 Specification SEN03767-01 Specification and technical data SEN03768-01 10 Structure, function and maintenance standard SEN03769-02 Engine and cooling system SEN03770-01 Power train SEN03771-00 Undercarriage and frame SEN03772-01 Hydraulic system, Part 1 SEN03773-00 Hydraulic system, Part 2 SEN03774-01 Hydraulic system, Part 3 SEN03775-02 Work equipment SEN03776-00 Cab and its attachments SEN03777-00 Electrical system SEN03778-01 20 Standard value table SEN03779-02 Standard service value table SEN04113-02 30 Testing and adjusting SEN03780-02 Testing and adjusting, Part 1 SEN04114-02 Testing and adjusting, Part 2 SEN04115-02 Testing and adjusting, Part 3 SEN04116-00 40 Troubleshooting SEN03781-02 Failure code table and fuse locations SEN04117-02 General information on troubleshooting SEN04118-02 Troubleshooting by failure code, Part 1 SEN04119-01 Troubleshooting by failure code, Part 2 SEN04120-01 Troubleshooting by failure code, Part 3 SEN04121-01 Troubleshooting by failure code, Part 4 SEN04122-01 Troubleshooting of electrical system (E-mode) SEN04123-01

00 Index and foreword SEN03765-05 PC130-8 3 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04124-00 Troubleshooting of engine (S-mode) SEN04125-02 50 Disassembly and assembly SEN03782-03 General information on disassembly and assembly SEN04126-02 Engine and cooling system SEN04127-01 Power train SEN04128-01 q Undercarriage and frame SEN04129-00 Hydraulic system SEN04130-00 Work equipment SEN04131-00 Cab and its attachments SEN04132-00 Electrical system SEN04134-00 90 Diagrams and drawings SEN03783-01 Hydraulic diagrams and drawings SEN03784-00 Electrical diagrams and drawings SEN03785-01

SEN03765-05 00 Index and foreword 4 PC130-8 Table of contents 1 00 Index and foreword Index SEN03765-05 Composition of shop manual ....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN03766-01 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard .......................................................................... 9 Handling of electric equipment and hydraulic component ........................................................... 11 Handling of connectors newly used for engines .......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN03768-01 Specification dimension drawings ............................................................................................... 2 Working range diagram ............................................................................................................... 3 Specifications .............................................................................................................................. 4 List of weights.............................................................................................................................. 8 List of lubricant and coolant to be filled ....................................................................................... 10 10 Structure, function and maintenance standard Engine and cooling system SEN03770-01 Engine mount .............................................................................................................................. 2 PTO ............................................................................................................................................. 3 Cooling system............................................................................................................................ 4 Power train SEN03771-00 Power train .................................................................................................................................. 2 Swing circle ................................................................................................................................. 3 Swing machinery ......................................................................................................................... 4 Undercarriage and frame SEN03772-01 Track frame ................................................................................................................................. 2 Idler cushion ................................................................................................................................ 3 Idler ............................................................................................................................................. 4 Track roller................................................................................................................................... 5 Carrier roller ................................................................................................................................ 6 Sprocket ...................................................................................................................................... 7 Track shoe ................................................................................................................................... 8 Hydraulic system, Part 1 SEN03773-00 Hydraulic equipment layout drawing ........................................................................................... 2 Valve control ................................................................................................................................ 4 Hydraulic tank and filter ............................................................................................................... 6 Hydraulic pump ........................................................................................................................... 8 Hydraulic system, Part 2 SEN03774-01 Control valve ............................................................................................................................... 2 CLSS ........................................................................................................................................... 12 Functions and operation by valve................................................................................................ 16 Hydraulic system, Part 3 SEN03775-02 PPC valve.................................................................................................................................... 2

00 Index and foreword SEN03765-05 PC130-8 5 Swing motor ................................................................................................................................ 17 Travel motor ................................................................................................................................ 25 Center swivel joint ....................................................................................................................... 34 Solenoid valve ............................................................................................................................. 36 Accumulator ................................................................................................................................ 40 Holding valve............................................................................................................................... 42 Hydraulic cylinder ........................................................................................................................ 48 Work equipment SEN03776-00 Work equipment .......................................................................................................................... 2 Dimensions of components ......................................................................................................... 4 Cab and its attachments SEN03777-00 Air conditioner ............................................................................................................................. 2 Electrical system SEN03778-01 Electronic control system ............................................................................................................ 2 Machine monitor system ............................................................................................................. 33 KOMTRAX system ...................................................................................................................... 47 Sensor ......................................................................................................................................... 49 20 Standard value table Standard service value table SEN04113-02 Standard value table for engine related parts.............................................................................. 2 Standard value table for chassis related parts ............................................................................ 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN04114-02 Tools for testing, adjusting, and troubleshooting ......................................................................... 3 Sketches of special tools ............................................................................................................ 8 Testing engine speed .................................................................................................................. 9 Testing exhaust temperature ....................................................................................................... 10 Checking exhaust gas color ........................................................................................................ 11 Adjusting valve clearance ........................................................................................................... 12 Testing compression pressure .................................................................................................... 14 Testing blow-by pressure ............................................................................................................ 16 Testing engine oil pressure ......................................................................................................... 17 Reduced cylinder mode operation ............................................................................................. 18 No-injection cranking .................................................................................................................. 18 Handling fuel system parts .......................................................................................................... 19 Releasing residual pressure from fuel system ............................................................................ 19 Testing fuel pressure ................................................................................................................... 20 Testing fuel return rate and fuel leakage ..................................................................................... 21 Bleeding air from fuel circuit ........................................................................................................ 23 Checking fuel circuit for leakage ................................................................................................. 24 Testing and adjusting alternator belt tension ............................................................................... 25 Checking and adjusting air conditioner compressor belt tension ................................................ 26 Testing swing circle bearing clearance........................................................................................ 27 Checking and adjusting track shoe tension................................................................................. 28 Testing and adjusting oil pressure in work equipment, swing, and travel circuits........................ 30 Testing control circuit basic pressure .......................................................................................... 33 Testing and adjusting oil pressure in pump PC control circuit ..................................................... 34 Testing and adjusting oil pressure in pump LS control circuit ..................................................... 37 Testing solenoid valve output pressure ....................................................................................... 40 Testing PPC valve output pressure ............................................................................................. 44 Adjusting play of work equipment and swing PPC valves........................................................... 45 Checking parts which cause hydraulic drift of work equipment ................................................... 46 Testing and adjusting travel deviation ......................................................................................... 48 Releasing residual pressure from hydraulic circuit ...................................................................... 50

SEN03765-05 00 Index and foreword 6 PC130-8 Testing oil leakage ....................................................................................................................... 51 Bleeding air from each part ......................................................................................................... 54 Checking cab tipping stopper ...................................................................................................... 56 Installation and adjustment of mirrors and camera ..................................................................... 57 Inspection of air conditioner Recirc/Fresh air filter ...................................................................... 61 Testing and adjusting, Part 2 SEN04115-02 Special functions of machine monitor .......................................................................................... 2 Testing and adjusting, Part 3 SEN04116-00 Handling voltage circuit of engine controller ................................................................................ 2 Preparation work for troubleshooting of electrical system ........................................................... 3 Procedure for testing diodes ....................................................................................................... 8 Pm Clinic service ......................................................................................................................... 9 40 Troubleshooting Failure code table and fuse locations SEN04117-02 Failure code table ........................................................................................................................ 2 Fuse locations ............................................................................................................................. 6 General information on troubleshooting SEN04118-02 Points to remember when troubleshooting .................................................................................. 2 Sequence of events in troubleshooting ....................................................................................... 3 Checks before troubleshooting.................................................................................................... 4 Classification and procedures for troubleshooting ...................................................................... 5 Information in troubleshooting table ............................................................................................ 6 Phenomena looking like troubles and troubleshooting Nos. ....................................................... 8 Connection table for connector pin numbers............................................................................... 11 T- branch box and T- branch adapter table ................................................................................. 47 Troubleshooting by failure code, Part 1 SEN04119-01 Failure code [989L00] Engine controller lock caution 1............................................................... 3 Failure code [989M00] Engine controller lock caution 2.............................................................. 3 Failure code [989N00] Engine controller lock caution 3 .............................................................. 4 Failure code [AA10NX] Air cleaner clogging ............................................................................... 5 Failure code [AB00KE] Charge voltage low ................................................................................ 6 Failure code [B@BAZG] Eng oil press. low................................................................................. 8 Failure code [B@BAZK] Eng oil level low ................................................................................... 9 Failure code [B@BCNS] Eng coolant overheat........................................................................... 10 Failure code [B@BCZK] Eng water level low .............................................................................. 12 Failure code [B@HANS] Hydr oil overheat ................................................................................. 14 Failure code [CA111] ECM critical internal failure ....................................................................... 16 Failure code [CA115] Eng Ne and Bkup speed sensor error ...................................................... 19 Failure code [CA122] Charge air press sensor high error ........................................................... 20 Failure code [CA123] Charge air press sensor low error ............................................................ 22 Failure code [CA131] Throttle sensor high error ......................................................................... 24 Failure code [CA132] Throttle sensor low error ........................................................................... 26 Failure code [CA144] Coolant temp. sensor high error ............................................................... 28 Failure code [CA145] Coolant temp. sensor low error ................................................................ 30 Failure code [CA153] Charge air temp. sensor high error ........................................................... 32 Failure code [CA154] Charge air temp. sensor low error ............................................................ 34 Failure code [CA155] Chg air temp high speed derate ............................................................... 34 Failure code [CA187] Sensor sup. 2 volt. low error ..................................................................... 35 Failure code [CA221] Ambient air press. sensor high error ........................................................ 36 Failure code [CA222] Ambient air press. sensor low error .......................................................... 38 Failure code [CA227] Sensor sup. 2 volt. high error ................................................................... 39 Failure code [CA234] Eng. overspeed ........................................................................................ 40 Failure code [CA238] Ne speed sensor sup. volt. error .............................................................. 42 Failure code [CA271] IMV/PCV1 short error ............................................................................... 44 Failure code [CA272] IMV/PCV1 open error ............................................................................... 45

00 Index and foreword SEN03765-05 PC130-8 7 Failure code [CA322] Injector #1 (L #1) system open/short error ............................................... 46 Failure code [CA324] Injector #3 (L #3) system open/short error ............................................... 48 Failure code [CA331] Injector #2 (L #2) system open/short error ............................................... 50 Failure code [CA332] Injector #4 (L #4) system open/short error ............................................... 52 Troubleshooting by failure code, Part 2 SEN04120-01 Failure code [CA342] Calibration code incompatibility ................................................................ 3 Failure code [CA351] Inj. drive circuit error ................................................................................. 4 Failure code [CA352] Sensor sup. 1 volt. low error ..................................................................... 7 Failure code [CA386] Sensor sup. 1 volt. high error ................................................................... 8 Failure code [CA435] Abnormality in engine oil pressure switch ................................................ 10 Failure code [CA441] Battery voltage low error .......................................................................... 11 Failure code [CA442] Battery voltage high error ......................................................................... 12 Failure code [CA449] Rail press. very high error ........................................................................ 13 Failure code [CA451] Rail press. sensor high error .................................................................... 14 Failure code [CA452] Rail press. sensor low error ...................................................................... 16 Failure code [CA488] Chg air temp high torque derate............................................................... 17 Failure code [CA553] Rail press. high error ................................................................................ 18 Failure code [CA559] Rail press. low error ................................................................................. 19 Failure code [CA689] Eng. Ne speed sensor error ..................................................................... 22 Failure code [CA731] Eng. Bkup speed sensor phase error ....................................................... 24 Failure code [CA757] All persistent data lost error ...................................................................... 25 Failure code [CA778] Eng. Bkup speed sensor error .................................................................. 26 Failure code [CA1633] KOMNET datalink timeout error ............................................................. 28 Failure code [CA2185] Throttle sens. sup. volt. high error .......................................................... 30 Failure code [CA2186] Throttle sens. sup. volt. low error ........................................................... 32 Failure code [CA2249] Rail press. very low error ........................................................................ 32 Failure code [CA2311] Abnormality in IMV solenoid ................................................................... 33 Failure code [D110KB] Battery relay drive short ......................................................................... 34 Failure code [D19JKZ] Personal code relay abnormality ............................................................ 36 Failure code [D862KA] GPS antenna discon .............................................................................. 38 Failure code [DA22KK] Pump solenoid power low error ............................................................. 40 Failure code [DA25KP] 5V sensor 1 power abnormality ............................................................. 42 Failure code [DA26KP] 5V sensor 2 power abnormality ............................................................. 45 Failure code [DA29KQ] Model selection abnormality.................................................................. 46 Troubleshooting by failure code, Part 3 SEN04121-01 Failure code [DA2RMC] CAN discon (Pump controller detected) ............................................... 4 Failure code [DAF8KB] Short circuit in camera power supply .................................................... 6 Failure code [DAFGMC] GPS module error ................................................................................ 8 Failure code [DAFRMC] CAN discon (Monitor detected) ............................................................ 10 Failure code [DGH2KB] Hydr oil sensor short ............................................................................. 12 Failure code [DHPAMA] Pump press sensor abnormality ........................................................... 14 Failure code [DHSFMA] Travel left forward PPC press sensor abnormality ............................... 16 Failure code [DHSGMA] Travel right forward PPC press sensor abnormality ............................ 18 Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality............................... 20 Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ............................. 22 Failure code [DHX1MA] Overload sensor abnormality (Analog) ................................................. 24 Failure code [DV20KB] Travel alarm short circuit ....................................................................... 25 Failure code [DW43KA] Travel speed sol discon ........................................................................ 26 Failure code [DW43KB] Travel speed sol short .......................................................................... 27 Failure code [DW45KA] Swing brake sol discon ......................................................................... 28 Failure code [DW45KB] Swing brake sol short ........................................................................... 30 Failure code [DW91KA] Travel junction sol discon ..................................................................... 32 Failure code [DW91KB] Travel junction sol short ........................................................................ 34 Failure code [DWJ0KA] Merge-divider sol discon ....................................................................... 36 Failure code [DWJ0KB] Merge-divider sol short ......................................................................... 38 Failure code [DWK0KA] 2-stage relief sol discon ....................................................................... 40 Failure code [DWK0KB] 2-stage relief sol short .......................................................................... 42

SEN03765-05 00 Index and foreword 8 PC130-8 Troubleshooting by failure code, Part 4 SEN04122-01 Failure code [DXA8KA] PC-EPC sol discon ................................................................................ 2 Failure code [DXA8KB] PC-EPC sol short .................................................................................. 4 Failure code [DXE4KA] Service current EPC discon .................................................................. 6 Failure code [DXE4KB] Service current EPC short ..................................................................... 8 Failure code [DY20KA] Wiper working abnormality .................................................................... 10 Failure code [DY20MA] Wiper parking abnormality .................................................................... 12 Failure code [DY2CKA] Washer drive discon .............................................................................. 14 Failure code [DY2CKB] Washer drive short ................................................................................ 16 Failure code [DY2DKB] Wiper drive (for) short ........................................................................... 18 Failure code [DY2EKB] Wiper drive (rev) short ........................................................................... 20 Troubleshooting of electrical system (E-mode) SEN04123-01 Before carrying out troubleshooting of electrical system ............................................................. 3 Information in troubleshooting table ............................................................................................ 5 E-1 When starting switch turned ON, machine monitor displays nothing.................................... 6 E-2 When starting switch turned ON (before starting engine), basic check item lights up .......... 8 E-3 Engine does not start (Engine does not turn) ....................................................................... 11 E-4 Preheater does not operate .................................................................................................. 14 E-5 Automatic warm-up system does not operate (in cold season) ............................................ 16 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked .......... 18 E-7 Precaution lights up while engine is running......................................................................... 20 E-8 Emergency stop item lights up while engine is running ........................................................ 25 E-9 Engine coolant temperature gauge does not indicate normally ............................................ 26 E-10 Hydraulic oil temperature gauge does not indicate normally .............................................. 27 E-11 Fuel level gauge does not indicate normally ....................................................................... 29 E-12 Contents of display by machine monitor are different from applicable machine ................. 31 E-13 Machine monitor does not display some items ................................................................... 31 E-14 Function switch does not work............................................................................................ 31 E-15 Auto-decelerator does not operate normally....................................................................... 32 E-16 Working mode does not change ......................................................................................... 33 E-17 Travel speed does not change............................................................................................ 34 E-18 Alarm buzzer cannot be stopped ........................................................................................ 35 E-19 Windshield wiper and window washer do not operate ........................................................ 36 E-20 Power maximizing function does not operate normally ...................................................... 40 E-21 Swing holding brake does not operate normally ................................................................. 42 E-22 Travel alarm does not sound or does not stop sounding .................................................... 44 E-23 Air conditioner does not operate normally (including air conditioner abnormality record) .. 45 E-24 While starting switch is in OFF position, service meter is not displayed............................. 57 E-25 Machine monitor cannot be set in service mode ................................................................ 57 E-26 Monitoring function does not display lever control signal normally ..................................... 58 E-27 KOMTRAX system does not operate normally ................................................................... 74 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04124-00 Information contained in troubleshooting table............................................................................ 3 System chart for hydraulic and mechanical systems .................................................................. 4 H-1 Speed or power of all work equipment, swing, and travel are low ........................................ 6 H-2 Engine speed sharply drops or engine stalls ........................................................................ 7 H-3 No work equipment, travel and swing move ......................................................................... 8 H-4 Abnormal noise is heard from around hydraulic pump ......................................................... 8 H-5 Fine control mode does not function .................................................................................... 9 H-6 Speed or power of boom is low ............................................................................................ 10 H-7 Speed or power of arm is low ............................................................................................... 11 H-8 Speed or power of bucket is low ........................................................................................... 12 H-9 Work equipment does not move in its single operation ........................................................ 13 H-10 Hydraulic drift of work equipment is large........................................................................... 14 H-11 Time lag of work equipment is large ................................................................................... 15 H-12 Power maximizing function does not operate normally ...................................................... 15 H-13 Work equipment loaded more is slower during compound operation................................. 16

00 Index and foreword SEN03765-05 PC130-8 9 H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE ..................... 16 H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel .. 17 H-16 Machine deviates during travel ........................................................................................... 18 H-17 Travel speed is low ............................................................................................................. 19 H-18 Machine cannot be steered easily or steering power is low ............................................... 20 H-19 Travel speed does not change or it is kept low or high ...................................................... 21 H-20 Track does not move (Only either side).............................................................................. 21 H-21 Machine does not swing ..................................................................................................... 22 H-22 Swing acceleration or swing speed is low .......................................................................... 23 H-23 Excessive overrun when stopping swing............................................................................ 24 H-24 When upper structure stops swinging, it makes large shock ............................................. 25 H-25 When upper structure stops swinging, it makes large sound ............................................. 25 H-26 Hydraulic drift of swing is large........................................................................................... 26 H-27 Flow rate in attachment circuit cannot be adjusted ............................................................ 27 Troubleshooting of engine (S-mode) SEN04125-02 Method of using troubleshooting chart ........................................................................................ 4 S-1 Starting performance is poor ................................................................................................ 8 S-2 Engine does not start ............................................................................................................ 9 S-3 Engine does not pick up smoothly ........................................................................................ 12 S-4 Engine stops during operations ............................................................................................ 13 S-5 Engine does not rotate smoothly .......................................................................................... 14 S-6 Engine lacks output (or lacks power) .................................................................................... 15 S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 16 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 17 S-9 Oil becomes contaminated quickly ....................................................................................... 18 S-10 Fuel consumption is excessive ........................................................................................... 19 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 20 S-12 Oil pressure drops .............................................................................................................. 21 S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 22 S-14 Coolant temperature becomes too high (overheating) ....................................................... 23 S-15 Abnormal noise is made ..................................................................................................... 24 S-16 Vibration is excessive ......................................................................................................... 25 50 Disassembly and assembly General information on disassembly and assembly SEN04126-02 How to read this manual ............................................................................................................. 2 Coating materials list ................................................................................................................... 4 Special tool list ............................................................................................................................ 7 Sketch of special tool .................................................................................................................. 11 Engine and cooling system SEN04127-01 Removal and installation of fuel supply pump assembly ............................................................. 2 Removal and installation of fuel injector assembly ..................................................................... 5 Removal and installation of front oil seal ..................................................................................... 8 Removal and installation of rear oil seal ..................................................................................... 10 Removal and installation of cylinder head assembly .................................................................. 13 Removal and installation of radiator assembly ............................................................................ 23 Removal and installation of aftercooler assembly ....................................................................... 25 Removal and installation of work equipment oil cooler assembly ............................................... 27 Removal and installation of engine and work equipment pump assembly .................................. 29 Removal and installation of fuel tank assembly .......................................................................... 37 Power train SEN04128-01 Removal and installation of travel motor and final drive assembly ............................................. 2 Disassembly and assembly of travel motor and final drive assembly ......................................... 4 Removal and installation of swing motor and swing machinery assembly .................................. 41 Disassembly and assembly of swing machinery assembly......................................................... 43 Removal and installation of swing circle assembly ..................................................................... 49

Komatsu Pc130-8 Hydraulic Excavator Service Shop Repair Manual

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